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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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NASA NTRS2005

Liquid Nitrogen Removal of Critical Aerospace Materials

Identification of innovative solutions to unique materials problems is an every-day quest for members of the aerospace community. Finding a technique that will minimize costs, maximize throughput, and generate quality results is always the target. United Space Alliance Materials Engineers recently conducted such a search in their drive to return the Space Shuttle fleet to operational status. The removal of high performance thermal coatings from solid rocket motors represents a formidable task during post flight disassembly on reusable expended hardware. The removal of these coatings from unfired motors increases the complexity and safety requirements while reducing the available facilities and approved processes. A temporary solution to this problem was identified, tested and approved during the Solid Rocket Booster (SRB) return to flight activities. Utilization of ultra high-pressure liquid nitrogen (LN2) to strip the protective coating from assembled space shuttle hardware marked the first such use of the technology in the aerospace industry. This process provides a configurable stream of liquid nitrogen (LN2) at pressures of up to 55,000 psig. The performance of a one-time certification for the removal of thermal ablatives from SRB hardware involved extensive testing to ensure adequate material removal without causing undesirable damage to the residual materials or aluminum substrates. Testing to establish appropriate process parameters such as flow, temperature and pressures of the liquid nitrogen stream provided an initial benchmark for process testing. Equipped with these initial parameters engineers were then able to establish more detailed test criteria that set the process limits. Quantifying the potential for aluminum hardware damage represented the greatest hurdle for satisfying engineers as to the safety of this process. Extensive testing for aluminum erosion, surface profiling, and substrate weight loss was performed. This successful project clearly demonstrated that the liquid nitrogen jet possesses unique strengths that align remarkably well with the unusual challenges that space hardware and missile manufacturers face on a regular basis. Performance of this task within the confines of a critical manufacturing facility marks a milestone in advanced processing.

Noah, Donald E.↗

NASA NTRS2001

NASA/ARMY/BELL XV-15 Tiltrotor Low-Noise Terminal Area Operations Flight Research Program

To evaluate the noise reduction potential for tiltrotor aircraft, a series of three XV- 15 acoustic flight tests were conducted over a five-year period by a NASA/Army/Bell Helicopter team. Lower hemispherical noise characteristics for a wide range of steady-state terminal area type operating conditions were measured during the Phase I test and indicated that the takeoff and level flight conditions were not significant contributors to the total noise of tiltrotor operations. Phase I results were also used to design low-noise approach profiles that were tested later during the Phase 2 and Phase 3 tests. These latter phases used large area microphone arrays to directly measure ground noise footprints. Approach profiles emphasized noise reduction while maintaining handling qualities sufficient for tiltrotor commercial passenger ride comfort and flight safety under Instrument Flight Rules (IFR) conditions. This paper will discuss the weather, aircraft, tracking, guidance, and acoustic instrumentation systems, as well as the approach profile design philosophy, and the overall test program philosophy. Acoustic results are presented to document the variation in tiltrotor noise due to changes in operating condition, indicating the potential for significant noise reduction using the unique tiltrotor capability of nacelle tilt. Recommendations are made for a final XV-15 test to define the acoustic benefits of the automated approach capability which has recently been added to this testbed aircraft.

Edwards, Bryan D.↗

NASA NTRS1991

Reactor safety for the Space Exploration Initiative

A task force was created by the National Aeronautics and Space Administration to conduct a 90-day study to support efforts to determine requirements to meet the goals of the Space Exploration Initiative. The task force identified the need for a nuclear reactor to provide the electrical power required as the outpost power demands on the moon and Mars evolve into hundreds of kilowatts. A preliminary hazards analysis has been performed to examine safety aspects of nuclear reactor power systems for representative missions to the moon and Mars. Mission profiles were defined for reference lunar and Martian flights. Potential alternatives to each mission phase were also defined. Accident scenarios were qualitatively defined for the mission phases. The safety issues decay heat removal, reactor control, disposal, criticality, end-of-mission shutdown, radiation exposure, the Martian environment, high speed impact on the surfaces of the moon or Mars, and return flyby trajectories were identified.

