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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 NTRS2017

Vehicle-Level Oxygen/Methane Propulsion System Hotfire Testing at Thermal Vacuum Conditions

A prototype integrated liquid oxygen/liquid methane propulsion system was hot-fire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). This test campaign served two purposes: 1) Characterize the performance of the Plum Brook facility in vacuum accumulator mode and 2) Collect the unique data set of an integrated LOX/Methane propulsion system operating in high altitude and thermal vacuum environments (a first). Data from this propulsion system prototype could inform the design of future spacecraft in-space propulsion systems, including landers. The test vehicle for this campaign was the Integrated Cryogenic Propulsion Test Article (ICPTA), which was constructed for this project using assets from the former Morpheus Project rebuilt and outfitted with additional new hardware. The ICPTA utilizes one 2,800 lbf main engine, two 28 lbf and two 7 lbf reaction control engines mounted in two pods, four 48-inch propellant tanks (two each for liquid oxygen and liquid methane), and a cold helium system for propellant tank pressurization. Several hundred sensors on the ICPTA and many more in the test cell collected data to characterize the operation of the vehicle and facility. Multiple notable experiments were performed during this test campaign, many for the first time, including pressure-fed cryogenic reaction control system characterization over a wide range of conditions, coil-on-plug ignition system demonstration at the vehicle level, integrated main engine/RCS operation, and a non-intrusive propellant mass gauging system. The test data includes water-hammer and thermal heat leak data critical to validating models for use in future vehicle design activities. This successful test campaign demonstrated the performance of the updated Plum Brook In-Space Propulsion thermal vacuum chamber and incrementally advanced the state of LOX/Methane propulsion technology through numerous system-level and subsystem experiments.

Morehead, Robert L.↗

DOE OSTI2016

Study on balance of axial force in helium circulator for HTR-PM - 18490

The helium circulator is one of the key equipment in the first loop of the High Temperature gas-cooled Reactor Pebble bed Module (HTR-PM). The active magnetic bearings are employed in the helium circulator, so that the inlet ring sealing clearance is about 5 to 10 times larger than that if the mechanical bearings are employed. Bigger clearance results in bigger leakage flow and bigger axial force. A new design of balance holes was proposed to reduce the axial aerodynamic force and the design principle was analyzed. To investigate the axial aerodynamic force due to leakage flow, numerical simulation of fluid dynamic was conducted in the impeller with two kinds of inlet ring sealing clearance and four types of balance holes, respectively. The calculation results shows that the balance holes with diameter 12 mm have high performance and that the designed balance holes reduce effectively about 78% of the axial aerodynamic force. The axial force was obtained from the measured real-time electric current of the axial active magnetic bearings in one helium circulator prototype. The comparison of experimental data with the CFD analysis results showed that the new design of balance holes was successful. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

An Organic, Direct Bonded Copper, Multi-Layered, Ultra-Low Inductance Package for High-Power UWBG MOSFETs

The most common metalized substrates used in high-power switching packages consist of a ceramic layer such as Aluminum Nitride (AlN) sandwiched between two copper layers. Ceramic substrates are used because it has the key characteristic of having high dielectric strength while being thermally conductive. A large drawback to ceramic substrates is that they do not allow for a multi-layered circuit design. By replacing the traditional ceramic substrate with organic direct bonded copper (ODBC) we can open a wide range of possibilities when it comes to power module layout such as multi-layered circuits and double-sided cooling. Both benefits are critical while packaging high-performance Gallium Oxide (Ga2O3) MOSFETs. Because of Ga2O3's relatively poor thermal conductivity, a double-sided cooled package becomes necessary. Therefore, the use of ODBC provides the flexibility to fabricate copper traces carrying much higher currents, and by creating a multi-layered package, we can drastically reduce the parasitic inductance inside the power module. Achieving lower parasitic inductance is critical for an ultra-fast Ga2O3 package to avoid excessive voltage overshoot and ringing. Using ODBC, we have designed novel packages capable of handling the challenges presented by fast Ga2O3 switching. Using multi-physics modeling software, we can validate our design before building the prototype. Due to the simple process parameters needed to work with ODBC, we can rapidly create prototypes without using external vendors. This flexibility allows us to quickly design, build, and validate highly complex switching power modules to accommodate next generation, Ga2O3 switching devices.

