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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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The alignment of the SSR1 cryomodule components was studied as the acceptable beam deflection. We are showing an innovative alignment monitoring strategy through optical targets installed on the internal assembly.
The Electron Ion Collider (EIC) Hadron Storage Ring (HSR) will reuse most of the existing superconducting magnets from the RHIC storage ring. However, the existing stripline beam position monitors (BPM) used for RHIC will not be compatible with the planned EIC hadron beam parameters that include higher intensity, shorter bunches, and some operational scenarios with large radial offsets of the beam in the vacuum chamber. To address these challenges, the existing RHIC stripline BPMs will be shielded, and a new BPM design using button pick-ups and integrated in a new vacuum interconnect/bellows assembly that will be installed adjacent to the existing BPMs. A thermal analysis of the new arc BPM housing and button pick-up design has been conducted to assess the effects caused by beam induced resistive wall heating and signal propagation through the button pick-up cables for several operational scenarios. This report will describe the analysis results to quantify the heat transfer and temperature distribution that can be expected on the new HSR cryogenic arc BPM housings, button pick-ups, and cryo-signal cables.
The structures assembly model (SAM) was installed, and wind tunnel systems were checked out. The first run, with hydrogen cooling and SAM inserted in the wind tunnel stream (M = 7.7, P sub TOTAL = 900 psia, T sub TOTAL = 2500 deg R), was accomplished. The condition of the SAM after the run was satisfactory, with no visible signs or data indications of overheating or overloading.
An outline of the organization and capabilities of the Engine Structures Computational Simulator (Simulator) at NASA Lewis Research Center is given. One of the goals of the research at Lewis is to integrate various discipline specific structural mechanics codes into a software system which can be brought to bear effectively on a wide range of engineering problems. This system must possess the qualities of being effective and efficient while still remaining user friendly. The simulator was initially designed for the finite element simulation of gas jet engine components. Currently, the simulator has been restricted to only the analysis of high pressure turbine blades and the accompanying rotor assembly, although the current installation can be expanded for other applications. The simulator presently assists the user throughout its procedures by performing information management tasks, executing external support tasks, organizing analysis modules and executing these modules in the user defined order while maintaining processing continuity.
This paper reports an approach used to retrofit a set of full-scale main rotor blades with 290 miniature pressure transducers, 46 strain gages, and 24 miniature accelerometers. Normally, in order to avoid disturbing the aerodynamics of the rotor flow field, the pressure instrumentation must be integrally built into the body of the rotor blades. However, using a method developed with NASA, miniature pressure transducers are mounted to the blade exterior surface without degrading the quality of the blade aerodynamics. Moreover, it is estimated that this approach reduced costs by more than 50 percent over building a set of pressure instrumented blades. The aerodynamic measurement objectives are presented as are instrumentation design considerations, type of instrumentation used, assembly process, and the installed instrumentation characteristics.
Footage shows press members inspecting Endeavour's main engine before installation as a Vehicle Assembly Building (VAB) official answers questions.
The multipurpose hydrogen test bed (MHTB), with an 18-cu m liquid hydrogen tank, was used to evaluate a combination foam/multilayer combination insulation (MLI) concept. The foam element (Isofoam SS-1171) insulates during ground hold/ascent flight, and allowed a dry nitrogen purge as opposed to the more complex/heavy helium purge subsystem normally required. The 45-layer MLI was designed for an on-orbit storage period of 45 days. Unique WI features include a variable layer density, larger but fewer double-aluminized Mylar perforations for ascent to orbit venting, and a commercially established roll-wrap installation process that reduced assembly man-hours and resulted in a roust, virtually seamless MLI. Insulation performance was measured during three test series. The spray-on foam insulation (SOFI) successfully prevented purge gas liquefaction within the MLI and resulted in the expected ground hold heat leak of 63 W/sq m. The orbit hold tests resulted in heat leaks of 0.085 and 0.22 W/sq m with warm boundary temperatures of 164 and 305 K, respectively. Compared to the best previously measured performance with a traditional MLI system, a 41-percent heat leak reduction with 25 fewer MLI layers was achieved. The MHTB MLI heat leak is half that calculated for a constant layer density MLI.
