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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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1,273 records · Page 69

GPS on-orbit battery performance

Three batteries designed for the GPS system were evaluated. The batteries were wired together, and during the eclipse period were discharged through parallel diodes into a boost converter which then boosted the battery voltage up to the totally regulated bus voltage. Each battery, with a system life of approximately five years, had its own charger. During testing the battery was maintained or used on trickle charge. Data are presented for the battery capacity during the reconditioning. Raw data for each eclipse period and calculations for the average discharge voltage for each battery are given. Thermal cycling for one of the batteries and reconditioning cycles and regimes for all of the batteries are discussed. A reconditioning discharge curve is also given. The problem of temperature cycling in one of the batteries was resolved by redesigning the battery radiator system.

Kasten, J. L.

Determination of Local Experimental Heat-Transfer Coefficients on Combustion Side of an Ammonia-Oxygen Rocket

Local experimental heat-transfer coefficients were measured in the chamber and throat of a 2400-pound-thrust ammonia-oxygen rocket engine with a nominal chamber pressure of 600 pounds per square inch absolute. Three injector configurations were used. The rocket engine was run over a range of oxidant-fuel ratio and chamber pressure. The injector that achieved the best performance also produced the highest rates of heat flux at design conditions. The heat-transfer data from the best-performing injector agreed well with the simplified equation developed by Bartz at the throat region. A large spread of data was observed for the chamber. This spread was attributed generally to the variations of combustion processes. The spread was least evident, however, with the best-performing injector.

Curt H Liebert

Applications Technology Satellites Battery and Power System Design

A summary of the ATS battery design which is onboard the Applications Technology Satellite (ATS) is provided. The 15 ampere hour nickel cadmium cells were manufactured by Gulton, 19 series connected cells per battery, and there are two batteries in each spacecraft. The operating design life was two years in a synchronous orbit, and a maximum depth of discharge of 50 percent. The design temperature for the batteries in the spacecraft was 0 to 25 C, and the charge control consisted of 1 volt versus temperature on a constant percentage voltage. Also, C/10 current limit, and a commandable trickle charge rate, using C/20 or C/60. The undervoltage was sent across a 9 cell and a 10 cell group, and it was set at one volt average per group on either group.

F E Ford

In-Space Laser Forming Simulated Under Thermal Vacuum (TVAC) Conditions

NASA Marshall Space Flight Center is investigating laser forming under thermal vacuum conditions representative of the space environment through a partnership with the DARPA NOM4D program. The thermal gradient mechanism (TGM) is used to bend a metal sheet towards the laser optics. Laser equipment and process parameters are being optimized for thermal vacuum conditions. Such conditions are representative of the extreme cold and hot temperatures and high vacuum that exist on orbit or on the lunar surface. in situ photogrammetry and thermography assess the bend/counterbend and elucidate the TGM in thermal vacuum. Structured light scanning and metallography after bending reveal the macroscopic and microscopic structure after TGM.

thermal vacuum

Crystal Growth of Selected II-VI Semiconducting Alloys By Directional Solidification

A Hg 0.84 Zn 0.16 Te alloy crystal was back-melted and partially resolidified during the first United States Microgravity Laboratory (USML-1) mission in the Marshall Space Flight Center's Crystal Growth Furnace. The experiment was inadvertently terminated at about 30% of planned completion. Nonetheless, it was successfully demonstrated that HgZnTe alloy ingots partially grown and quenched on the ground can be back-melted and regrown in space under nearly steady state growth conditions. An identical 'ground-truth' experiment was performed following the mission. Preliminary results are presented for both crystals, as well as for a series of other crystals grown prior to the mission for the purposes of optimizing in-flight growth conditions.