ADVANCED PROPULSION SYSTEMS,ENGINEERING↗

DOE OSTI2024

The Spherical Tokamak for Energy Production: theme issue introduction

This theme issue collects together papers summarising the conceptual design of the Spherical Tokamak for Energy Production (STEP). In 2019, the UK government funded the first design stages of a prototype fusion powerplant based on a compact toroidal geometry, called STEP. The primary technical aims of STEP are to produce net energy, to be self-sufficient in tritium fuel and to demonstrate a maintenance regime that would extrapolate to appropriate availability for commercial powerplants. After 5 years and over 1000 person-years of detailed scientific and engineering conceptual design, this theme issue acts as a compendium of the current design basis for STEP, noting that this is a snapshot in time and that the design will continue to evolve. This article is part of the theme issue ‘Delivering Fusion Energy – The Spherical Tokamak for Energy Production (STEP)’.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2002

Meteorological Support of the Helios World Record High Altitude Flight to 96,863 Feet

In characterizing and understanding atmospheric behavior when conducting high altitude solar powered flight research flight planning engineers and meteorologists are able to maximize the use of available airspace and coordinate aircraft maneuvers with pilots to make the best use of changing sun elevation angles. The result of this cooperative research produced a new world record for absolute altitude of a non-rocket powered aircraft of 96,863 ft (29,531.4 m). The Helios prototype solar powered aircraft, with a wingspan of 247 ft (75.0m), reached this altitude on August 13, 2001, off the coast of Kauai, Hawaii. The analyses of the weather characterization, the planning efforts, and the weather-of-the-day summary that led to at record flight are described in this paper.

Teets, Edward H., Jr.↗

NASA NTRS1999

Affordable Manufacturing Technologies Being Developed for Actively Cooled Ceramic Components

Efforts to improve the performance of modern gas turbine engines have imposed increasing service temperature demands on structural materials. Through active cooling, the useful temperature range of nickel-base superalloys in current gas turbine engines has been extended, but the margin for further improvement appears modest. Because of their low density, high-temperature strength, and high thermal conductivity, in situ toughened silicon nitride ceramics have received a great deal of attention for cooled structures. However, high processing costs have proven to be a major obstacle to their widespread application. Advanced rapid prototyping technology, which is developing rapidly, offers the possibility of an affordable manufacturing approach.

Bhatt, Ramakrishna T.↗

NASA NTRS2010

Study - Radiation Shielding Effectiveness of the Prototyped High Temperature Superconductivity (HTS) 'Artificial' Magnetosphere for Deep Space Missions

The high temperature superconductor (HTS) is being used to develop the magnets for the Variable Specific Impulse Magneto-plasma Rocket (VASIMR ) propulsion system and may provide lightweight magnetic radiation shielding to protect spacecraft crews from radiation caused by GCR and SPEs on missions to Mars. A study is being planned to assess the radiation shielding effectiveness of the artificial magnetosphere produced by the HTS magnet. VASIMR is an advanced technology propulsion engine which is being touted as enabling one way transit to Mars in 90 days or less. This is extremely important to NASA. This technology would enable a significant reduction in the number of days in transit to and from Mars and significantly reduce the astronauts exposure to a major threat - high energy particles from solar storms and GCR during long term deep space missions. This paper summarizes the plans for the study and the subsequent testing of the VASIMR technology onboard the ISS slated for 2013.

