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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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238 records · Page 8

Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Battery Assessment

In 2013, the Boeing Company model 787-8 Dreamliner commercial aircraft experienced three catastrophic lithium (Li) battery failures. The cause of each failure resulted in a single-cell thermal runaway (TR) condition, which propagated to adjacent battery cells. Two of the failures involved rechargeable lithium-ion (Li-Ion) batteries, and the third event involved a nonrechargeable lithium-manganese dioxide (Li-MnO2) battery. In response to these Li battery failures, the NASA Engineering and Safety Center (NESC) approved a technical assessment of the International Space Station Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Li non-rechargeable battery. This assessment was conducted to evaluate the SAFER Li nonrechargeable battery safety design features against Boeing 787 Dreamliner Li battery failure lessons learned. Specifically, this investigation focused on assessing the severity of a SAFER battery TR hazard conditions.

Iannello, Christopher J.

Erosion, Corrosion and Foreign Object Damage Effects in Gas Turbines [Les consequences de l'endommagement des turbines I gaz par erosion, corrosion et objets étrangers]

The Conference Proceedings contains 31 papers presented at the Propulsion and Energetics Panel Symposium on Erosion, Corrosion and Foreign Object Damage Effects in Gas Turbines which was held from 25-28th April 1994, in Rotterdam, The Netherlands. The Technical Evaluation Report and the Keynote Address are included at the beginning and discussions follow most papers. The Symposium was arranged in the following Sessions: Operational Experience and Requirements (7); Deposition and Erosion (7); Foreign Object Damage (5); Coatings, Repairs and Materials Aspects - 1 (4); Coatings, Repairs and Materials Aspects - 2 (7); and Testing and Certification Procedures (1).

Deposition

Barium Fluoride as a Standard Reference Material for Infrared Refractometry

This work proposes a standard reference material (SRM) for measurements of refractive index in the infrared spectral region (1–12 μm). The purpose of this material is to enable cross-method comparison of refractive index data obtained through minimum deviation, ellipsometry, interferometry, and prism coupling techniques. This will allow vendors and metrology laboratories, regardless of which technique they employ, to certify that their measurements meet required levels of accuracy, precision, and repeatability. Drawing on foundational work by Tilton at the National Bureau of Standards, a figure of merit for candidate SRM materials is outlined, and three materials are selected for further evaluation. Ultimately, barium fluoride is proposed as the most suitable SRM for the infrared spectral region, based on its broad transmission range, chemical and mechanical stability, low temperature dependence of refractive index, and well-characterized dispersion behavior.

Andrew Howe

Multifrequency, Multipolarization External Calibration of the SIR-C/X-SAR Radars

Progress and the future plans for the following objectives are discussed: (1) Assess the accuracy at which the SIR-C/X-SAR standard data products can be calibrated through the use of ground calibrators to estimate the end-to-end system polarization calibration constants (or distortion parameters) and incorporate the constants into the data processing; (2) Study the cross-calibration between three multipolarization systems: SIR-C, the National Aeronautics and Space Administration/Jet Propulsion Laboratory (NASA/JPL) DC-8 SAR, and the University of Michigan ground-based polarimetric scatterometer; (3) Evaluate the calibration "stability" of SIR-C/X-SAR (measured by variations in the calibration constants) over the range swath width and over a specified distance in azimuth. Variations over a 12-hour period (between ascending and descending passes) will also be studied; and (4) Develop a cost-effective calibration plan including development of inexpensive polarimetric active calibrators.

Anthony Freeman

Conclusions of a Cryogenic Motor Configuration Study for Aircraft Propulsion

Cryogenic electric machines are a promising technology for multi megawatt electric aircraft drivetrains. Superconducting stators that make use of low AC loss superconducting wires are considered to be a key component for these cryogenic machines. This paper shares the lessons learned from a design study that evaluated several configurations of a 5 MW cryogenic motor for this application. The lessons are drawn from a qualitative study of 16 configurations and a quantitative study of 8 down selected configurations. The quantitative study involved using analytical calculations (electromagnetic, thermofluid, mechanical, and motor sizing) to determine each configuration’s Pareto front of total efficiency and total specific power. The conclusions from a preliminary assessment of different stator conductors (superconductors and cryogenic metals) are also presented. One motor configuration is down selected for future detailed design and demonstration at the multi megawatt level.