S L Lehoczky

The In-Orbit Battery Reconditioning Experience On Board the Orion 1 Spacecraft

The Orion 1 spacecraft is a three-axis stabilized geostationary earth orbiting commercial communications satellite which was launched on November 29, 1994 aboard an Atlas II launch vehicle. The power subsystem is a dual bus, dual battery semi-regulated system with one 78 Ampere-hour nickel-hydrogen battery per bus. The batteries were built and tested by Eagle Picher Industries, Inc., of Joplin, MO and were integrated into the spacecraft by its manufacturer, Matra Marconi Space UK Ltd. This paper presents the results obtained during the first four in-orbit reconditioning cycles and compares the battery performance to ground test data. In addition, the on-station battery management strategy and implementation constraints are described. Battery performance has been nominal throughout each reconditioning cycle and subsequent eclipse season.

Hoover, S. A.

Battery performance of the SKYNET 4A spacecraft during the first six years of on station operation

The SKYNET 4A spacecraft is a three-axis stabilized geostationary earth-orbiting military communications satellite which was launched on 1 Jan. 1990 aboard a Titan 3 launch vehicle. The power subsystem is a twin bus, twin battery semi-regulated system and is equipped with one 28-cell, 35 Ampere-hour battery per bus. The cells were manufactured by Gates Aerospace Batteries of Gainesville, FL, and the batteries were built, tested and integrated by British Aerospace Space Systems Ltd. This paper presents a brief survey of the first six years of on-station operation and the operational battery management strategy that has been adopted. Thermal management constraints have led to an unconventional battery operational regime. However, no sign of degradation is evident and the observed spacecraft battery performance remains nominal.

Johnson, P. J.

Composite battery separator

A composite battery separator comprises a support element (10) having an open pore structure such as a ribbed lattice and at least one liquid permeable sheet (20,22) to distribute the compressive force evenly onto the surfaces of the layers (24, 26) of negative active material and positive active material. In a non-flooded battery cell the compressible, porous material (18), such as a glass mat which absorbs the electrolyte, is compressed into a major portion of the pores or openings (16) in the support element. The unfilled pores in the material (18) form a gas diffusion path as the channels (41) formed between adjacent ribs in the lattice element (30,36). Facing two lattice elements (30, 31) with acute angled cross-ribs (34, 38) facing each other prevents the elements from interlocking and distorting a porous, separator (42) disposed between the lattice elements.

Edwards, Dean B.

Initial Jitter Analysis of Lynx, a Proposed Future Large Astrophysics Facility

Lynx is an X-Ray telescope large-mission concept for consideration in NASA's 2020 Astrophysics Decadal Survey. A conceptual structural design is evolving that leverages the success and lessons learned from Chandra and that takes into account unique needs of Lynx. Space optics systems require extreme stability. Any motion in-service (thermal effects, structural dynamics, etc.) impacts performance. An initial analysis was performed to predict the first-cut dynamic responses, jitter, at two selected points on the Lynx observatory. One point is on the Lynx X-ray Mirror Assembly (LMA) and the other, on the focal plane Integrated Science Instrument Module (ISIM). Relative motion between these two points was predicted along with vibration spectra. This information will be used in upcoming analyses of the LMA and the ISIM.

J Brent Knight

Marshall Space Flight Center CFD Overview

Computational Fluid Dynamics (CFD) activities at Marshall Space Flight Center (MSFC) have been focused on hardware specific and research applications with strong emphasis upon benchmark validation. The purpose here is to provide insight into the MSFC CFD related goals, objectives, current hardware related CFD activities, propulsion CFD research efforts and validation program, future near-term CFD hardware related programs, and CFD expectations. The current hardware programs where CFD has been successfully applied are the Space Shuttle Main Engines (SSME), Alternate Turbopump Development (ATD), and Aeroassist Flight Experiment (AFE). For the future near-term CFD hardware related activities, plans are being developed that address the implementation of CFD into the early design stages of the Space Transportation Main Engine (STME), Space Transportation Booster Engine (STBE), and the Environmental Control and Life Support System (ECLSS) for the Space Station. Finally, CFD expectations in the design environment will be delineated.

