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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Using Additive Manufacturing to Print a CubeSat Propulsion System

CubeSats are increasingly being utilized for missions traditionally ascribed to larger satellites CubeSat unit (1U) defined as 10 cm x 10 cm x 11 cm. Have been built up to 6U sizes. CubeSats are typically built up from commercially available off-the-shelf components, but have limited capabilities. By using additive manufacturing, mission specific capabilities (such as propulsion), can be built into a system. This effort is part of STMD Small Satellite program Printing the Complete CubeSat. Interest in propulsion concepts for CubeSats is rapidly gaining interest-Numerous concepts exist for CubeSat scale propulsion concepts. The focus of this effort is how to incorporate into structure using additive manufacturing. End-use of propulsion system dictates which type of system to develop-Pulse-mode RCS would require different system than a delta-V orbital maneuvering system. Team chose an RCS system based on available propulsion systems and feasibility of printing using a materials extrusion process. Initially investigated a cold-gas propulsion system for RCS applications-Materials extrusion process did not permit adequate sealing of part to make this a functional approach.

electric propulsion systems↗
NASA NTRSDate not supplied

Adaptative Site Management for a 115 Acre Chlorinated Solvent Plume with Two Separate Source Areas at Kennedy Space Center, Florida

Background/Objectives. During Resource Conservation and Recovery Act (RCRA) Facility Investigation (RFI) activities, Geosyntec delineated a chlorinated volatile organic compound (CVOC) plume at the National Aeronautics and Space Administration’s (NASA’s) Vehicle Assembly Building (VAB) area located at KSC, Florida. The RFI activities identified an approximate 115-acre dissolved plume (primarily vinyl chloride) and a trichloroethene (TCE) source area in an active aerospace complex that is surrounded by sensitive wetland/waterbodies. Due to the size of the impacted area, the Corrective Measure Design included a multi-component strategy: (i) address the source area via bioremediation; (ii) protect sensitive wetlands from impacted groundwater discharge via biosparging; and (iii) Long Term Monitoring (LTM) of the remaining dissolved plume. After the Corrective Measures implementation (CMI), NASA and Geosyntec worked with Florida Department of Environmental Protection (FDEP) to implement an adaptive site management for the complex, 115-acre site outside of the traditional RCRA process. The adaptive site management approach relied on performing supplemental assessments and implementing Interim Measures (IMs) to further assess and implement remedies over time while working within site and budget constraints, with an overall goal of achieving enough mass reduction to transition the entire site to LTM and eventually achieve site closure. Approach/Activities. After the biosparge barrier was operational and bioremediation within the source area (referred to as Hot Spot 1) achieved the Corrective Action Objective (CAO), supplemental assessment of the area between Hot Spot 1 and the biosparge barrier was performed. The conceptual site model was updated using the supplemental assessment results and an air sparge system IM was designed to treat an approximate 1.2 acre area (referred to as Hot Spot 2). After installation of the air sparge system, supplemental assessment within the remainder of the 115-acre dissolved plume was performed and a second TCE source area was identified. The TCE source area and associated areas with elevated CVOC concentrations (referred to as Hot Spot 3) were delineated and a bioremediation IM was implemented. Also, the downgradient impacts from Hot Spot 3 were adjacent to a sensitive waterbody, and negotiations with the FDEP allowed the area to be monitored using LTM. Results/Lessons Learned. The performance of supplemental assessment activities and implementation of remedial alternatives as IMs allowed NASA to successfully address groundwater impacts over time, while working within the FDEP regulatory framework. The implementation of the CMI and multiple IMs has achieved the following goals: (i) the biosparge barrier has mitigated the potential discharge of impacted groundwater to an adjacent wetland; (ii) enhanced bioremediation within Hot Spot 1 achieved the CAO within 2 years and transitioned the area into LTM; (iii) operation of an air sparge system within Hot Spot 2 removed TCE as a constituent of concern and contributed to a reduction (approximately 43%) in the impacted groundwater area outside the air sparge treatment area (plume collapse); and (iv) bioremediation within Hot Spot 3 removed approximately 80% of the CVOC mass and contributed to a reduction (approximately 47%) in the impacted groundwater area outside the bioremediation IM treatment area. Overall, the adaptive approach is protecting the sensitive water bodies surrounding the complex site and reducing the area of impacted groundwater, which is moving the entire site towards LTM.