Electrified aircraft propulsion

Spacecraft Disposal Rosetta Stone: Parametric Tool for Orbital Lifetime, Disposal, and Cost Assessment

This Technical Memorandum documents a simplified, parametric method for evaluating spacecraft orbital lifetime, disposal compliance, and disposal-related cost impacts during early mission formulation and preliminary design. The method captures the dominant drivers of orbital decay—effective ballistic coefficient, operating altitude, and solar-cycle variability—using conservative bounding assumptions. Solar maximum conditions are used to bound achievable mission lifetime, while solar minimum conditions are used to bound disposal timelines and compliance with orbital debris requirements. A single tabulated dataset provides orbital lifetime under both solar-cycle extremes together with representative disposal ΔV required to ensure compliant disposal, enabling rapid assessment of disposal feasibility, cost sensitivity, and system-level impacts prior to committing to higher-fidelity analyses.

Orbital debris mitigation

Final Report Document: Microgravity Medical Eyewash B

Senior Capstone Design Team 15 has been commissioned by the National Aeronautics and Space Administration (NASA) to redesign the current microgravity eye wash station. The current design exhibits four primary limitations: single-use operation, excessive mass and volume, operational complexity requiring coordination with external systems, and dependence on frequent Earth resupply missions. Our updated eyewash design will be deployed on long-range space missions that could last multiple years. Based on these and other requirements from our customer, we have developed our updated eyewash design. Our compact, single-eye system uses capillary-driven flow and a free-floating water ball. This design allows us to eliminate pumps and bulky tubing, decreasing the mass and volume of the overall system. The containment eyecup is held to the astronaut's face with a strap, and a silicone seal prevents leakage while improving user comfort. Contaminated water is contained within a disposal bag containing wicking material to pull it back out of the eyecup after washing the eye. This system is reusable, efficient, and easy to activate quickly. We evaluated our design through calculations, microfluidic testing, and user try-on testing to verify our requirements. Our work demonstrated that steady-state flow was capable with our capillary framework, achieving 1.31 L/min. The prototype construction confirmed mass and volume reductions, and try-on-testing evaluated the ability to put on the system quickly. Almost all major design requirements were achieved, and water loss could be validated by testing in microgravity. Our design went through a number of iterations to reach the final solution presented in this report. These changes were driven by our testing and collaboration from each member of the team. Updated models optimized tube placement and geometry of the eyecup to better direct flow as it pools across the eye. Changes to our tubing bends improved capillary efficiency and increased the flow rate we were capable of achieving. And improved bracket placements adjusted the fit, comfort, and seal of the eyecup to the astronaut's face. Our capillary-based eyewash system is technically feasible and has been theoretically validated to operate effectively in microgravity conditions. Testing and analysis indicate that it can meet or exceed the required performance metrics, including flow rate and safety constraints. Overall, the design represents a viable alternative to current ISS-dependent eyewash systems for future space missions.

Jeffrey Allen

Parametric-Based Heat Rejection Trade Study for Lunar and Martian Surface Operations

Establishing and maintaining a sustained presence on the lunar and/or Martian surfaces will require a diverse portfolio of surface elements (e.g., habitation, mobility, power generation, etc.). Many of these systems generate excess heat that must be rejected across a wide range of magnitudes, temperatures, and duty cycles and under variable environmental conditions. To identify the most promising heat rejection approaches for this diverse portfolio, a heat rejection trade study was conducted to evaluate the performance of different technology approaches across a spectrum of surface environments and heat-load requirements. The trade study consisted of three stages: (1) development of a parametric-based modeling framework, (2) creation of a database of heat rejection technologies, surface elements, and environmental conditions for the Moon and Mars, and (3) execution of a quantitative analysis of various heat rejection technologies across different operating conditions and surface elements. The modeling framework is developed in Python and Excel to prioritize small model size and hence low computational cost to enable large parametric sweeps while avoiding the reliance on proprietary software. Individual heat rejection processes are represented as simple Excel models, and a centralized Python script interfaces with the models to coordinate the parametric study. These simple sizing models were developed to take heat load requirements and environmental parameters as inputs and compute mass, power, and volume as outputs. Rather than assess each heat rejection technology separately for each surface element, a unified parametric space was developed to evaluate all technologies across all elements. This parametric space includes factors related to heat load (e.g., magnitude or temperature) and environment (e.g., surface temperature, sky temperature, solar flux). This effort generated a database containing information on over 60 heat rejection technologies and 30 surface elements. For each surface element, the expected heat rejection requirements were documented and analyzed to determine the most common needs shared across all elements. Environmental conditions at various lunar and Martian latitudes were also established for worst-case hot and worst-case cold scenarios. High-fidelity heat rejection models are currently under development. Preliminary trades between heat rejection technologies including radiators, venting technologies, convective coolers, and more have been conducted to identify promising options. This presentation will summarize the preliminary trade results and provide an overview and discussion of the expected heat loads and thermal environments for sustained surface operations on the Moon and Mars.