The Friction Stir Welding process developed by The Welding Institute (TWI) has found application throughout the transportation industry. This technique has proven to be a viable joining process for aluminum alloys, producing virtually defect free welds with improved mechanical properties as compared to conventional fusion welding. Lockheed Martin Space Systems - Michoud Operations has been developing this technology for application on aluminum 2219 and 2195 cryogenic tankage since 1995. This effort will come to fruition with implementation on the longitudinal welds of the External Fuel Tank (ET) of the Shuttle. To this end, sub-and full-scale demonstration programs coupled with process development and optimization have been complete. Full size ET tool has been designed, fabricated and are being installed at the Michoud Assembly Facility. Upon completion of the tooling certification and materials allowables testing, production will commence. This implementation will result in increased reliability and safety of flight for the Shuttle.
A multi-purpose thermal insulation test apparatus is used for testing insulation materials, or other components. The test apparatus is a fluid boil-off calorimeter system for calibrated measurement of the apparent thermal conductivity (k-value) of a specimen material at a fixed vacuum level. The apparatus includes an inner vessel for receiving a fluid with a normal boiling point below ambient temperature, such as liquid nitrogen, enclosed within a vacuum chamber. A cold mass assembly, including the inner vessel and thermal guards, is suspended from the top of the vacuum chamber. Handling tools attach to the cold mass assembly for convenient manipulation of the assembly and for the installation or wrapping of insulation test materials. Liquid nitrogen is typically supplied to the inner vessel using a fill tube with funnel. A single port through the top of the vacuum chamber facilitates both filling and venting. Aerogel composite stacks with reflective films are fastened to the top and the bottom of the inner vessel as thermal guards. The comparative k-value of the insulation material is determined by measuring the boil-off flow rate of gas, the temperature differential across the insulation thickness, and the dimensions (length and diameters) of the test specimen.
The Space Launch Initiative Program (SLI) in conjunction with the National Center for Advanced Manufacturing (NCAM) will demonstrate the ability to produce large-scale complex curvature hardware using the self-reacting friction stir welding process. This multi-phased risk reduction program includes friction stir welding process development and manufacture of a 22-ft diameter quarter dome using a conventional tooling approach; it culminates in a 27.5-ft diameter quarter dome demonstration performed on a 5-axis Universal Weld System. The design, fabrication, and installation of the Universal Weld System is made possible through a collaboration between the State of Louisiana, NASA, and the University of New Orleans. The Universal Weld System, manufactured by MTS Systems Corporation, will be installed at the Michoud Assembly Facility in New Orleans, Louisiana, and will be capable of manufacturing domes up to 30 ft in diameter. All welding will be accomplished using the Adaptable Adjustable Pin Tool (AdAPT) weld head and controller manufactured by MTS. Weld parameters will be developed for an aluminum alloy in gauges ranging from 0.320 to 0.400 in. thick. Weld quality will be verified through radiography, mechanical property testing at ambient and LN2 temperatures, and metallurgical analysis. The AdAPT weld head will then be mounted on a 22-ft diameter dome tool, which will be modified to include a welding track and drive system for moving the AdAPT weld head along the weld joint. This tool will then be used to manufacture a 22-ft diameter dome of an aluminum alloy, with 0.320-in. constant thickness joints, consisting of three individual gore panels. Finally, the 27.5-ft diameter quarter dome will be welded on the Universal Weld System. The quarter dome will consist of three individual gore panels with weld lands tapering from 0.320 to 0.360 in. in thickness. With the demonstration of these welds, the ability to manufacture large diameter domes using the friction stir weld process in conjunction with a universal weld system provides a low risk approach to the fabrication of aluminum tanks for future launch vehicle applications.
For assemblies of cavities in cleanrooms, single-use tooling systems are made for the alignment and installation of ancillary components such as couplers and bellows. To minimize the number of tooling sets created, a design has been created to standardize alignment features to allow for assembly of different components with one set of tooling. A prototype set of tooling has been developed to with the required degrees of freedom for multiple assemblies while minimizing deformation during the assembly process. Prototype designs have been created for PIP-II SSR2 and 650 Cavities and for AUP Crab Cavities. Using 3D printing, this tooling can be quickly adjusted to allow for different ancillary components. The development process and status of the design will be discussed.
For assemblies of cavities in cleanrooms, single-use tooling systems are made for the alignment and installation of ancillary components such as couplers and bellows. To try and minimize the amount of tooling sets used, a design has been created to standardize alignment features to allow for assembly of different components with one set of tooling. A prototype set of tooling has been developed to with the required degrees of freedom for multiple assemblies while minimizing deformation during the assembly process. Prototype designs have been created for PIP-II SSR2 and 650 Cavities and for AUP Crab Cavities. Using 3D printing, this tooling can be quickly adjusted to allow for different ancillary components. The development process and status of the design will be discussed.