Rebecca C Daprato↗
DOE OSTI2021

Magnetic properties of CrFeCoNi based high entropy alloys

Monte Carlo simulations are performed on three high entropy alloys: Cr0.25Fe0.25Co0.25Ni0.25, Cr0.2Fe0.2Co0.2Ni0.2Pd0.2, and Cr0.2Mn0.2Fe0.2Co0.2Ni0.2, with exchange interactions extracted from The ab initio Korringa-Kohn-Rostoker method combined with the coherent potential approximation calculations. Using finite size scaling analyses, we estimate the magnetic phase transition temperature for the four component alloy to be 108(2) K, and although the individual critical exponents are different from 3D Heisenberg universality class, the reduced exponent follows Suzuki weak universality. With the additional Palladium component, the transition temperature elevates to about 200 K. In contrast, we find no magnetic order for the five component alloy with Manganese at any finite temperatures.

Yin, Junqi↗
NASA NTRS1994

A structural design decomposition method utilizing substructuring

A new method of design decomposition for structural analysis and optimization is described. For this method, the structure is divided into substructures where each substructure has its structural response described by a structural-response subproblem, and its structural sizing determined from a structural-sizing subproblem. The structural responses of substructures that have rigid body modes when separated from the remainder of the structure are further decomposed into displacements that have no rigid body components, and a set of rigid body modes. The structural-response subproblems are linked together through forces determined within a structural-sizing coordination subproblem which also determines the magnitude of any rigid body displacements. Structural-sizing subproblems having constraints local to the substructures are linked together through penalty terms that are determined by a structural-sizing coordination subproblem. All the substructure structural-response subproblems are totally decoupled from each other, as are all the substructure structural-sizing subproblems, thus there is significant potential for use of parallel solution methods for these subproblems.

Scotti, Stephen J.↗
NASA NTRS1995

ROSAT observations of NGC 2146: Evidence for a starburst-driven superwind

We have imaged the edge-on starburst galaxy NGC 2146 with the Position Sensitive Proportional Counter (PSPC) and the High Resolution Imager (HRI) on board ROSAT and have compared these data to optical images and long-slit spectra. NGC 2146 possesses a very large X-ray nebula with a half-light radius of 1 min (4 kpc) and a maximum diameter of approximately 4 min, or 17 kpc. The X-ray emission is resolved by the PSPC and preferentially oriented along the minor axis, with a total flux of 1.1 x 10(exp -12) ergs/sq cm/s over 0.2 - 2.4 keV and a luminosity of approximately 3 x 10(exp 40) ergs/s. The inner X-ray nebula is resolved by the HRI into at least four bright knots together with strong diffuse emission responsible for at least 50% of the flux within a radius of 0.5 min (approximately 2 kpc). The brightest knot has a luminosity of (2 - 3) x 10(exp 39) ergs/s. The X-ray nebula has a spatial extent much larger than the starburst ridge seen at centimeter wavelengths by Kronberg & Biermann (1981) and is oriented in a `X-like' pattern along the galaxy minor axis at a position angle of approximately 30 degrees. This minor-axis X-ray emission is associated with a region of H alpha and dust filaments seen in optical images. Optical spectra show that the emission-line gas along the minor axis is characterized by relatively broad lines (approximately 250 km/s full width half-maximum (FWHM)) and by `shocklike' emission-line flux ratios. Together with the blue-asymmetric nuclear emission-line and NaD interstellar absorption-line profiles, these optical data strongly suggest the presence of a starburst-driven superwind. The X-ray spectrum extracted from the central 5 min contains a strong Fe L emission-line complex at 0.6 - 1.0 keV and a hard excess above 1.0 keV. The spectrum is best described with a two-component model, containing a soft (kT approximately 400 - 500 eV) Raymond-Smith thermal plasma together with either a Gamma = 1.7 power-law or a kT greater than 2.2 keV bremsstrahlung component. The soft thermal component provides approximately 30% of the total luminosity over 0.2 - 2.4 keV, or approximately 10(exp 40) ergs/s. The pressure derived from the soft component of the X-ray spectrum is consistent with that predicted from a starburst-driven superwind if the filling factor of the warm gas is approximately 1% - 10 %. If the hard X-ray component is thermal gas associated with the galactic outflow, the filling factor must be close to unity. Predictions of the luminosity, temperature, and size of an adiabatic starburst-generated windblown bubble are consistent with those measured for the soft thermal X-ray emission in NGC 2146. The hard X-ray component, however, has a luminosity much larger than predicted by the superwind model if this component is thermal emission from gas heated by an internal shock in the expanding bubble. We briefly review various possibilities as to the nature of the hard X-ray component in NGC 2146.