Heat Rejection

The Benard Problem: A Comparison of Finite Difference and Spectral Collocation Eigen Value Solutions

The application of spectral methods, using a Chebyshev collocation scheme, to solve hydrodynamic stability problems is demonstrated on the Benard problem. Implementation of the Chebyshev collocation formulation is described. The performance of the spectral scheme is compared with that of a 2 nd order finite difference scheme. An exact solution to the Marangoni-Benard problem is used to evaluate the performance of both schemes. The error of the spectral scheme is at least seven orders of magnitude smaller than finite difference error for a grid resolution of N = 15 (number of points used). The performance of the spectral formulation far exceeded the performance of the finite difference formulation for this problem. The spectral scheme required only slightly more effort to set up than the 2 nd order finite difference scheme. This suggests that the spectral scheme may actually be faster to implement than higher order finite difference schemes.

J Raymond Lee Skarda

Impact of Inertia, Friction, and Backlash upon Force Control in Telemanipulation

The mechanical behavior of master controllers of telemanipulators has been a concern of both designers and implementors of telerobotic systems. In general, the literature recommends that telemanipulator systems be constructed that minimize inertia, friction, and backlash in an effort to improve telemanipulative performance. For the most part, these recommendations are founded upon theoretical analysis or simply intuition. Although these recommendations are not challenged on their merit, the material results are measured of building and fielding telemanipulators that possess less than ideal mechanical behaviors. Experiments are described in which forces in a mechanical system with human input are evaluated as a function of mechanical characteristics such as inertia, friction, and backlash. Results indicate that the ability of the human to maintain gripping forces was relatively unaffected by dynamic characteristics in the range studied, suggesting that telemanipulator design in this range should be based on task level force control requirements rather than human factors.

Neil A Duffie

Manufacturing Process Development of a Carbon Fiber Reinforced Polymer Composite Shaft for Electric Motors

Electric aircraft applications require electric motors with increased specific power and efficiency. Composite structural components in motors are a potential solution for reducing motor mass, reducing magnetic losses, and limiting undesired conduction paths for fault, electromagnetic interference, or common-mode currents. In this report, manufacturing trials for a high-speed carbon fiber reinforced polymer composite motor shaft are presented. Four prototype shafts were produced using a hybrid biaxial/triaxial fabric that was circumferentially wrapped onto an additively manufactured high-temperature washout mandrel. An additional traditional overbraid approach was also evaluated and shows promise for high-rate, high-performance parts using automated manufacturing. This paper discusses the shaft design, manufacturing methods explored, material selection, the manufacturing trials, and the lessons learned. The results of this manufacturing investigation show feasibility for manufacturing composite shafts for electric motors.