Denkins, Pamela↗

NASA NTRS1995

SPARTNIK: Engineering catalyst for government and industry

Industrial demands for highly motivated and competent technical personnel to carry forward with the technological goals of the US has posed a significant challenge to graduating engineers. While curricula has improved and diversified over time to meet these industry demands, relevant industry experience is not always available to undergraduates. The microsatellite development program at San Jose State University (SJSU) has allowed an entire undergraduate senior class to utilize a broad range of training and education to refine their engineering skills, bringing them closer to becoming engineering professionals. Close interaction with industry mentors and manufacturers on a real world project provides a significant advantage to educators and students alike. With support from companies and government agencies, the students have designed and manufactured a microsatellite, designed to be launched into a low Earth orbit. This satellite will gather telemetry for characterizing the state of the spacecraft. This will enable the students to have a physical check on their predicted value of spacecraft subsystem performance. Additional experiments will also be undertaken during the two year lifetime, including micro-meteorite impact sensing and capturing digital color images of the Earth. This paper will detail the process whereby students designed, prototype and manufactured a small satellite in a large team environment, along with the experiments that will be performed on board. With the project's limited funds, it needed the support of many industry companies to help with technical issues and hardware acquisition. Among the many supporting companies, NASA's space shuttle small payloads program could be used for an affordable launch vehicle for the student project. The paper address these collaborations between the student project and industry support, as well as explaining the benefits to both. The paper draws conclusion on how these types of student projects can be used by industry as a feasible resource for developing small platforms for space based experiments, as well as increasing the practical experience and engineering knowledge of graduating students. These benefits to industry and universities, can lead to a close working relationship between the two. These types of projects can facilitate the development of low-cost space rated parts to be used by the industry and university projects. It can also help with the understanding and use of acceptable risk non-space rated parts reducing the cost of the spacecraft. This will lead to the development of low cost platforms for space based experiments, providing research companies an inexpensive, long duration platform to conduct their in-space experiments, while better preparing engineering undergraduates for their transition into the work force.

Prass, James D.↗

DOE OSTI2018

Prototype System for Detecting Interactions between Current Plant Configuration States and Component Manipulations Directed by In-Use Procedures

This research effort is a part of the Light Water Reactor Sustainability (LWRS) Program, which is a research and development (R&D) program sponsored by the Department of Energy. The LWRS Program is performed in close collaboration with industry R&D programs that provide the technical foundations for licensing and managing the long term, safe, and economical operation of current nuclear power plants (NPPs). The LWRS Program serves to help the United States (U.S.) nuclear industry adopt new technologies and engineering solutions that facilitate the continued safe operation of these NPPs and extension of their current operating licenses. The Outage Risk Management Improvement Pilot Project seeks to improve the management of nuclear power plant outages through the development of tools to assist in evaluating pending activities against requirements to detect undesired interactions. Significant efforts are expended to manage the nuclear risk of an outage. The utilities conduct pre outage risk assessments, based on a very detailed review of the outage schedule, to identify where combinations of outage work and equipment out of service would result in degraded conditions with respect to nuclear safety or regulatory compliance. Probabilistic risk assessment studies are conducted to quantify the incremental core damage frequency as a result of the outage activities and system unavailability. These studies are usually presented to site and fleet management, the site plant operational review committee, and the NPP’s independent Nuclear Safety Review Board for concurrence that the outage is planned safely and that reasonable measures have been taken to reduce the added risk of conducting the outage. During the outage, the plant configuration is monitored continuously to ensure that it conforms to the approved safety plan. Deviations must be assessed and approved by management committees and, in some cases, the plant operational review committee. In virtually all outage meetings and job briefings, the current nuclear safety status of the plant is communicated, including information on the specific equipment that is being relied on to meet the requirements of the nuclear safety plan. In addition, Operations and the Outage organizations implement several layers of physical and administrative barriers to prevent unintended interaction with the systems and equipment credited for nuclear safety. In spite of all these efforts, nuclear safety challenges still occur too frequently in outages. While some of these are due to failures of equipment credited for safety, the majority occur because of human error. These typically involve some form of interaction between work activities and plant configuration changes. Some of them are very subtle and are extremely challenging to detect in advance. Nevertheless, they are not acceptable and represent clear opportunities to improve nuclear safety during outages. This project will develop tools and strategies to minimize these interactions. This report describes a prototype tool designed to support plant personnel in controlling work during NPP outages to prevent unintended interactions. A software application was created to manage and display important configuration information and utilize natural language processing to access the impacts of upcoming procedures and work orders. Initial industry feedback is also presented.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2017