L A Schutzenhofer

Manufacturing and Scale-Up of Natural Fiber Composite eVTOL Propeller Skin and C-Channel

This report presents the manufacturing and scale-up of natural fiber composites for aerospace applications, conducted within NASA’s Convergent Aeronautics Solutions portfolio to advance aircraft capabilities and efficiency. The effort focused on the development and demonstration of two proof-of-concept articles, an Electric Vertical Take-off and Landing (eVTOL) propeller skin and a C-channel, produced through an iterative design and process optimization approach. Best practices and guidance on addressing key challenges with bio-based composite materials and manufacturing is provided. Ideally suited for non-load-bearing structural components, these emerging materials offer potential for weight reduction, vibration damping, noise mitigation, interference-free communication, and cost savings, without compromising the performance of safety-critical primary structures.

Natural fibers

Hellas, Ken and Me: Adventures in Exhumation and Inundation

Hellas is the largest and deepest basin on Mars. A 1993 study by Moore and Edgett (GRL, 20, 1599-1602) noted that Hellas undergoes net dust erosion. Thus, the exposed surface must represent whatever lag or rock surface and could not be removed by the strong winds blowing at these low elevations. The particle size distributions and particularly the rock or boulder population in this lag was thought to be potentially useful for distinguishing between processes that formed the lithologic units that comprise Hellas Planitia. Earlier studies had suggested the Hellas floor might be paved with basalt or glacial deposits. Ken, who at the time was working with Viking Orbiter IRTM data knew that there were late mission observations of the Hellas floor acquired though clear skies. His derived thermal inertia from these observations strongly suggested that the abundance of particles larger than coarse sand was very low. Hence, our study concluded that the floor deposits were, among other possibilities, ancient loess or lacustrine deposits. In 2001 a subsequent study on the Hellas basin by Moore and Wilhelms (Icarus, 54, 258-276) proposed that the basin was once a site of an ice covered sea, based on a series of circum-basin scarps that follow constant elevations as well as other landforms seen my Mars Global Surveyor’s MOC (an instrument that Ken played a major role in daily operations and data analysis) and topography derived from MOLA. Subsequently the best contiguous observations of the Hellas basin have been acquired from the Mars Reconnaissance Orbiter’s Context Camera, which again Ken has been a central player in its operations. Much of what we know about the grain-scale sedimentology of martian lacustrine deposits comes from the Curiosity Rover’s Mars Hand Lens Imager (which Ken was the PI through development and original operations within Gale crater). Under Ken’s watch several members of the Murray Formation were determined to be deposited in a lacustrine environment. A conclusion strongly demonstrated by MHLI imaging. My personal relationship with Hellas isn’t over. The Europa Clipper flew directly over the Hellas basin including its deepest regions. Ther REASON Ice Penetrating Radar system collected data during this flyby ostensibly for calibration, yet the quality of the observations may yet provide new discoveries from Hellas.

Jeffrey M Moore

Space Station battery system design and development

The Space Station Electric Power System will rely on nickel-hydrogen batteries in its photovoltaic power subsystem for energy storage to support eclipse and contingency operations. These 81-Ah batteries will be designed for a 5-year life capability and are configured as orbital replaceable units (ORUs), permitting replacement of worn-out batteries over the anticipated 30-year Station life. This paper describes the baseline design and the development plans for the battery assemblies, the battery ORUs and the battery system. Key elements reviewed are the cells, mechanical and thermal design of the assembly, the ORU approach and interfaces, and the electrical design of the battery system. The anticipated operational approach is discussed, covering expected performance as well as the processor-controlled charge management and discharge load allocation techniques. Development plans cover verification of materials, cells, assemblies and ORUs, as well as system-level test and analyses.

Haas, R. J.

A High Temperature Cyclic Oxidation Data Base for Selected Materials Tested at NASA Glenn Research Center

The cyclic oxidation test results for some 1000 high temperature commercial and experimental alloys have been collected in an EXCEL database. This database represents over thirty years of research at NASA Glenn Research Center in Cleveland, Ohio. The data is in the form of a series of runs of specific weight change versus time values for a set of samples tested at a given temperature, cycle time, and exposure time. Included on each run is a set of embedded plots of the critical data. The nature of the data is discussed along with analysis of the cyclic oxidation process. In addition examples are given as to how a set of results can be analyzed. The data is assembled on a read-only compact disk which is available on request from Materials Durability Branch, NASA Glenn Research Center, Cleveland, Ohio.