Electric moto shaft

Ejecta Generation and Redistribution on 433 Eros: Modeling Ejecta Launch Conditions

The NEAR-Shoemaker mission to asteroid 433 Eros presents an unprecedented opportunity to gain fundamental new knowledge about the processes governing regolith formation and redistribution on small bodies. NEAR-Shoemaker’s high-resolution imaging of the surface of Eros makes the asteroid a valuable and heretofore unparalleled laboratory for the detailed study of impact ejecta reaccretion and regolith redistribution on low-gravity (of order 10 -3 g) objects. Regolith is produced on asteroids by impact cratering, and the existence of regolith on the smallest solar system bodies supports the view that some of the ejecta from impact events on such objects may be retained. Impact craters and retained ejecta on low-gravity objects like Eros represent valuable natural laboratories for evaluating various models of impact cratering processes, since they may present crater structures or ejecta features that either do not form or are hidden on higher-gravity bodies like the Moon. Further, quantifying the extent to which impact processes generate and redistribute regoliths on small body surfaces (excavation depths, retained fraction, turnover timescales, etc.) is pivotal to the issue of how to relate meteoritical samples to their asteroidal parent bodies when surficial processes ( i.e., “space weathering”) may disguise or cover up underlying material and confound the ability of remote sensing techniques to provide reliable mineralogical assays of the parent objects. The rich variety of data on Eros’ regolith properties and distribution returned by NEAR-Shoemaker now require detailed analysis in order to take full advantage of the clues these observations offer for elucidating details of the impact cratering process on small bodies. Complicating simple interpretations of crater and ejecta morphology are dynamical effects on ejecta emplacement resulting from Eros’ irregular shape, rapid (5.27 hr) rotation, and low gravity. Figure 1 shows the very different ejecta deposit morphology that can result if the effects of rotation alone are neglected. Considering the additional complicating factors of Eros’ irregular shape and complex gravitational field, simple calculations of the extent and thickness of ejecta blankets and the spatial distribution of ejecta blocks from basic crater scaling laws or numerical hydrocodes alone do not suffice. In order to fully interpret the suite of NEAR-Shoemaker observations of regolith features across the surface of Eros and to evaluate various impact models for specific craters on the asteroid, detailed dynamical modeling of the deposition of crater ejecta from those craters is required . Here, I describe some modifications and improvements to the dynamical model being used for these studies.

D D Durda

Thermoplastic Matrix Composite Design for Cryotanks Using Multiscale Modeling and Bayesian Optimization

Designing lightweight, robust cryogenic storage tanks is critical for future launch vehicles, in-space propellant storage, and hydrogen powered aircraft. This work presents a multiscale modeling and Bayesian optimization framework for the design of thermoplastic matrix composite cryotanks. Molecular dynamics simulations are first used to determine temperature-dependent constituent properties for candidate thermoplastic matrices, which are homogenized to the lamina scale using NASA’s Multiscale Analysis Tool (NASMAT). These lamina properties, in combination with laminate family generation rules, are evaluated in HyperX structural optimization software to identify stacking sequences that meet all cryogenic load requirements. A Bayesian optimization framework is applied, with HyperX in the loop (via the HyperX API) to efficiently search across material and laminate design variables, yielding an optimized cryotank configuration with significant reductions in design cycle time compared to exhaustive search approaches.

thermoplastics

Exposure of Highly Reflective Far-Ultraviolet Coatings to LEO Environment for TRL Advancement for the Habitable Worlds Observatory

Over the past several years, our team at the NASA Goddard Space Flight Center (GSFC), in collaboration with the Jet Propulsion Laboratory (JPL) and the Naval Research Laboratory (NRL), have developed several new protected Al coating technologies with improved Far-Ultraviolet (FUV) reflectance performance and more robust environmental stability. These include Al protected with lithium-based fluoride (LiF) coatings such as hot deposited LiF (eLiF), XeF 2 -passivated LiF coatings (XeLiF), Li 3 AlF 6 overcoats, AlF 3 (plasma passivated), and XeF 2 passivated MgF 2 coatings (XeMgF 2 ). However, despite these developments, relatively little experimental information exists regarding the long-term stability of these coatings after simultaneous exposure to the Low Earth Orbit (LEO) environment. To evaluate their environmental durability and advance their Technology Readiness Level (TRL), representative samples of these coating technologies, Al+XeLiF, Al+eLiF, Al+Li 3 AlF 6 , Al+AlF 3 , Al+XeMgF 2 , and bare Al as reference samples, were flown onboard the International Space Station (ISS) as part of the Materials International Space Station Experiment 20 (MISSE-20). The MISSE platform is operated by Aegis Aerospace for relatively long-duration (e.g. 6 months) external exposure experiments in a space environment. The coatings were deposited on ULE and Zerodur substrates, and witness samples deposited on the same coatings runs, but on glass slides were left on Earth as control. A subset of the flight samples were fitted with MgF 2 windows to reduce direct exposure to atomic oxygen (AO) and charged particles, and still let through UV and other types of radiation on these samples. After approximately 6 months of exposure in the forward-facing (RAM) direction, the samples were returned to Earth and characterized by performing FUV/NUV/VIS/NIR reflectance measurements to quantify degradation, spectroscopic ellipsometry to evaluate coating thickness and optical constants, atomic force microscopy (AFM) to quantify surface roughness evolution during the flight in the ISS. The MgF 2 protective windows were also analyzed through FUV transmission measurements. Comparison with the witness samples left on the ground and with the flown bare Al samples (with just the naturally occurring Al 2 O 3 layer) provided a quantitative assessment of coating thickness variations, optical performance degradation, and morphological changes induced by prolonged exposure to the LEO environment.