Steady-State and Small-Signal Analysis of A-Source Converter

This paper presents a detailed steady-state analysis and ac small-signal modeling of the power stage of pulse-width modulated A-source converter. The voltage and current waveforms along with their corresponding expressions describing the converter operation are presented in detail. The input-to-output and input-to-capacitor dc voltage transfer functions are determined. The minimum inductance required to ensure continuous conduction mode is derived. The expressions for the semiconductor devices stresses are also presented. The dc, averaged equivalent circuit is derived using the circuit averaging technique. A complete derivation of the small-signal model including the converter parasitic resistances are presented followed by the power stage transfer functions relevant to the capacitor voltage loop, such as: 1) duty cycle-to-capacitor voltage; and 2) input-to-capacitor voltage. In addition, the expressions for the network input impedance and output impedance are derived. Finally, experimental validations of the derived small-signal models are performed, both in frequency and time domain for a laboratory prototype of an A-source converter. The theoretical predictions were in good agreement with the experimental results over a wide range of frequencies.

42 ENGINEERING↗

DOE OSTI2017

Develop and Manufacture an Ergonomically Sound Glovebox Glove Report

Ergonomic injury and radiation exposure are two safety concerns for the Plutonium Facility at Los Alamos National Laboratory (LANL). This facility employs the largest number of gloveboxes (GB) at LANL with approximately 6000 gloves installed. The current GB glove design dates back to the 1960’s and is not based on true hand anatomy, revealing several issues: short fingers, inappropriate length from the wrist to finger webbing, nonexistent joint angles and incorrect thumb placement. These design flaws are directly related to elbow (lateral epicondylitis) and thumb (DeQuervain’s tenosynovitis) injuries. The current design also contributes to increased wear on the glove, causing unplanned glove openings (failures) which places workers at risk of exposure. An improved glovebox glove design has three significant benefits: 1) it will reduce the risk of injury, 2) it will improve comfort and productivity, and 3) it will reduce the risk of a glovebox failures. The combination of these three benefits has estimated savings of several million dollars. The new glove design incorporated the varied physical attributes of workers ranging from the 5 th percentile female to the 95th percentile male. Anthropometric hand dimensions along with current GB worker dimensions were used to develop the most comprehensive design specifications for the new glove. Collaboration with orthopedic hand surgeons also provided major contributtions to the design. The new glovebox glove was developed and manufactured incorporating over forty dimensions producing the most comprehensive ergonomically sound design. The new design received a LANL patent (patent attorney docket No: LANS 36USD1 “Protective Glove”, one of 20 highest patents awarded by the Richard P. Feynman Center for Innovation. The glove dimensions were inputed into a solid works model which was used to produce molds. The molds were then shipped to a glove manufacturer for production of the new glovebox gloves. The new glovebox gloves were tested against the presently used glovebox gloves for design validity. The testing included a subjective survey and four dexterity tests. The prototype was statistically significant in 3 dexterity tests and favorable on 8 out of 10 survey questions. The more ergonomically sound glovebox glove will improve worker comfort, mitigate glovebox worker injuries, and reduce glove breaches.

