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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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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Data Applicability of Heritage and New Hardware for Launch Vehicle System Reliability Models

Many launch vehicle systems are designed and developed using heritage and new hardware. In most cases, the heritage hardware undergoes modifications to fit new functional system requirements, impacting the failure rates and, ultimately, the reliability data. New hardware, which lacks historical data, is often compared to like systems when estimating failure rates. Some qualification of applicability for the data source to the current system should be made. Accurately characterizing the reliability data applicability and quality under these circumstances is crucial to developing model estimations that support confident decisions on design changes and trade studies. This presentation will demonstrate a data-source classification method that ranks reliability data according to applicability and quality criteria to a new launch vehicle. This method accounts for similarities/dissimilarities in source and applicability, as well as operating environments like vibrations, acoustic regime, and shock. This classification approach will be followed by uncertainty-importance routines to assess the need for additional data to reduce uncertainty.

Al Hassan Mohammad↗
NASA NTRS2021

Comparing Cumulative Flight Thermal Fatigue to Ground Test Results for Memory Components on the Mars Curiosity Rover

This paper explores the methods used to examine Mars Curiosity Rover’s flight temperature data in relation to the Package Qualification and Verification (PQV) accelerated thermal cycle life test data in response to flight anomalies. The redundant Rover Compute Element (RCE-A, B) has experienced an inability to mount the flash memory several times. The leading cause of these anomalies is likely the loss of electrical connectivity, which is theorized to be due to cracks on the memory component solder joints by thermal cycle fatigue. To investigate this theory, the number of thermal cycles accumulated in flight was compared to PQV accelerated thermal cycle life test data. The goal of this study was to inform mission operations of the risk associated with thermal cycling damage on the RCE. However, since the RCE-B does not have continuous temperature data from the Platinum Resistance Thermometer (PRT) closest to the flash memory, a model was made to correlate continuous data from two other nearby sensors on the RCE-B to the noncontiguous sensor. Using the Rainflow Counting Algorithm, the reconstituted data was converted into the number of equivalent thermal cycles. The Coffin-Manson Equation was used to compare flight thermal cycles to the PQV test. The accelerated life test showed cracking on the memory component solder joints after 500 cycles of 80°C temperature excursions. This study found that the RCE-A and RCE-B have undergone an equivalent of 144 and 430 cycles of 80°C temperature excursions during flight, respectively.

Bell, Charles↗
NASA NTRS2007

Design of Electrical Systems for Rocket Propulsion Test Facilities at the John C. Stennis Space Center

This viewgraph presentation reviews the design of the electrical systems that are required for the testing of rockets at the Rocket Propulsion Facility at NASA Stennis Space Center (NASA SSC). NASA/SSC s Mission in Rocket Propulsion Testing Is to Acquire Test Performance Data for Verification, Validation and Qualification of Propulsion Systems Hardware. These must be accurate reliable comprehensive and timely. Data acquisition in a rocket propulsion test environment is challenging: severe temporal transient dynamic environments, large thermal gradients, vacuum to 15 ksi pressure regimes SSC has developed and employs DAS, control systems and control systems and robust instrumentation that effectively satisfies these challenges.

Hughes, Mark S.↗
DOE OSTI2021

Report on FY 2021 Fabrication and Testing of Qualified Alloy 709 Welds at ORNL

Alloy 709 is a candidate construction material for the Sodium Fast Reactor (SFR). As part of the Alloy 709 ASME Code Case development team under the Advanced Reactor Technologies (ART) Program, this work covers the development of the technical basis for weld fabrication and weld qualification of Alloy 709. This report summarizes the research conducted in FY 2021 and relevant results from previous reporting periods, aimed at welding commercial heat of Alloy 709 plates of relatively high phosphorous (P) level in support of ASME code case data package. Welding, code qualification tests, and associated microstructure characterization were carried out in determining the effect of P levels of weld wire on the weldability of the high P commercial heat of Alloy 709. The Alloy 709 weld creep strength was evaluated though preliminary creep testing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS2007