The American Society of Mechanical Engineers Boiler Pressure and Vessel Code (ASME BPVC) Section III, Division 5, Article HHA-3000 outlines graphite core component and graphite core assembly design guidelines. Graphite core components are defined as ?components manufactured from graphite that are installed to form a graphite core assembly within the reactor pressure vessel of a high temperature, graphite moderated fission reactor.? (p. 413) Graphites? inherent defect distributions do not allow for deterministic material reliability. Rather, graphite has variable strength distributions which change by grade. Article HHA-3000 outlines two semi-probabilistic methods, the full and simplified assessments, which set design load limit targets for each of three component structural reliability classes. The Design Task Group was officially recognized as a specialized task group within ASME November of 2023, though we?ve been collaborating since 2022. The purpose of the Design Task Group is to correct, clarify, and make HHA-3000 function as intended. The Design Task Group will sunset once we?ve achieved our objectives. The Design Task Group was specifically told to not write new Code. While there may be more precise and more accurate methods to determine reliability targets, the current methods are conservative, relatively simple to implement, and have thus far been considered satisfactory for setting design reliability targets. Much of the ground-work to write proposal files and background documents for records to make the changes needed to achieve our objective have been completed. The Design Task Group has documented much of their work through papers, presentations, and memorandums. Three memorandums in which INL team members had substantial contributions are found in the Appendices: FEA Modeling for the Baseline Program, Evaluating the Effects on Margin of Updating the Threshold and Shape Parameters in the Full Assessment, and Interpretations of the Full and Simplified Assessments in ASME BPVC. Most of the on-going work to achieve the Design Task Group?s objective will be addressing comments on existing records and moving records through the balloting process. The Design Task Group met bi-weekly mostly through the end of FY2023. Since February 2024, the Design Task Group has mostly been completed with solving and documenting the technical issues associated with the assessments. Unless new tasks are identified, the remaining work of the Design Task Group will be political and editorial.
System requirements and basic design criteria were defined for berthing or docking a payload to the 25 kW power module which will provide electrical power and attitude control, cooling, data transfer, and communication services to free-flying and Orbiter sortie payloads. The selected umbilical system concept consists of four assemblies and command and display equipment to be installed at the Orbiter payload specialist station: (1) a movable platen assembly which is attached to the power system with EVA operable devices; (2) a slave platen assembly which is attached to the payload with EVA operable devices; (3) a fixed secondary platen permanently installed in the power system; and (4) a fixed secondary platen permanently installed on the payload. Operating modes and sequences are described.
We have developed, tested, and flown a caddy capable of collecting aseptic samples from external surfaces of the ISS (International Space Station). The sampling caddy is certified for use during US EVA (extra vehicular activity) and was launched to ISS in the summer of 2023. We are scheduled to collect samples from 6 locations outside ISS during an EVA in May of 2024. We will freeze these samples at -80°C on orbit and return them to Earth. We will then extract and sequence any DNA collected during the EVA using next generation sequencing technologies to characterize the community composition and function of each sample. Measuring the type and quantity of microbes present on the exterior of ISS will allow us to address knowledge gap 2B, “Acceptable levels of microbial/organic releases from humans and support systems” described in a 2019 COSPAR report. Collecting data about microbial release from current crewed vehicles will inform requirements for acceptable leak rates for future crewed missions to Mars. The sampling kit consists of eight commercially available, sterile, DNA free, macrofoam swabs ( 23 mm. diameter ) installed in custom aluminum end effectors. Each end effector is housed in and individual aluminum canister. Each canister contains a 0.2 μm Teflon filter to allow the interior volume to accommodate pressure changes without permitting microbial contaminants to enter the sterile interior volume. A handle repurposed from the space shuttle tile repair kit is used to remove the end effector from the sample canister, collect a sample by swabbing a surface and then replace the end effector in its canister. The canisters and end effectors were cleaned and assembled on Earth. Prior to installing the sterile swab the canisters and end effectors were sterilized in an autoclave at 134°C, 215 kPA, for 7 min.. The final assembly occurred in a sterilized class II biosafety cabinet. We will collect six samples from the 1) airlock vestibule, 2) airlock thermal cover, 3) a gap in the micrometeorite shielding near the airlock, 4) a handrail near the airlock, 5) the CDRA (Carbon Dioxide Removal Assembly) vent, and 6) the VES (Vacuum