42 ENGINEERING↗

DOE OSTI2020

Multiscale-Informed Modeling of High Temperature Component Response with Uncertainty Quantification

This report summarizes a joint effort between Argonne National Laboratory, Idaho National Laboratory, and Los Alamos National Laboratory to develop and deploy constitutive models targeted at predicting the life of Grade 91 alloy components subjected to high temperature environments typical of those that structural components in advanced nuclear reactors would experience. Two distinct, but complementary constitutive modeling approaches have been taken here. The first employs a phenomenological viscoplastic model for which parameters have been calibrated based on experimental data for a wide range of Grade 91 alloy that has undergone a variety of processing. A Bayesian approach was used to derive distributions of uncertain parameters for this model based on this data set. The second approach is a reduced order model suitable for engineering-scale analysis that is based on the results of a large set of mesoscale simulations. Mesoscale models allow for the microstructure and composition of a particular alloy to be directly taken into account in the computation of the viscoplastic response, but are computationally expensive, which makes it impractical to directly call those models for the material constitutive response in an engineering-scale simulation. The reduced-order representation of the response of the underlying model used here allows for an engineering-scale model to take into account the characteristics of the underlying microstructure, while only incurring a reasonable computational expense. Both of these approaches have different strengths, and are applicable for different parts of the design/analysis process. The phenomenological models can be readily parameterized based on a set of experimental data for a given class of materials and used for scoping calculations. Once a specific material is chosen and adequately characterized, the reduced order models can accurately predict the response of that specific alloy, and because the models are based on predictive models of the underlying microstructure, they can be used to more confidently predict the response under conditions in regions where there is limited experimental data. Both of these models have been integrated in the Grizzly code, which is used here to perform proof-of-concept uncertainty quantification analyses of a simple component under prototypical conditions. The built- in stochastic analysis capabilities in the MOOSE framework that Grizzly is built on are used here to run large sets of simulations for this uncertainty quantification analysis. As would be expected, because the reduced order models are developed for a much more tightly defined alloy, they predict tighter distributions of the time to failure than the phenomenological models, which are calibrated to a broader set of data. Also important is that these simulations demonstrate that a reduced order modeling approach can be successfully deployed to propagate uncertainties from the material scale to practical engineering-scale component simulations.

42 ENGINEERING↗

NASA NTRS2021

ED1: Design and Prototype of a 3D Printed Wind Tunnel Model with Integrated Force Measurement

Wind tunnel testing using conventionally manufactured force measurement systems (balances) is able to yield precise and accurate results. These balances are delicate, complex instruments. Due to the nature of this high-precision complexity, balances are expensive and time-consuming to produce. These factors can limit the design potential of the model because using conventionally manufactured balances generally means that the model is designed to accommodate balances that already exist. Ideally, engineers would be able to design a measurement system that is tailored to fit the needs of the model, rather than the other way around. The goal of this research project was to determine if it is possible to overcome these drawbacks by designing a wind tunnel model with a modifiable integrated force measurement system that leverages additive manufacturing. This was undertaken by utilizing the existing UT-63 wind tunnel balance (measurement system), integrating it with a model based on the existing AGARD-B model, and performing stress analysis to optimize the design. Due to time constraints, the result of this endeavor is currently incomplete. Continued analysis and optimization are required to have a thorough understanding of the success or failure of the attempted design. As additive manufacturing technology evolves, the ability for it to become the primary method of fabrication for sensitive measurement systems increases. This project contributes to this by providing one method for design, a framework for optimizing existing balances for additive manufacturing, and resources for performing necessary stress analysis.

Callie Ellsworth↗

DOE OSTI2023

Computational and Experimental Determination of the Properties, Structure, and Stability of Peptoid Nanosheets and Nanotubes