Space Flight Requirements for Fiber Optic Components; Qualification Testing and Lessons Learned

"Qualification" of fiber optic components holds a very different meaning than it did ten years ago. In the past, qualification meant extensive prolonged testing and screening that led to a programmatic method of reliability assurance. For space flight programs today, the combination of using higher performance commercial technology, with shorter development schedules and tighter mission budgets makes long term testing and reliability characterization unfeasible. In many cases space flight missions will be using technology within years of its development and an example of this is fiber laser technology. Although the technology itself is not a new product the components that comprise a fiber laser system change frequently as processes and packaging changes occur. Once a process or the materials for manufacturing a component change, even the data that existed on its predecessor can no longer provide assurance on the newer version. In order to assure reliability during a space flight mission, the component engineer must understand the requirements of the space flight environment as well as the physics of failure of the components themselves. This can be incorporated into an efficient and effective testing plan that "qualifies" a component to specific criteria defined by the program given the mission requirements and the component limitations. This requires interaction at the very initial stages of design between the system design engineer, mechanical engineer, subsystem engineer and the component hardware engineer. Although this is the desired interaction what typically occurs is that the subsystem engineer asks the components or development engineers to meet difficult requirements without knowledge of the current industry situation or the lack of qualification data. This is then passed on to the vendor who can provide little help with such a harsh set of requirements due to high cost of testing for space flight environments. This presentation is designed to guide the engineers of design, development and components, and vendors of commercial components with how to make an efficient and effective qualification test plan with some basic generic information about many space flight requirements. Issues related to the ~ physics of failure, acceptance criteria and lessons learned will also be discussed to assist with understanding how to approach a space flight mission in an ever changing commercial photonics industry.

Ott, Melanie N.↗
NASA NTRS2015

NASA Propulsion Concept Studies and Risk Reduction Activities for Resource Prospector Lander

The trade study has led to the selection of propulsion concept with the lowest cost and net lowest risk -Government-owned, flight qualified components -Meet mission requirements although the configuration is not optimized. Risk reduction activities have provided an opportunity -Implement design improvements while development with the early-test approach. -Gain knowledge on the operation and identify operation limit -Data to anchor analytical models for future flight designs; The propulsion system cold flow tests series have provided valuable data for future design. -The pressure surge from the system priming and waterhammer within component operation limits. -Enable to optimize the ullage volume to reduce the propellant tank mass; RS-34 hot fire tests have successfully demonstrated of using the engines for the RP mission -No degradation of performance due to extended storage life of the hardware. -Enable to operate the engine for RP flight mission scenarios, outside of the qualification regime. -Provide extended data for the thermal and GNC designs. Significant progress has been made on NASA propulsion concept design and risk reductions for Resource Prospector lander.

Trinh, Huu P.↗
DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Design of Mini-Plate-1 Irradiation Test for Qualification of High-Density, Low-Enriched U-10Mo Monolithic Fuel

The United States High Performance Research Reactor project is tasked with fuel development and qualification leading to conversion of higher power research and test reactors in the US from high-enriched uranium (HEU) to low-enriched uranium (LEU) fuels. Here, this manuscript identifies the functional and operational design requirements of the first miniature test plate (mini-plate [MP]) irradiation campaign (MP-1) of commercially fabricated LEU U-10Mo monolithic plate-type fuel and is the precursor to a large parametric mini-plate test (MP-2) aimed at producing the data to support regulatory qualification of the LEU U-10Mo monolithic fuel. The manuscript (1) provides a general description of the selected U-10Mo LEU fuel and (2) defines the overall experiment design and functional requirements to accomplish the specific test objective of MP-1, which is to confirm that the commercially manufactured LEU U-10Mo monolithic fuel meets the established requirements of geometric stability, mechanical integrity and stable and predictable behavior. The fuel testing parameters are established by the need to bound performance behavior within the operational envelope of the reactors being converted.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1979