Far Ultraviolet (FUV)

Investigation of Bipropellant Plume-Induced Contamination Effects on Coverglass Materials

Contamination and degradation of external spacecraft materials by unburned and partially combusted species from bipropellant thruster plumes has long been observed as a key component of the induced space environment. Space shuttle flight experiments and returned flight hardware from the International Space Station (ISS) have both experienced microscopic impact features induced by high-velocity thruster plume droplets. Analytical results have shown that droplet impingement angle relative to a receiving surface plays a key role in the surface damage. Although impacts with normal impingement angles contribute more severely to surface degradation than highly oblique angles, surface effects at higher impingement angles should not be dismissed. Thruster plume-induced materials degradation is a complex phenomenon that depends on a variety of parameters, including but not limited to material type, system temperature and pressure, plume composition, and thruster firing specifications such as number of pulses, pulse duration, and sample distance from the thruster. For space applications, attaining the vacuum pressure and temperature conditions necessary for flight-like plume expansion and exposure conditions is not a trivial task. The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt, DLR) is a facility uniquely capable of simulating such conditions. Test coupons were exposed to bipropellant thruster firings under high vacuum at the DLR facility. Percent area coverage (PAC) and droplet size distributions were evaluated for the uncoated and coated solar array coverglass materials over a range of impingement angles (0̊ to 75̊). A post-test imaging workflow was developed that aimed to quantify changes in sample surface morphology obtained from scanning electron microscopy (SEM) images using the Image Processing and Analysis in Java (ImageJ) tool; an opensource image processing software. The goal was to create a framework through which to evaluate the effect of bipropellant-induced PAC and droplet size distribution on solar array coverglass optical transmission losses. Understanding this relationship is important because optical transmission losses are known to lead to current reduction in solar power generation systems. In addition to the development of surface characterization workflows, valuable lessons learned as they pertain to future investigations and experiments will be discussed. The authors hope that sharing these lessons will facilitate more utilization of DLR’s unique capabilities as well as open the conversation for how best to address experimental characterization of flight-like plume expansion and its impacts on materials surface degradation effects.

Gateway

AC and DC Fault Management for Megawatt Electrified Aircraft Electrical Powertrains - Task 2: Power Quality Filtering Using Nanocrystalline Soft Magnetic Inductor