Exhaust System) vent. The remaining two swabs will be reserved as controls. One swab will be exposed during the EVA without touching any surfaces to act as a blank. The final swab will remain sealed until the entire sampling kit is returned to earth. Based on previously published results from the Russian segment, we hypothesize that there will be detectable microbes at some or all of these locations. Ground-based testing of this sampling caddy confirms that the swabs remain sterile as the canisters transition in and out of vacuum. We were able to retrieve, viable bacterial and fungal cells as well as DNA from samples collected from US space suits during vacuum chamber tests lasting as long as seven hours. Based on these results and feedback from the test subjects the sampling caddy was modified to improve ergonomics and meet US EVA safety requirements. Bayonet probes were added to the sides of the sample kit as alternate mounting points. Additional locking features were added to the end effector and the filter stack to prevent inadvertent release during use. The opening mechanism was changed from one where the end effector was rocked laterally to defeat a ball detent to a twist-to-open threaded closure for similar reasons. Demonstrating, this sampling caddy’s effectiveness during a US EVA will allow us to address knowledge gaps identified in COSPAR reports and begin to define planetary protection requirements for life support systems on crewed missions to mars. This kit could also be used to collect contamination control samples during Artemis missions to verify requirements and could be easily modified for robotic sample collection.
We have developed, tested, and flown a caddy capable of collecting aseptic samples from external surfaces of the ISS (International Space Station). The sampling caddy is certified for use during US EVA (extra vehicular activity) and was launched to ISS in the summer of 2023. We are scheduled to collect samples from 6 locations outside ISS during an EVA in May of 2024. We will freeze these samples at -80°C on orbit and return them to Earth. We will then extract and sequence any DNA collected during the EVA using next generation sequencing technologies to characterize the community composition and function of each sample. Measuring the type and quantity of microbes present on the exterior of ISS will allow us to address knowledge gap 2B, “Acceptable levels of microbial/organic releases from humans and support systems” described in a 2019 COSPAR report. Collecting data about microbial release from current crewed vehicles will inform requirements for acceptable leak rates for future crewed missions to Mars. The sampling kit consists of eight commercially available, sterile, DNA free, macrofoam swabs ( 23 mm. diameter ) installed in custom aluminum end effectors. Each end effector is housed in and individual aluminum canister. Each canister contains a 0.2 μm Teflon filter to allow the interior volume to accommodate pressure changes without permitting microbial contaminants to enter the sterile interior volume. A handle repurposed from the space shuttle tile repair kit is used to remove the end effector from the sample canister, collect a sample by swabbing a surface and then replace the end effector in its canister. The canisters and end effectors were cleaned and assembled on Earth. Prior to installing the sterile swab the canisters and end effectors were sterilized in an autoclave at 134°C, 215 kPA, for 7 min.. The final assembly occurred in a sterilized class II biosafety cabinet. We will collect six samples from the 1) airlock vestibule, 2) airlock thermal cover, 3) a gap in the micrometeorite shielding near the airlock, 4) a handrail near the airlock, 5) the CDRA (Carbon Dioxide Removal Assembly) vent, and 6) the VES (Vacuum Exhaust System) vent. The remaining two swabs will be reserved as controls. One swab will be exposed during the EVA without touching any surfaces to act as a blank. The final swab will remain sealed until the entire sampling kit is returned to earth. Based on previously published results from the Russian segment, we hypothesize that there will be detectable microbes at some or all of these locations. Ground-based testing of this sampling caddy confirms that the swabs remain sterile as the canisters transition in and out of vacuum. We were able to retrieve, viable bacterial and fungal cells as well as DNA from samples collected from US space suits during vacuum chamber tests lasting as long as seven hours. Based on these results and feedback from the test subjects the sampling caddy was modified to improve ergonomics and meet US EVA safety requirements. Bayonet probes were added to the sides of the sample kit as alternate mounting points. Additional locking features were added to the end effector and the filter stack to prevent inadvertent release during use. The opening mechanism was changed from one where the end effector was rocked laterally to defeat a ball detent to a twist-to-open threaded closure for similar reasons. Demonstrating, this sampling caddy’s effectiveness during a US EVA will allow us to address knowledge gaps identified in COSPAR reports and begin to define planetary protection requirements for life support systems on crewed missions to mars. This kit could also be used to collect contamination control samples during Artemis missions to verify requirements and could be easily modified for robotic sample collection.