Dix, Terry E.↗

NASA NTRS2000

NASA/ARMY/BELL XV-15 Tiltrotor Low Noise Terminal Area Operations Flight Research Program

A series of three XV-15 acoustic flight tests have been conducted over a five year period by a NASA/Army/Bell Helicopter team to evaluate the noise reduction potential for tiltrotor aircraft during terminal area operations. Lower hemispherical noise characteristics for a wide range of steady-state terminal area type operating conditions were measured during the phase 1 test and indicated that the takeoff and level flight conditions were not significant contributors to the total noise of tiltrotor operations. Phase 1 results were used to design low noise approach profiles that were tested during the phase 2 and phase 3 tests, which used large area microphone arrays to directly measure the ground noise footprints. Approach profile designs emphasized noise reduction while maintaining handling qualities sufficient for tiltrotor commercial passenger ride comfort and flight safety under Instrument Flight Rules (IFR) conditions. This paper will discuss the weather, aircraft, tracking, guidance, and acoustic instrumentation systems, as well as the approach profile design philosophy, and the overall test program philosophy. Acoustic results are presented documenting the variation in tiltrotor noise due to changes in operating condition, indicating the potential for significant noise reduction using the unique tiltrotor capability of nacelle tilt.

Conner, David A.↗

NASA NTRS1975

Modification to area navigation equipment for instrument two-segment approaches

A two-segment aircraft landing approach concept utilizing an area random navigation (RNAV) system to execute the two-segment approach and eliminate the requirements for co-located distance measuring equipment (DME) was investigated. This concept permits non-precision approaches to be made to runways not equipped with ILS systems, down to appropriate minima. A hardware and software retrofit kit for the concept was designed, built, and tested on a DC-8-61 aircraft for flight evaluation. A two-segment approach profile and piloting procedure for that aircraft that will provide adequate safety margin under adverse weather, in the presence of system failures, and with the occurrence of an abused approach, was also developed. The two-segment approach procedure and equipment was demonstrated to line pilots under conditions which are representative of those encountered in air carrier service.

Source record↗

DOE OSTI2022

Xanthohumol microbiome and signature in adults with Crohn’s disease (the XMaS trial): a protocol for a phase II triple-masked, placebo-controlled clinical trial

Xanthohumol (XN), a bioactive flavonoid from Humulus lupulus with anti-inflammatory properties, has potential benefits for patients with Crohn’s disease (CD), a type of inflammatory bowel disease. We recently completed and published results of a placebo-controlled phase I clinical trial demonstrating the safety and tolerability of 24 mg XN daily for 8 weeks. The present study aims to evaluate the safety and tolerability of the same dose of XN adults with clinically active CD in a placebo-controlled phase II clinical trial. Additional aims will assess the impact of XN on inflammatory biomarkers, platelet function, CD clinical activity, and stool microbial composition. The metabolism of XN will also be evaluated. This article provides a model protocol for consideration in investigations of XN or other natural products in disease states. A triple-masked, randomized, placebo-controlled trial will be conducted in adults with clinically active CD. Participants (n ≤ 32) will be randomized to either 24 mg encapsulated XN per day or placebo and followed for 8 weeks. Throughout the trial, participants will be queried for adverse events. Biomarkers of clinical safety, blood and stool markers of inflammation, platelet function, Crohn’s Disease Activity Index score, stool microbial composition, and XN metabolite profiles in blood, urine, and stool will be assessed every 2 weeks. We describe the protocol for a phase II clinical trial that evaluates the safety and tolerability of XN in adults with active CD, as well as evaluate metabolism and mechanisms that are relevant to CD and other diseases with underlying inflammation and/or gut permeability. The effects of XN on inflammatory biomarkers, platelet function, the microbiota, and multi-omics biomarkers measured in this phase II trial of adults with CD will be compared to the effects of XN in healthy adults in our previous phase I trial. The results of the study will advance the evidence guiding the use of XN in patients with CD.