Peptoids (N-substituted glycines) are a group of highly controllable peptidomimetic polymers. Amphiphilic diblock peptoids have been engineered to assemble crystalline nanospheres, nanofibrils, nanosheets, and nanotubes with biochemical, biomedical, and bioengineering applications. The mechanical properties of peptoid nanoaggregates and their relationship to the emergent self-assembled morphologies have been relatively unexplored and are critical for the rational design of peptoid nanomaterials. In this work, we consider a family of amphiphilic diblock peptoids consisting of a prototypical tube-former (Nbrpm6Nc6, a NH 2 -capped hydrophobic block of six N-((4-bromophenyl)methyl)glycine residues conjugated to a polar NH 3 (CH 2 ) 5 CO tail), a prototypical sheet-former (Nbrpe6Nc6, where the hydrophobic block comprises six N-((4-bromophenyl)ethyl)glycine residues), and an intermediate sequence that forms mixed structures ((NbrpeNbrpm)3Nc6). We combine all-atom molecular dynamics simulations and atomic force microscopy to determine the mechanical properties of the self-assembled 2D crystalline nanosheets and relate these properties to the observed self-assembled morphologies. We find good agreement between our computational predictions and experimental measurements of Young’s modulus of crystalline nanosheets. A computational analysis of the bending modulus along the two axes of the planar crystalline nanosheets reveals bending to be more favorable along the axis in which the peptoids stack by interdigitation of the side chains compared to that in which they form columnar crystals with π-stacked side chains. Here, we construct molecular models of nanotubes of the Nbrpm6Nc6 tube-forming peptoid and predict a stability optimum in good agreement with experimental measurements. A theoretical model of nanotube stability suggests that this optimum is a free energy minimum corresponding to a “Goldilocks” tube radius at which capillary wave fluctuations in the tube wall are minimized.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Recyclable Design for Retaining High Solar Absorptivity of the Media in CSP

Efficient thermal energy storage is pivotal to lowering the levelized cost of electricity (LCOE) for Concentrating Solar Power (CSP) plants. In solid-particle systems, however, prolonged high-temperature service degrades particle solar absorptivity, eroding overall efficiency. This project demonstrates a hydrogen-assisted recovery process that reliably restores absorptivity to >90 %, offering a practical route to sustain long-term CSP performance. Bench-scale investigations mapped the reduction kinetics of optically faded particles across hydrogen concentrations, temperatures, and residence times. Coupling mass-spectrometric monitoring with machine-learning optimization minimized energy demand while maximizing absorptivity gain. The resulting process window—moderate hydrogen partial pressures, 15–30 min dwell times, and temperatures well below initial calcination levels—cuts energy consumption well below that of incumbent re-blackening methods. A prototype recovery reactor processed multiple 2 kg batches with repeatable outcomes, confirming scalability and operational robustness. Integrated techno-economic analysis indicates material and operating cost reductions exceeding 15 % relative to conventional particle replacement or chemical re-coating, translating directly into lower LCOE for next-generation CSP facilities. By uniting fundamental reaction-kinetics insight with pragmatic engineering, this work advances the solid-particle pathway, delivering a cost-effective, field-deployable solution to one of CSP’s key durability challenges and strengthening the commercial outlook for high-temperature renewable power.

14 SOLAR ENERGY↗

NASA NTRS1983

Fabrication and quality assurance processes for superhybrid composite fan blades

The feasibility of fabricating full-scale fan blades from superhybrid composites (SHC) for use large, commercial gas turbine engines was evaluated. The type of blade construction selected was a metal-spar/SHC-shell configuration, in which the outer shell was adhesively bonded to a short, internal, titanium spar. Various aspects of blade fabrication, inspection, and quality assurance procedures developed in the investigation are described. It is concluded that the SHC concept is feasible for the fabrication of prototype, full-scale, metal-spar/SHC-shell fan blades that have good structural properties and meet dimensional requirements.

Lark, R. F.↗

NASA NTRS1986

Fabrication and quality assurance processes for superhybrid composite fan blades

Lark, R. F.↗

NASA NTRS1991

Help for the Steel Industry

A collaboration between NASA Lewis Research Center (LRC) and Gladwin Engineering resulted in the adaptation of aerospace high temperature metal technology to the continuous casting of steel. The continuous process is more efficient because it takes less time and labor. A high temperature material, once used on the X-15 research plane, was applied to metal rollers by a LRC developed spraying technique. Lewis Research Center also supplied mold prototype of metal composites, reducing erosion and promoting thermal conductivity. Rollers that previously cracked due to thermal fatigue, lasted longer. Gladwin's sales have increased, and additional NASA-developed innovations are anticipated.

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