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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 1,567 records · Page 87

Reducing Fuel Consumption on a Heavy-Duty Nonroad Vehicle: Conventional Powertrain Modifications

This investigation focuses on conventional powertrain technologies that provide operational synergy based on customer utilization to reduce fuel consumption for a heavy-duty, nonroad (off-road) material handler. The vehicle of interest is a Pettibone Cary-Lift 204i, with a base weight of 50,000 lbs. and a lift capacity of 20,000 lbs. The conventional powertrain consists of a US Tier 4 Final diesel engine, a non-lockup torque converter, a four-speed powershift automatic transmission, and all-wheel drive. The paper will present a base vehicle energy/fuel consumption breakdown of propulsion, hydraulic and idle distribution based on a representative end-user drive cycle. The baseline vehicle test data was then used to develop a correlated lumped parameter model of the vehicle-powertrain-hydraulic system that can be used to explore technology integration that can reduce fuel consumption. Two conventional powertrain modifications are explored that provide potential pathways that significantly alter the base powertrain and include 1.) a torque converter disconnect clutch and 2.) a low voltage stop-start system that have the potential to reduce fuel consumption on the end user representative drive cycle by 10.3% and 9.8%, respectively. Details of how the powertrain modifications would be executed, physical hardware, and application to other heavy-duty nonroad vehicle applications are included in the discussion.

33 ADVANCED PROPULSION SYSTEMS↗

Electric Vehicle Lithium-Ion Battery Life Cycle Management

There is no question that electric vehicles (EVs), which are key for addressing climate change impacts from the transportation sector, are quickly gaining popularity and availability. With limits and other challenges related to the supply of critical battery minerals, maximizing the use of EV batteries and ensuring recovery of battery minerals is imperative. Therefore, proper end-of-life-cycle management (reuse and recycling) of these batteries must be part of the EV ecosystem from the perspective of both the supply chain and environmental footprint. Second use of batteries for energy storage systems extends the initial life of these resources and provides a buffer until economical material recovery facilities are in place. Although there are multiple pathways to recycling and recovery of materials, new recovery technologies are moving toward commercially available hydrometallurgy and promising direct recycling, which analysis has shown has the lowest overall carbon footprint. Strategically locating these plants close to battery collection further reduces transportation and thus recycling and recovering costs. Proper life cycle management could alleviate future lithium-ion battery materials supply chains for EVs. Governments and other stakeholders around the world have started initiatives and proposed regulations to address the challenges associated with life cycle management of EV lithium batteries. Finally, as manufacturers are increasingly faced with the likelihood of such extensive regulatory requirements, attention should be given to new designs, sales, and service models that can reduce life cycle management costs.

25 ENERGY STORAGE↗

TCO Analysis Approach and Regional Analysis of dWPT for Class 8 Tractors

Dynamic Wireless Power Transfer (dWPT) is a method by which battery electric vehicles (BEVs) can charge their battery while traveling on the road without the need for a physical conductive connection to the power source. dWPT has been proposed as a strategy to enable a reduction in vehicle battery capacity and associated mass and cost. In this slide deck presented at the EVs@Scale Consortium - Wireless Power Transfer Pillar Deep-Dive Meeting on November 11th, 2023, NREL provides results from an evaluation of dWPT using data from Class 8 tractors driving in the Atlanta Metro Area. NREL selected data for archetypal days representing local, regional, and long-haul trips, defined according to trip length, that included travel on primary roadways. EVI-InMotion (Electric Vehicle Infrastructure - InMotion), a systems planning and optimization tool developed at NREL, was used to evaluate dWPT performance assuming dWPT charging on 120 road segments for a total roadway lane distance of 2,365 miles. The EVI-InMotion results and representative day drive cycles were analyzed with NREL's T3CO (Transportation Technology Total Cost of Ownership) tool to estimate the total cost of ownership (TCO) for scenarios comprising two model years - 2030 and 2040 - and two technology progress cases. TCO was calculated for diesel, fuel cell electric, BEVs with batteries sized assuming no dWPT capabilities, and 200kWh BEVs with dWPT installed. This analysis finds that en-route stationary charging frequency and downtime when not on electrified roadways are the main contributors to TCO for the dWPT vehicles and that these vehicles can achieve cost parity with FCEVs at low electricity costs. Based on the scenario assumptions used here, low electricity costs would further help the cost parity with diesel vehicles in regional and long-haul cases due to stationary fueling downtime. This presentation also concludes that key factors affecting the parity potential of dWPT-capable vehicles include more extensive dWPT road coverage, higher en-route charging power, less expensive power batteries, and higher hydrogen or diesel fuel costs.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗

Probabilistic Structural Analysis Methods (PSAM) for select space propulsion system components, part 2

The technical effort and computer code enhancements performed during the sixth year of the Probabilistic Structural Analysis Methods program are summarized. Various capabilities are described to probabilistically combine structural response and structural resistance to compute component reliability. A library of structural resistance models is implemented in the Numerical Evaluations of Stochastic Structures Under Stress (NESSUS) code that included fatigue, fracture, creep, multi-factor interaction, and other important effects. In addition, a user interface was developed for user-defined resistance models. An accurate and efficient reliability method was developed and was successfully implemented in the NESSUS code to compute component reliability based on user-selected response and resistance models. A risk module was developed to compute component risk with respect to cost, performance, or user-defined criteria. The new component risk assessment capabilities were validated and demonstrated using several examples. Various supporting methodologies were also developed in support of component risk assessment.