60 APPLIED LIFE SCIENCES↗

NASA NTRS2011

C-Band Airport Surface Communications System Engineering-Initial High-Level Safety Risk Assessment and Mitigation

This document is being provided as part of ITT's NASA Glenn Research Center Aerospace Communication Systems Technical Support (ACSTS) contract: "New ATM Requirements--Future Communications, C-Band and L-Band Communications Standard Development." ITT has completed a safety hazard analysis providing a preliminary safety assessment for the proposed C-band (5091- to 5150-MHz) airport surface communication system. The assessment was performed following the guidelines outlined in the Federal Aviation Administration Safety Risk Management Guidance for System Acquisitions document. The safety analysis did not identify any hazards with an unacceptable risk, though a number of hazards with a medium risk were documented. This effort represents an initial high-level safety hazard analysis and notes the triggers for risk reassessment. A detailed safety hazards analysis is recommended as a follow-on activity to assess particular components of the C-band communication system after the profile is finalized and system rollout timing is determined. A security risk assessment has been performed by NASA as a parallel activity. While safety analysis is concerned with a prevention of accidental errors and failures, the security threat analysis focuses on deliberate attacks. Both processes identify the events that affect operation of the system; and from a safety perspective the security threats may present safety risks.

Zelkin, Natalie↗

NASA NTRSDate not supplied

NASA’S Current Efforts and Applications of NDE to Improve Space Flight Safety

National Aeronautics and Space Administration (NASA) continues to push the boundary of manned flight. Current mission profiles include flights to the moon and mars. Many of these missions require advance manufacturing and planned off planet resource utilization. As NASA continues to develop highly advance materials and manufacturing techniques to meet these mission profiles, inspection of these increasingly complex parts has had to evolve as well. Additive manufacturing is coming to the forefront as a primary manufacturing technique but offers unique challenges when inspection and certification are required. NASA has been working diligently to be a leader in developing and utilizing inspection techniques capable of inspecting these highly advanced parts. Additionally additive manufacturing techniques can also be used to build parts in space and provides a vehicle for in-situ resource utilization for off world missions. As NASA and its commercial crew partners move forward inspection techniques will need to continue to advance to ensure safe manned space flight. In this talk NASA will highlight many of the advanced nondestructive evaluation efforts going on across the agency. As well as highlights for points of infusion for helping NASA meet it’s future missions.

NDE↗

DOE OSTI2026

Current ramp-up studies for NSTX-U in support of the development of non-inductive current ramp-up scenarios in STs

The Spherical Tokamak (ST) is a low-aspect-ratio tokamak projected to enable simultaneous operation at high normalized toroidal beta and high bootstrap current fraction. However, a compact ST reactor cannot be built with a full-sized solenoid. The remaining current required for sustained operation must be ramped up non-inductively. Sustained 100% non-inductive current drive at the MA level has not yet been demonstrated on an ST. Non-inductive current ramp-up is therefore a more challenging objective that the NSTX-U research program aims to address. In support of this development, free-boundary TRANSP simulations have been used to develop a current ramp-up scenario in which a significant fraction of the current is driven non-inductively by a combination of neutral-beam and bootstrap current drive. The resulting discharge has properties favorable for non-inductive current drive, such as a low normalized internal plasma inductance of approximately 0.45, a minimum safety factor exceeding 2, and a slightly reversed-shear q-profile. In these discharges, the plasma current ramps to 900 kA within 250 ms in an L-mode configuration, with varying electron density and density profiles. These discharges should be suitable for next-step NSTX-U experiments aimed at generating a robust L-mode fiducial scenario with low central solenoid flux consumption, which could be progressively improved as new NSTX-U experimental discharges are developed.