The NASA RTAPS program on AC and DC Fault Management for Megawatt Electrified Power Train is a multi-year joint project with Pratt & Whitney (P&W), Collins Aerospace (CA), and RTX Technology Research Center (RTRC). This research program focuses on the high-voltage distribution issues that present a significant technological obstacle in the adoption of Electrified Aviation Propulsion (EAP) systems. One challenge to the adoption of high-voltage distribution systems with power electronic converters is the need for filter elements to limit the generation and propagation of noise, protect the cable systems from premature aging and prevent against excessive heating within subcomponents due to high-frequency induced currents. While increased distribution voltages aide in reducing the cable mass for a fixed power system, the associated mass with the filtering elements for power electronic converter can grow with increasing distribution voltages – thereby mitigating any benefit associated with increasing the distribution system voltage. To enable high-voltage distribution systems with high system specific power densities, new magnetic materials must be developed. Therefore, the second task of the NASA RTAPS program is associated with the design and application of advanced soft magnetic components for Megawatt class electric propulsion systems, specifically the motor drive system. This report covers the collaborative work between NASA Glenn Research Center (GRC), RTRC, P&W and CA in the development of three types of magnetic components over the span of the three-year program. These critical magnetic components are the DC side EMI filter, which limits the propagation of harmful electromagnetic noise to the rise of the distribution system, and the AC side damping with the dv/dt filter, which limits the fast rise time of the power electronic converter output voltage to limit the degradation on the cable/motor insulation systems. Each of these components are investigated from component level design and are optimized at the system level with a combined modelling and testing effort. In the final experimental evaluation of the NASA developed soft magnetic material with a dv/dt filter, a commercial-off-the-shelf (COTS) magnetic core and the GRC magnetic core are optimized and loaded at 320Arms to evaluate their difference in performance. After a run time of 30 minutes in a MW-class motor driver at RTRC, the NASA GRC cores were found to not only offer a lower temperature rise of nearly 25°𝐶, but also a reduction in measured core loss of 25% (12.75W to 9.5W).

Elecrified Aircraft Propulsion

Spacecraft thermal balance testing using infrared sources

A thermal balance test (controlled flux intensity) on a simple black dummy spacecraft using IR lamps was performed and evaluated, the latter being aimed specifically at thermal mathematical model (TMM) verification. For reference purposes the model was also subjected to a solar simulation test (SST). The results show that the temperature distributions measured during IR testing for two different model attitudes under steady state conditions are reproducible with a TMM. The TMM test data correlation is not as accurate for IRT as for SST. Using the standard deviation of the temperature difference distribution (analysis minus test) the SST data correlation is better by a factor of 1.8 to 2.5. The lower figure applies to the measured and the higher to the computer-generated IR flux intensity distribution. Techniques of lamp power control are presented. A continuing work program is described which is aimed at quantifying the differences between solar simulation and infrared techniques for a model representing the thermal radiating surfaces of a large communications spacecraft.

G. B. T. Tan

A SIMULINK Environment for Flight Dynamics and Control Analysis - Application to the DHC-2 'Beaver', Part 1. Implementation of a Model Library in SIMULINK

The design of advanced Automatic Aircraft Control Systems (AACS's) can be improved upon considerably if the designer can access all models and tools required for control system design and analysis through a graphical user-interface, from within one software environment. This MSc-thesis presents the first step in the development of such an environment, which is currently being done at the Section for Stability and Control of Delft University of Technology, Faculty of Aerospace Engineering. The environment is implemented within the commercially available software package MATLAB/SIMULINK. The report consists of two parts. Part I gives a detailed description of the AACS design environment. The heart of this environment is formed by the SIMULINK implementation of a nonlinear aircraft model in block-diagram format. The model has been worked out for the old laboratory aircraft of the Faculty, the De Havilland DHC-2 'Beaver', but due to its modular structure, it can easily be adapted for other aircraft. Part I also describes MATLAB programs which can be applied for finding steady-state trimmed-flight conditions and for linearization of the aircraft model, and it shows how the built-in simulation routines of SIMULINK have been used for open-loop analysis of the aircraft dynamics. Apart from the implementation of the models and tools, a thorough treatment of the theoretical backgrounds is presented. Part II of this report presents a part of an autopilot design process for the 'Beaver' aircraft, which clearly demonstrates the power and flexibility of the AACS design environment from part I. Evaluations of all longitudinal and lateral control laws by means of nonlinear simulations are treated in detail. The AACS design environment from part I proved to be a very useful tool for designing the control laws of the 'Beaver' autopilot within a very tight time-schedule. The autopilot design process itself will be used as a guideline for future AACS research at the Faculty of Aerospace Engineering. Flight tests of the 'Beaver' autopilot, done after evaluating the control laws in the SIMULINK package, proved to be quite successful. In the future, the AACS design package will evolve into a standardized, integrated design environment which can be applied to virtually any type of aircraft. The AACS design cycle will be shortened further by developing tools for automatically porting control laws from the MATLAB/SIMULINK environment to a piloted real-time flight simulator and the Flight Control Computers of the aircraft.

Aircraft Modelling