Armus, L.↗
NASA NTRSDate not supplied

Cruise Propulsion System Thermal Analysis for NASA’s X-57 “Maxwell” Mod II Configuration

The X-57 “Maxwell” is NASA’s flight demonstrator for distributed electric propulsion technologies. The X-57 Mod II configuration is designed to test the electric cruise propulsion system for X-57 and features an electric cruise motor mounted in an integral nacelle on each wing. The electric motors and associated control equipment for X-57 Mod II are air-cooled; therefore, they require adequate cooling airflow to stay within temperature limits set by the X-57 project in all relevant flight conditions. A computational flow analysis was conducted to estimate the internal flow properties of the X-57 Mod II cruise nacelles in three critical flight conditions. These flow properties were then used to determine the boundary conditions for individual component thermal models, which were used to estimate individual component operating temperatures. The results indicated that the low-speed, low-altitude initial takeoff climb during hot day conditions was the sizing condition from a cooling perspective. The analysis found that the cooling flowpaths in the X-57 Mod II cruise nacelles are adequate to provide cooling to most of the components with the appropriate amount of thermal margin. The two components that are not anticipated to have the appropriate margin can be accommodated with a small (< 2°C) adjustment to the project operating limitations.

Nicholas K. Borer↗
NASA NTRS1999

Particle Segregation in Collisional Shearing Flows

The size segregation of flowing or shaken grains is a commonly observed phenomenon in industrial processes and in nature. In systems that do not involve much agitation of the grains, several mechanisms that involve gravity have been identified as leading to such segregation. In highly agitated flows, there is a mechanism independent of gravity that is available to drive separation of different grains. This is associated with spatial gradients in the energy of their velocity fluctuations. Because collisions between grains inevitably dissipate energy, collisional granular shear flows are usually of limited extent in the direction transverse to the flow. One consequence of this is that shear flows are strongly influenced by their boundaries. Because grains, on average, slip relative to boundaries, a bumpy or frictional boundary can convert slip energy into fluctuation energy. However, because each collision between a grain and the boundary dissipates fluctuation energy, there is a competition between production and dissipation. In principle, it is possible to design the geometry of the boundary - for example, the size and spacing of the bumps - so that the boundary either produces or dissipates fluctuation energy. This permits the control of the component of the spatial gradient of the fluctuation energy that is normal to the boundary. The gradients in fluctuation energy established by such boundaries may be exploited to drive the separation by size or other properties in a binary mixture of spherical grains. Microgravity makes the visual observations possible by permitting us to employ moderate rates of shear. On earth, the effects of gravity can be minimized by shearing so rapidly that the particle pressure overwhelms gravity. However, in this event, separation takes place too rapidly for visual observation, buoyancy and/or condensation associated with the centripetal acceleration must be accounted for, and the particles can be severely damaged. Because, in the absence of gravity, the only available time scale is proportional to the speed of the moving boundary, this speed can be made arbitrarily slow to permit observations and to avoid particle damage, without altering the phenomenon under study. The primary goal of this research is to carry out a physical experiment in which particle segregation is induced and maintained in a collisional flow of a binary mixture of two different types of spheres.