Raman, Roger [Univ. of Washington, Seattle, WA (Un↗

NASA NTRS2025

A Summary of Results from Vertical Drop Testing of Hybrid III and WIAMan ATDs

With the development and maturation of the Urban Air Mobility (UAM) market, many new types of electric vertical take-off and landing (eVTOL) vehicles will be flying in the national airspace carrying goods, people or conducting operations for a variety of missions. These types of vehicles are unlike current aircraft due to their novel design and operational profile. Several considerations must be examined in areas including noise, comfort and safety in order for these vehicles to be utilized and accepted into the current airspace system. Researchers at NASA Langley Research Center (LaRC) have conducted sub-scale and full-scale tests on representative eVTOL airframes and seats under a variety of dynamic impact conditions. These tests were conducted to generate data necessary to inform the development of standards in the areas specific to crashworthiness of eVTOL vehicle systems and safety. The data in this report relates to occupant responses obtained during a test campaign utilizing various makes, models, and sizes of Anthropomorphic Test Devices (ATD’s, a.k.a. crash test dummies) undergoing vertical impacts in a variety of seats. The data is intended to provide occupant behavior response and injury metrics for several anticipated impact scenarios that may occur in eVTOL operations. This report will present test data highlighting the effects of several variables on the test results. Discussions on the ATD sizes, along with comparisons between different ATD makes and types will be included. The performance of an in-house developed energy absorbing seat will be detailed, and discussions pertaining to the applicability in various loading conditions will be presented. Finally, a discussion as to the applicability of the tested results to eVTOL full-scale conditions will be included.

Dynamic Drop Testing↗

NASA NTRS2005

The Effects of Safety Information on Aeronautical Decision Making

The importance of aeronautical decision making (ADM) has been considered one of the most critical issues of flight education for future professional pilots. Researchers have suggested that a safety information system based on information from incidents and near misses is an important tool to improve the intelligence and readiness of pilots. This paper describes a study that examines the effect of safety information on aeronautical decision making for students in a collegiate flight program. Data was collected from study participants who were exposed to periodic information about local aircraft malfunctions. Participants were then evaluated using a flight simulator profile and a pen and pencil test of situational judgment. Findings suggest that regular access to the described safety information program significantly improves decision making of student pilots.

Lee, Jang R.↗

NASA NTRSDate not supplied

Predicting Maximum Temperatures of a Li-ion Battery on a Simulated Flight Profile using a Model-based Prognostics

One of the challenges in using Li-ion packs in aeronautics is their safety, and thermal runaway (TR) is a major concern. The current engineering solutions to prevent a Li-ion pack from a catastrophic TR require additional mass and volume to isolate cells. The excess mass could be reduced by improving detection and, thus, preventing a TR event. One of the possible early warning indicators of a TR is crossing a threshold temperature. We have developed an approach, based on the Unscented Kalman Filter (UKF), to predict the likelihood of reaching the threshold temperature for simulated flight profiles. The current battery prognostics algorithms for aerospace predict state-of-charge (SOC) and end-of-life (EOL) [1]. We extended this two-level algorithm to predict the maximum temperature during discharge. The amount of heat generated in a cell depends on factors such as cell chemistry, cell packaging, total cycles, operating temperature, and abuse history [2]. Our semi-empirical thermal model depends on three phenomenological parameters which account for those factors. In addition, a two-parameter reduced-order model is developed to predict the temperature rise for short bursts of “random-walk” (RW) discharge current sequence, which simulates a flight's current-loading profile. The performance of these models on different datasets and types of current loading will be presented. To predict the maximal temperatures for future cycles we must estimate the evolution of thermal parameters as the batteries age. It is found that the parameters of the 3-parametric thermal model cannot be estimated only from the RW data. To address the issue, we will present two alternative approaches: i) expanding the datasets to include discharge profiles beyond RWs; ii) model reduction to a two-parametric model. The two approaches will be illustrated by an application to the cycling data from a commercial LG 18650 cell. References: 1. M. Daigle, C.S. Kulkarni, End-of-discharge and End-of-life Prediction in Lithium-ion Batteries with Electrochemistry-based Aging Models, in: AIAA Infotech @ Aerospace, American Institute of Aeronautics and Astronautics, San Diego, California, USA, 2016. 2. M. Börner, et. al, Correlation of aging and thermal stability of commercial 18650-type lithium ion batteries, Journal of Power Sources. 342 (2017) 382–392.