Description and orbit data of variable-conductance heat-pipe system for the communications technology satellite

A variable-conductance heat-pipe system (VCHPS) with methanol as the working fluid and a nitrogen and helium mixture as the control gas was used for the thermal control of a 200 W RF traveling wave tube of the Communication Technology Satellite. Three stainless steel heat pipes (one redundant) and an aluminum radiator were designed to transfer 196 watts for an evaporator temperature of 50 C. The system has operated for three years with no noticeable change in performance. On four occasions the heat pipes apparently deprimed. A short time after reducing the tube power, the heat pipes reprimed and the system continued to operate normally. The description, qualification testing, and orbit data of the VCHPS are presented.

Gedeon, L.↗
DOE OSTI2023

Promoting the Regulatory Acceptance of Combined Ion and Neutron Irradiation for Material Degradation in Nuclear Reactors

The Advanced Materials and Manufacturing Technologies (AMMT) program within the Department of Energy Office of Nuclear Energy has developed its current recommendation for promoting the use of combined ion and neutron irradiation data for the accelerated qualification of nuclear reactor materials. This plan is intended to provide a collaborative path forward that can be adopted by academia, national laboratories, and industry, and has been developed with input from the regulatory research arm of the U.S. Nuclear Regulatory Commission (NRC). In the context of nuclear energy, the U.S. Department of Energy is responsible for nuclear energy-related research and development and promotion of nuclear technologies, while the NRC is an independent regulatory agency responsible for the safety of the civilian use of nuclear technologies. These two agencies thus have distinct but interconnected roles regarding the development and deployment of nuclear technologies. As the needs for the nuclear energy industry continue to evolve in the 21st century, it is critical to set the pace for timely industry adoption of new technological solutions that also can be accepted by regulatory agencies. New ways of collecting and utilizing data for regulatory purposes have become a necessity.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Microstructure and Mechanical Properties of Ni-based Alloys Fabricated by Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies (AMMT) program is aiming at the accelerated incorporation of new materials and manufacturing technologies into nuclear-related systems. Complex Ni-based components fabricated by laser powder bed fusion (LPBF) could enable operating temperatures at T > 700°C in aggressive environments such as molten salts or liquid metals. However, available mechanical properties data relevant to material qualification remains limited, in particular for Ni-based alloys routinely fabricated by LPBF such as IN718 (Ni- 19Cr-18Fe-5Nb-3Mo) and Haynes 282 (Ni-20Cr-10Co-8.5Mo-2.1Ti-1.5Al). Creep testing was conducted on LPBF 718 at 600°C and 650°C and on LPBF 282 at 750°C. finding that the creep strength of the two alloys was close to that of wrought counterparts. with lower ductility at rupture. Heat treatments were tailored to the LPBF-specific microstructure to achieve grain recrystallization and form strengthening γ' precipitates for LPBF 282 and γ' and γ" precipitates for LPBF 718. In-situ data generated during printing and ex-situ X-ray computed tomography (XCT) scans were used to correlate the creep properties of LPBF 282 to the material flaw distribution. In- situ data revealed that spatter particles are the potential causes for flaws formation in LPBF 282. with significant variation between rods based on their location on the build plate. XCT scans revealed the formation of a larger number of creep flaws after testing in the specimens with a higher initial flaw density. which led to a lower ductility for the specimen.

Dryepondt, Sebastien↗
NASA NTRS2005

Offgassing Characterization of the Columbus Laboratory Module

Trace gaseous contamination in the cabin environment is a major concern for manned spacecraft, especially those designed for long duration missions, such as the International Space Station (ISS). During the design phase, predicting the European-built Columbus laboratory module s contribution to the ISS s overall trace contaminant load relied on "trace gas budgeting" based on material level and assembled article tests data. In support of the Qualification Review, a final offgassing test has been performed on the complete Columbus module to gain cumulative system offgassing data. Comparison between the results of the predicted offgassing load based on the budgeted material/assembled article-level offgassing rates and the module-level offgassing test is presented. The Columbus module offgassing test results are also compared to results from similar tests conducted for Node 1, U.S. Laboratory, and Airlock modules.