Jenkins, J. T.↗
NASA NTRS2004

Aluminum-Alloy-Matrix/Alumina-Reinforcement Composites

Isotropic composites of aluminum-alloy matrices reinforced with particulate alumina have been developed as lightweight, high-specific-strength, less-expensive alternatives to nickel-base and ferrous superalloys. These composites feature a specific gravity of about 3.45 grams per cubic centimeter and specific strengths of about 200 MPa/(grams per cubic centimeter). The room-temperature tensile strength is 100 ksi (689 MPa) and stiffness is 30 Msi (206 GPa). At 500 F (260 C), these composites have shown 80 percent retention in strength and 95 percent retention in stiffness. These materials also have excellent fatigue tolerance and tribological properties. They can be fabricated in net (or nearly net) sizes and shapes to make housings, pistons, valves, and ducts in turbomachinery, and to make structural components of such diverse systems as diesel engines, automotive brake systems, and power-generation, mining, and oil-drilling equipment. Separately, incorporation of these metal matrix composites within aluminum gravity castings for localized reinforcement has been demonstrated. A composite part of this type can be fabricated in a pressure infiltration casting process. The process begins with the placement of a mold with alumina particulate preform of net or nearly net size and shape in a crucible in a vacuum furnace. A charge of the alloy is placed in the crucible with the preform. The interior of the furnace is evacuated, then the furnace heaters are turned on to heat the alloy above its liquidus temperature. Next, the interior of the furnace is filled with argon gas at a pressure about 900 psi (approximately equal to 6.2 MPa) to force the molten alloy to infiltrate the preform. Once infiltrated, the entire contents of the crucible can be allowed to cool in place, and the composite part recovered from the mold.

Kashalikar, Uday↗
NASA NTRS2020

A Flexible Parameterization for Shortwave and Longwave Optical Properties of Ice Crystals and Derived Bulk Optical Properties for Climate Models

We provide a parameterization of the extinction efficiency, single scattering albedo and asymmetry parameter of single ice crystals with any combination of particle volume, projected area, component aspect ratio and crystal distortion at any wavelength between 0.2 and 100 mm. The paramerization is an extension of the one previously published by van Diedenhoven et al. (2014, https://doi.org/10.1175/JAS-D-13-0205.1). In addition, the parameterized optical properties are integrated over size distributions yielding bulk extinction efficiencies, single scattering albedos and asymmetry parameters for large ranges of effective radii, particle component aspect ratios and crystal distortion values. The parameterization of single particle optical properties is evaluated with a reference database. The bulk optical properties are evaluated against the ice model selected for the Moderate Resolution Imaging Spectroradiometer (MODIS) Collection 6 products, for which accurate optical properties are available. Mean absolute errors in parameterized extinction efficiency, asymmetry parameter and single scattering albedo are shown to be 0.0272, 0.00890 and 0.00468, respectively for shortwave wavelengths, while they are 0.0641, 0.0368 and 0.0200 in the longwave. Shortwave and longwave asymmetry parameter and single scattering albedos are shown to vary strongly with particle component aspect ratio and distortion, resulting in substantial variation in shortwave fluxes, but relatively small variations in longwave cloud emissivity. The parameterization and bulk optical properties are made publicly available.

Bastiaan Van Diedenhoven↗
NASA NTRSDate not supplied

More / All Electric Vertical Take-Off and Landing (VTOL) Vehicle Sensitivities to Propulsion and Power Performance

Battery power and energy density are important parameters for the emerging concepts for more / all-electric vehicles. Electric propulsion and power system performance is also important. To better understand how electric propulsion and power systems component performance influences overall vehicle design, a sensitivity assessment was performed noting changes in vehicle gross weight and energy usage. Updated versions of the Revolutionary Vertical lift Technology (RVLT) Project vertical take-off and landing (VTOL) urban air mobility (UAM) reference vehicles and missions were used. NASA electric vehicle studies are discussed which were used to help select the range of electric propulsion and power system performance parameters used in this assessment. Thermal management systems (TMS) considerations are also important; new and innovative power management and distribution systems can reduce electric system weight and losses, reducing thermal management constraints often imposed by electric systems modest maximum use temperatures. Vehicles with higher disk loadings (smaller rotors) require higher power levels per unit weight for VTOL operations, which make them more sensitive to electric system weights and efficiencies. Battery, all-electric vehicles show different sensitivities to component performance than turboelectric or hybrids systems. Battery, all-electric propulsion systems may increase vehicle weight and size, but still results in lower mission energy usage than their hydrocarbon-fueled versions. Significant vehicle weight growth to electric propulsion and power system power-to-weight reductions also occurs at different levels among the various concepts. From these results, one can more readily identify required component performance levels, potential component choices or, research and development paths.