Combined heat and power (CHP), sometimes referred to as cogeneration, is an efficient and clean approach to generating electric power and useful thermal energy onsite from a single fuel source, offering reliable and affordable energy services to businesses and institutions. Furthermore, CHP provides a cost effective opportunity to improve the environmental footprint and resilience of industrial and commercial facilities across the United States. CHP equipment can be custom-engineered or installed as a predesigned and assembled package. A packaged CHP system is a standardized, pre-engineered system that includes all equipment, piping, wiring, and ancillary components to deliver electricity and thermal energy to a host facility with minimal onsite engineering and design time. Packaged CHP systems can be shipped as single or multiple modules with standard interconnections (e.g., fuel; electrical; thermal—hot water, steam, and/or chilled water), which simplifies installation and reduces the costs associated with the project. Most containerized or single packaged CHP system offerings range from 10 kW to 3 MW in capacity. Packaged CHP systems are extending the operating, efficiency, and emissions benefits of CHP to nontraditional markets in commercial, institutional, multifamily, light manufacturing, government, and military applications. These markets tend to be served by smaller systems (less than 5 MW) that are conducive to pre-engineered packaging and/or modularization. Many of these sectors have limited CHP experience and technical resources to adequately evaluate, install, and maintain onsite CHP systems. The introduction of packaged CHP offerings from experienced CHP Packagers and Solution Providers has accelerated CHP adoption, lowered energy costs, reduced emissions, and strengthened energy resilience in these sectors. In 2019, the US Department of Energy (DOE) launched the Packaged CHP eCatalog to promote increased acceptance of efficient, cost-effective CHP in these applications. The Packaged CHP eCatalog is a web-based, searchable platform that hosts DOE-recognized packaged CHP systems with features designed to reduce economic and performance risks for designers, developers, owners, and facility operators interested in installing CHP. DOE established the Packaged CHP Accelerator at the same time to help launch and publicize the eCatalog, and to validate project performance, cost, and installation time of CHP packages across a variety of applications. Accelerator efforts documented installed cost reductions and installation time reductions of more than 20% for packaged CHP systems over 100 kW compared with custom-engineered systems. The Packaged CHP Accelerator and eCatalog established a peer-to-peer network connecting public and private sector partners including utilities, state energy offices, and energy efficiency program administrators interested in promoting cost-effective, efficient CHP systems, Packagers, and Solution Providers. Feedback from these partners, along with input from DOE’s CHP Technical Assistance Partnerships (CHP TAPs), was critical in understanding the current market for packaged CHP technologies, stimulating investment in these technologies, and guiding future directions for packaged CHP systems and their applications. This report provides background on packaged CHP systems, an overview of their benefits, a profile of current packaged CHP installations, and a summary of future market trends; this report is intended for facility owners, project developers, engineers, policymakers, and other stakeholders looking to increase the adoption of efficient, flexible, and resilient packaged CHP systems.
The research team performed a detailed bottom-up manufacturing cost estimate for an advanced parabolic trough design - the Solar Dynamics Sunbeam-MT (Sunbeam Mid-Term). This includes all components for manufacturing and assembly in a manufacturing facility (e.g. space frame and arms), and the purchased parts (e.g. mirrors and receiver tubes). Estimates of the construction and assembly activities have been made to then determine an estimated installed cost. Prior analysis has already undertaken detailed bottom-up manufacturing, assembly, and construction analysis for the Ultimate Trough from schlaich bergermann partner (sbp), and this work updates the solar field cost estimates based on a similar aperture area as the SunBeam-MT. For this analysis, the Ultimate Trough is considered the commercial parabolic trough and the Sunbeam-MT as the advanced parabolic trough. For similarity, both the Sunbeam-MT and the Ultimate Trough have been modelled with a solar field with approximately 800,000 square meters (m2) in aperture area - the equivalent of a large CSP plant. The analysis has found a potential installed cost estimate of the Sunbeam-MT could be $120/m2 but must be built at scale to confirm this estimate. Compared to prior analysis, the commercial Ultimate Trough using U.S. conditions, has reduced in installed cost from $178/m2 to $152/m2. Both designs could be even cheaper with Chinese steel.