Scale Spalling Models

Analysis of Surface and Bulk Behavior in Ni-Pd Alloys

The most salient features of the surface structure and bulk behavior of Ni-Pd alloys have been studied using the BFS method for alloys. Large-scale atomistic simulations were performed to investigate surface segregation profiles as a function of temperature, crystal face, and composition. Pd enrichment of the first layer was observed in (111) and (100) surfaces, and enrichment of the top two layers occurred for (110) surfaces. In all cases, the segregation profile shows alternate planes enriched and depleted in Pd. In addition, the phase structure of bulk Ni-Pd alloys as a function of temperature and composition was studied. A weak ordering tendency was observed at low temperatures, which helps explain the compositional oscillations in the segregation profiles. Finally, based on atom-by-atom static energy calculations, a comprehensive explanation for the observed surface and bulk features will be presented in terms of competing chemical and strain energy effects.

Ordering

Multifaceted Considerations for Fission Surface Power Radiation Shielding Design

The purpose of the Fission Surface Power (FSP) nuclear system is to provide energy on the Moon and Mars for supporting their exploration and colonization. The FSP design and deployment can leverage the past research and development work in areas, such as reactor design, but such crucial components as radiation shielding and instrumentation still need material and manufacturing studies, modeling, and testing. The shielding components are needed for the protection of humans, electronics, and sensitive components. They are essential system components, but they are often the heaviest components of the system for which each kilogram matters. Different material combinations and layouts are possible. The studies presented were focused on the evaluation of several options. The initial analysis included their performance assessment, initial temperature distribution evaluation and manufacturability considerations. Several feasible shield design options were identified and discussed in this paper, as well.

Fission Surface Power

Deep RL for Fast Long-Horizon Operations Scheduling on NASA's Carruthers Geocorona Observatory Mission

Spacecraft operations scheduling is a highly constrained, long-horizon combinatorial optimization problem that traditionally relies on heuristics, constraint programming, or manual planning. We present a scalable deep reinforcement learning framework developed and deployed for NASA’s Carruthers Geocorona Observatory mission. Our framework introduces a macro-action abstraction known as activity blocks coupled with dynamic action-masking to navigate the intractably large search space and strictly enforce complex power, thermal, and instrument constraints. The resulting architecture generates globally feasible schedules with overwhelming probability, establishes operational trust, and executes a full training cycle in under six hours, circumventing the need for policy robustness by enabling rapid, on-demand retraining. Further, resulting schedules outperform baseline heuristics in scheduled science quality. The deep reinforcement learning framework was deployed as the default operational scheduler for the Carruthers Geocorona Observatory mission from the outset of the mission, demonstrating that deep reinforcement learning can be trusted for real spacecraft operations under complex, evolving constraints.

Geocorona

Battery Systems for X-38 Crew Return Vehicle (CRV) and Deorbit Propulsion Stage (DPS)

A 28V 32 Ah cell Li/MnO2 and a 28V NiMH battery systems for the Deorbit Propulsion Stage (DPS) and the X-38 Crew Return Vehicle (CRV) are developed in Friwo-Silforkraft, Germany with the following objectives and approach: Provide safe battery designs for lowest volume and cost, and within schedule; Take advantage of less complex requests for V201 vs OPS CRV to simplify design and reduce cost; Use only existing commercial cell designs as building blocks for larger battery; Derive battery designs from the ASTRO-SPAS design which is the largest lithium battery design with Shuttle flight experience; Place maximum amount of battery energy on DPS; DPS battery is non rechargeable; and CRV batteries are rechargeable. This paper contains the following sections: a brief introduction on CRV requirements, CRV advantages over Soyuz, and X-38 programs; Battery objectives and approach; Battery requirements and groundrules (performance, on-orbit operation, etc); Design trades, solutions, redundancy plan, and margins; Envelope, size, and mass; Interfaces (structural, electrical & thermal); and Deviation from OPS CRV.

Darcy, Eric