Electric Propulsion Systems (Aircraft)↗
NASA NTRSDate not supplied

More / All Electric Vertical Take-Off and Landing (VTOL) Vehicle Sensitivities to Propulsion and Power Performance

Battery power and energy density are important parameters for the emerging concepts for more / all-electric vehicles. Electric propulsion and power system performance is also important. To better understand how electric propulsion and power systems component performance influences overall vehicle design, a sensitivity assessment was performed noting changes in vehicle gross weight and energy usage. Updated versions of the Revolutionary Vertical lift Technology (RVLT) Project vertical take-off and landing (VTOL) urban air mobility (UAM) reference vehicles and missions were used. NASA electric vehicle studies are discussed which were used to help select the range of electric propulsion and power system performance parameters used in this assessment. Thermal management systems (TMS) considerations are also important; new and innovative power management and distribution systems can reduce electric system weight and losses, reducing thermal management constraints often imposed by electric systems modest maximum use temperatures. Vehicles with higher disk loadings (smaller rotors) require higher power levels per unit weight for VTOL operations, which make them more sensitive to electric system weights and efficiencies. Battery, all-electric vehicles show different sensitivities to component performance than turboelectric or hybrids systems. Battery, all-electric propulsion systems may increase vehicle weight and size, but still results in lower mission energy usage than their hydrocarbon-fueled versions. Significant vehicle weight growth to electric propulsion and power system power-to-weight reductions also occurs at different levels among the various concepts. From these results, one can more readily identify required component performance levels, potential component choices or, research and development paths.

electric propulsion systems (aircraft) mission ana↗
NASA NTRS1978

Nonlinear axisymmetric liquid currents in spherical annuli

A numerical analysis of non-linear axisymmetric viscous flows in spherical annuli of different gap sizes is presented. Only inner sphere was supposed to rotate at a constant angular velocity. The streamlines, lines of constant angular velocity, kinetic energy spectra, and spectra of velocity components are obtained. A total kinetic energy and torque needed to rotate the inner sphere are calculated as functions of Re for different gap sizes. In small-gap annulus nonuniqueness of steady solutions of Navier-Stokes equations is established and regions of different flow regime existences are found. Numerical solutions in a wide-gap annulus and experimental results are used in conclusions about flow stability in the considered range of Re. The comparison of experimental and numerical results shows close qualitative and quantitative agreement.

Astafyeva, N. M.↗
DOE OSTI2021

SURFACE FINISHING AND ELECTROLESS NICKEL PLATING OF ADDITIVELY MANUFACTURED (AM) METAL COMPONENTS

This study investigates the application of electroless nickel deposition on additively manufactured stainless steel samples. Current additive manufacturing (AM) technologies produce metal components with a rough surface. Rough surfaces generally exhibit fatigue characteristics, increasing the probability of initiating a crack or fracture to the printed part. For this reason, the direct use of as-produced parts in a finished product cannot be actualized, which presents a challenge. Post-processing of the AM parts is therefore required to smoothen the surface. This study analyzes chempolish (CP) and electropolish (EP) surface finishing techniques for post-processing AM stainless steel components CP has a great advantage in creating uniform, smooth surfaces regardless of size or part geometry EP creates an extremely smooth surface, which reduces the surface roughness to the sub-micrometer level. In this study, we also investigate nickel deposition on EP, CP, and as-built AM components using electroless nickel solutions. Electroless nickel plating is a method of alloy treatment designed to increase manufactured component's hardness and surface resistance to the unrelenting environment. The electroless nickel plating process is more straightforward than its counterpart electroplating.. We use low-phosphorus (2-5% P), medium-phosphorus (6-9% P), and high-phosphorus (10-13% P). These Ni deposition experiments were optimized using the L9 Taguchi design of experiments (TDOE), which compromises the prosperous content in the solution, surface finish, plane of the geometry, and bath temperature. The pre-and post-processed surface of the AM parts was characterized by KEYENCE Digital MicroscopeVHX-7000 and Phenom XL Desktop SEM. The experimental results show that electroless nickel deposition produces uniform Ni coating on the additively manufactured components up to 20 μm per hour. Mechanical properties of as-built and Ni coated AM samples were analyzed by applying a standard 10 N scratch test. Nickel coated AM samples were up to two times scratch resistant compared to the as-built samples. This study suggests electroless nickel plating is a robust viable option for surface hardening and finishing AM components for various applications and operating conditions.