Thermal runaway↗

NASA NTRS2006

Space Shuttle Body Flap Actuator Bearing Testing for NASA Return to Flight

The Space Shuttle body flap (BF) is located beneath the main engine nozzles and is required for proper aerodynamic control during orbital descent. The body flap is controlled by four actuators connected by a common shaft and driven by the hydraulic power drive unit. Inspection of the actuators during refurbishment revealed three shaft bearings with unexpected damage. One was coated with black oxide on the balls and race wear surfaces, a second contained a relatively deep wear scar, and the third with scratches and an aluminum particle in the wear track. A shaft bearing life test program was initiated to measure the wear life and explain the 5.08-micrometer wear scar. A tribological analysis was conducted to demonstrate that the black oxide coated wear surfaces did not damage the bearing, interfere with the lubrication, or cause severe bearing wear. Pre-damaged (equivalent of 30 missions), commercial equivalent bearings and previously flown shaft bearings were tested at axial loads, speeds, and temperatures seen during flight operations. These bearing were successfully life tested at 60 C for 24 hours or 90 flights. With a safety factor of 4X, the bearings were qualified for 22 flights when only a maximum of 12 flights are expected. Additional testing at 23 C was performed to determine the lubricant life and to further understand the mechanism that caused the blackened balls. Test results indicating bearing life was shortened at a lower temperature surprised the investigators. Start\Stop bearing testing that closely simulates mission profile was conducted at 23 C. Results of this testing showed lubricant life of 12 flights including a safety factor of four. Additional testing with bearings that have the equivalent of 30 missions of damage is being tested at 23 C. These tests are being performed over the Shuttle load profile to demonstrate the residual bearing life in the actuators exceeds 12 missions. Testing showed that the end of the shaft bearing life was characterized by bearing temperature rise, preload drop, and the onset of a severe wear bearing failure mechanism. The severe wear failure mechanism is characterized by rough wear scars, extensive bearing wear and steel transfer between the balls and the races.

Jet, Timothy R.↗

NASA NTRS2018

Remaining Flying Time Prediction Implementing Battery Prognostics Framework for Electric UAV's

In this paper the problem of building trust in the online safety prediction of an fixed wing small electric unmanned aerial vehicles (e-UAV) for remaining flying time is addressed. A series of flight tests are described to verify the performance of the remaining flying time prediction algorithm. The estimate of remaining flying time is used to activate an alarm when the predicted remaining time falls below a threshold of two minutes. This updates the pilot to transition to the landing sequence of the flight profile. A second alarm is activated when the battery state of charge (SOC) falls below a specified safety limit threshold. This SOC threshold is the point at which the battery energy reserve would no longer safely support enough aborted landing attempts. During the test flights, the motor system is operated with the same predefined timed airspeed profile for each test. To test the robustness of the developed prediction algorithm, partial tests were performed with and remaining were performed without a simulated power train fault. To simulate a partial power train fault in the e-UAV the pilot engages a resistor bank at a specified time during the test flight. The flying time prediction system is agnostic of the pilot's activation of the fault and must adapt to the vehicle's state. The time at which the limit threshold on battery SOC is reached, it is then used to measure the accuracy of the remaining flying time predictions. This is demonstrated through comparing results from two battery models being developed. Accuracy requirements for the alarms are considered and the results discussed.

Kulkarni, Chetan↗

DOE OSTI2021

Dispersion curve regression – assisted wideband local wavenumber analysis for characterizing three-dimensional (3D) profile of hidden corrosion damage