Rampini, riccardo↗
DOE OSTI2023

PIPII cryoplant non thermal cycling updates

The Proton Improvement Plan-II (PIP-II) is a crucial upgrade to the Fermilab accelerator complex, featuring a new 800-MeV Superconducting Radio-Frequency (SRF) linear accelerator (LINAC) with 23 cryomodules operating at 2K. The LINAC thermohydraulic conditions are satisfied by the cryogenic subsystems: Cryogenic Distribution System (CDS), a helium refrigerator cold box (CB), a warm compression station (WCS) and a helium recovery system (RSYS). The accelerator has a strict requirement of non-thermal cycling of the LINAC cryomodules during planned and unplanned subsystem outages. This paper presents an integrated operating modes analysis of the of the LINAC/CDS thermohydraulic loads satisfied by the CB/WCS cooling system supported by the RSYS inventory management system. The study is based on latest cryoplant and CDS engineering deliverables, as well as the recent performance data from single cryomodule qualification tests performed at the Fermilab PIP-II Injector Test test s tand. The study evaluates both normal and abnormal operating modes, with a focus on identifying integrated scenarios that put subsystems components under stress. The conclusions of this study will help build redundancy to reduce the risk of thermal cycles during planned and unplanned subsystem outages.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Integration of sensors through additive manufacturing leading to increased efficiencies of gas turbines for power generation and propulsion

To realize the full capability of additively manufactured components in complex energy systems, it is imperative to minimize early component failures during development phases and during operation. Traditional field feedback timelines and offline inspection protocols significantly reduce the design-manufacturing iteration times. To address this specific question, the project developed and demonstrated a method for the integration of sensors into complex components through additive manufacturing. The team used gas turbine engines as a platform, which meets the need of both power generation and propulsion and offer opportunities for cost reductions and efficiency increases. The innovation of this intelligent integration of sensors into complex components uniquely customized to address questions of integrity and durability for additively manufactured components. With real-time sensing data from additively manufactured components, turbine manufacturers will realize higher efficiencies, reduced component failures, and a 30-50% acceleration in product deployment of high efficiency gas turbine components due to a faster reduction in component risk assessment under actual operating conditions. This is a transformative shift towards a data-driven design and qualification of additively manufactured gas turbine components. To directly integrate sensors into additively manufactured components with all the complexities of actual hardware, powder bed fusion (direct metal laser sintering) and laser metal deposition technologies was developed. Validation took take place in two university laboratories both of which contain actual engine hardware and closely simulate a gas turbine prior to demonstrating the technology in a turbine development test. Indeed, two major technologies from this research cold impact turbine systems in the near future: (1) higher efficiency materials and designs enabled by additive manufacturing with 50% faster design to manufacturing cycle time, to enable faster time-to-market targets; and (2) integration of sensors into additively manufactured components enabling broad health and condition based prognostics for faster component and engine risk reduction.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1974

Communications constraints on a Jupiter probe mission

The use of the Saturn Uranus telemetry design for Jupiter entry requires the following qualifications in space probe data handling: A single dump substitute for the dual damp, a reduction in the neutral mass spectrometer rate, and providing that a second burn is made, a delta V correction.

Hinrichs, C.↗
NASA NTRS1979

Design package for programmable controller and hydronic subsystem

Information used in the evaluation of design of Sunkeeper Control's electronic controllers and hydronic packages is discussed. This information includes system performance specifications, a design data brochure, drawings, and qualification and acceptance test procedures.

Source record↗