Keywords: additive manufacturing, fatigue, chempol↗
NASA NTRSDate not supplied

Sensitivity of Hybrid NEP-Chemical Vehicle Mass to Assumptions for Crewed Opposition-Class Mars Missions

This research illustrates the impact of different technology choices and their associated performance on overall sizing for a hybrid Nuclear Electric Propulsion (NEP) and chemical crewed Mars transportation vehicle. A set of models for the trajectory and vehicle mass, power system specific mass(α), and power conversion performance enable the analysis. Vehicle mass required to close the mission is calculated as a function of α and specific impulse (Isp) for multiple choices of high-level assumptions including system alpha vs. power scaling and electric thruster type. System alpha is built up and compared for multiple cases of technology assumptions. A Brayton cycle model is used to illustrate the alpha sensitivities to assumptions in cycle design such as peak operating temperature and component performance. The analysis illustrates how technology performance sensitivities affect the alpha and thus vehicle sizing for a range of mission and technology assumptions.

Matthew Duchek↗
NASA NTRS1987

Energy dissipation associated with crack extension in an elastic-plastic material

Crack extension in elastic-plastic material involves energy dissipation through the creation of new crack surfaces and additional yielding around the crack front. An analytical procedure, using a two-dimensional elastic-plastic finite element method, was developed to calculate the energy dissipation components during a quasi-static crack extension. The fracture of an isotropic compact specimen was numerically simulated using the critical crack-tip-opening-displacement (CTOD) growth criterion. Two specimen sizes were analyzed for three values of critical CTOD. Results from the analyses showed that the total energy dissipation rate consisted of three components: the crack separation energy rate, the plastic energy dissipation rate, and the residual strain energy rate. All three energy dissipation components and the total energy dissipation rate initially increased with crack extension and finally reached constant values.

Shivakumar, K. N.↗
NASA NTRS1987

Energy dissipation associated with crack extension in an elastic-plastic material

Crack extension in elastic-plastic material involves energy dissipation through the creation of new crack surfaces and additional yielding around the crack front. An analytical procedure, using a two-dimensional elastic-plastic finite element method, was developed to calculate the energy dissipation components during a quasi-static crack extension. The fracture of an isotropic compact specimen was numerically simulated using the critical crack-tip-opening-displacement (CTOD) growth criterion. Two specimen sizes were analyzed for three values of critical CTOD. Results from the analysis showed that the total energy dissipation rate consisted of three components: the crack separation energy rate, the plastic energy dissipation rate, and the residual strain energy rate. All three energy dissipation components and the total energy dissipation rate initially increased with crack extension and finally reached constant values.

Shivakumar, K. N.↗
NASA NTRS1988

Optoelectronic techniques for broadband switching

Optoelectronic switching employs a hybrid optical/electronic principle to perform the switching function and is applicable for either analog broadband or high-bit rate digital switching. The major advantages of optoelectronic switching include high isolation, low crosstalk, small physical size, light weight, and low power consumption. These advantages make optoelectronic switching an excellent candidate for on-board satellite switching. This paper describes a number of optoelectronic switching architectures. System components required for implementing these switching architectures are discussed. Performance of these architectures are evaluated by calculating their crosstalk, isolation, insertion loss, matrix size, drive power, throughput, and switching speed. Technologies needed for monolithic optoelectronic switching are also identified.

Su, S. F.↗