Corrosion as common damage in civil, petrochemical, nuclear, and aerospace structures affects the integrity and safety of the structures and may lead to catastrophic failures. This paper presents dispersion curve regression-assisted local wavenumber analysis method, which can analyze the time–space wavefield containing wideband information of wave-damage interaction and further extract the structural information carried by such wavefield for characterizing hidden corrosion damage in an isotropic plate. To acquire the time–space wavefield, a noncontact scanning laser Doppler vibrometer is used. In our analysis method, the acquired time–space wavefield is firstly processed to generate a local wavenumber function. The derived wavenumber function is further analyzed with a dispersion curve regression step, which searches in a set of theoretical frequency-wavenumber dispersion curves for different plate thicknesses and identifies the optimal plate thickness whose theoretical curve best matches the frequency-wavenumber relation contained in the local wavenumber function. By this means, a 3D profile including both in plane and thickness dimensions of the structure can be constructed for corrosion visualization and quantification. The experimental study demonstrates that our method can quantify the profile of hidden uniform corrosion in metal plates in terms of its in-plane shape and size as well as its out-of-plane depth in the subwavelength scale. Moreover, compared to previous Lamb wave-based corrosion inspection methods, our technique allows for noncontact 3D characterization of hidden corrosion from a far distance to the structure. Finally, we believe this work will inspire new 3D damage quantification methods that are based on wavefield analysis as well as enable potential applications for the quantification of hidden corrosion in civil, petrochemical, nuclear, and aerospace structures.

42 ENGINEERING↗

DOE OSTI2025

Shadow masks predictions in SPARC tokamak plasma-facing components using HEAT code and machine learning methods

Here, this work uses machine learning (ML) to complement HEAT (Heat flux Engineering Analysis Toolkit) by developing 3-D footprint surrogate models for fast and accurate heat load calculations in the divertor of the SPARC tokamak. The focus is on shadowed regions, or magnetic shadows, caused by the 3-D geometry of plasma-facing components (PFCs). ML classifiers are employed to create a surrogate model for HEAT generated shadow masks, predicting these shadow masks and divertor heat flux profiles based on a diverse range of equilibria and only the plasma current, safety factor(q95) at the edge, and magnetic flux angles as input parameters. The ultimate goal is to integrate the model for real-time control and future operational decisions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Thermodynamic parametric analysis of refueling heavy-duty hydrogen fuel-cell electric vehicles

Reliable design and safe operation of heavy-duty hydrogen refueling stations are essential for the successful deployment of heavy-duty fuel cell electric vehicles (FCEVs). Fueling heavy-duty FCEVs is different from light-duty vehicles in terms of the dispensed hydrogen quantities and fueling rates, requiring tailored fueling station design for each vehicle class. In particular, the selection and design of the onboard hydrogen storage tank system and the fueling performance requirements influence the safe design of hydrogen fueling stations. A thermodynamic modeling and analysis are performed to evaluate the impact of various fueling parameters and boundary conditions on the fueling performance of heavy-duty FCEVs. Here, we studied the effect of dispenser pressure ramp rate and precooling temperature, initial tank temperature and pressure, ambient temperature, and onboard storage design parameters, such as onboard storage pipe diameter and length, on the fueling rate and final vehicle state-of-charge, while observing prescribed tank pressure and temperature safety limits. An important finding was the sensitivity of the temporal fueling rate profile and the final tank state of charge to the design factors impacting pressure drop between the dispenser and vehicle tank, including onboard storage pipe diameter selection, and flow coefficients of nozzle, valves, and fittings. The fueling rate profile impacts the design and cost of the hydrogen precooling unit upstream of the dispenser.

08 HYDROGEN↗

NASA NTRS1989

Flight motor set 360L001 (STS-26R). Volume 5: Nozzle component

A review of the performance and post-flight condition of the STS-26 Redesigned Solid Rocket Motor (RSRM) nozzles is presented. The nozzle assemblies, flown on the Space Shuttle Discovery on 29 September 1988, were tested to demonstrate flex bearing system reusability. The evaluation indicated no condition that would adversely affect the reusability of the flex bearing system. Inspection showed that the flex bearings did not leak, were not damaged by water impact, had the expected erosion profiles, and that the remaining ablative liner thicknesses met the performance margin of safety. Applicable Discrepancy Reports and Process Departures, the Nozzle Component Program Team performance evaluation, and the Redesign Program Review Board assessment are included.

George, Russell J.↗