Source record↗

Specialized data analysis of SSME and advanced propulsion system vibration measurements

The basic objectives of this contract were to perform detailed analysis and evaluation of dynamic data obtained during Space Shuttle Main Engine (SSME) test and flight operations, including analytical/statistical assessment of component dynamic performance, and to continue the development and implementation of analytical/statistical models to effectively define nominal component dynamic characteristics, detect anomalous behavior, and assess machinery operational conditions. This study was to provide timely assessment of engine component operational status, identify probable causes of malfunction, and define feasible engineering solutions. The work was performed under three broad tasks: (1) Analysis, Evaluation, and Documentation of SSME Dynamic Test Results; (2) Data Base and Analytical Model Development and Application; and (3) Development and Application of Vibration Signature Analysis Techniques.

Coffin, Thomas↗

Validation of a Computational Fluid Dynamics Model of Axial Jet Mixing for Cryogenic Propellant Tank Pressure Control

The Fluid Dynamics Branch at the NASA Marshall Space Flight Center is preparing to support flight programs through analysis of a variety of cryogenic fluid management (CFM) applications. Many vehicles being considered for future manned missions to the moon and beyond use chemical or nuclear thermal propulsion systems that rely on cryogenic propellants. Storing cryogenic propellants for later use is a challenge, though. Many areas of active CFM research, testing, and design involve propellant conditioning to ensure propellant remains a usable liquid for propulsion. Multiple technologies may be used to achieve adequate conditioning including the subject of this paper, a jet-based mixer. Mixing serves to homogenize fluid temperatures and decrease ullage pressure. Development and validation of a modeling methodology for jet-based mixing was conducted to prepare for in-line design work.

Jacob M Brodnick↗

Validation of a Computational Fluid Dynamics Model of Axial Jet Mixing for Cryogenic Propellant Tank Pressure Control

The Fluid Dynamics Branch at the NASA Marshall Space Flight Center is preparing to support flight programs through analysis of a variety of cryogenic fluid management (CFM) applications. Many vehicles being considered for future manned missions to the moon and beyond use chemical or nuclear thermal propulsion systems that rely on cryogenic propellants. Storing cryogenic propellants for later use is a challenge, though. Many areas of active CFM research, testing, and design involve propellant conditioning to ensure propellant remains a usable liquid for propulsion. Multiple technologies may be used to achieve adequate conditioning including the subject of this paper, a jet-based mixer. Mixing serves to homogenize fluid temperatures and decrease ullage pressure. Development and validation of a modeling methodology for jet-based mixing was conducted to prepare for in-line design work.

Jacob M. Brodnick↗

NASA’s Quiet Electric ENgines (QUEEN): Summary of the QUEEN V2 Test

A liquid-cooled electric ducted fan system was designed, built, and tested at the NASA Glenn Research Center. Main components of the system include a Commercial-Off- the-Shelf (COTS) fan and motor, and a custom-designed heat exchanger integrated into the fan duct. Fan speed, thrust, and cooling system thermal performance was measured in this static ground test of the propulsor. This propulsor prototype is one of NASA’s Quiet Electric ENgines (QUEENs) and is designated the ‘QUEEN V2.’ The Quiet Electric Engines are being developed for the 25% scale model of the Subsonic Aft Engine (SUSAN) Flight Research Vehicle and are intended to explore the potential of distributed electric propulsion for regional single-aisle aircraft. This test demonstrated the functionality of the QUEEN V2, quantified the thrust produced by the electrofan, and characterized the electrical and thermal performance of the system. Lessons learned will be used to guide development of future QUEEN prototypes.

Aerodynamics↗

NASA’s Quiet Electric ENgines (QUEEN): Summary of the QUEEN V2 Test

A liquid-cooled electric ducted fan system was designed, built, and tested at the NASA Glenn Research Center. Main components of the system include a Commercial-Off- the-Shelf (COTS) fan and motor, and a custom-designed heat exchanger integrated into the fan duct. Fan speed, thrust, and cooling system thermal performance was measured in this static ground test of the propulsor. This propulsor prototype is one of NASA’s Quiet Electric ENgines (QUEENs) and is designated the ‘QUEEN V2.’ The Quiet Electric Engines are being developed for the 25% scale model of the Subsonic Aft Engine (SUSAN) Flight Research Vehicle and are intended to explore the potential of distributed electric propulsion for regional single-aisle aircraft. This test demonstrated the functionality of the QUEEN V2, quantified the thrust produced by the electrofan, and characterized the electrical and thermal performance of the system. Lessons learned will be used to guide development of future QUEEN prototypes.

Aeronautics-General↗

Manufactured Porous Ambient Surface Simulants

The planetary science decadal survey for 2013-2022 (Vision and Voyages, NRC 2011) has promoted mission concepts for sample acquisition from small solar system bodies. Numerous comet-sampling tools are in development to meet this standard. Manufactured Porous Ambient Surface Simulants (MPASS) materials provide an opportunity to simulate variable features at ambient temperatures and pressures to appropriately test potential sample acquisition systems for comets, asteroids, and planetary surfaces. The original "flavor" of MPASS materials is known as Manufactured Porous Ambient Comet Simulants (MPACS), which was developed in parallel with the development of the Biblade Comet Sampling System (Backes et al., in review). The current suite of MPACS materials was developed through research of the physical and mechanical properties of comets from past comet missions results and modeling efforts, coordination with the science community at the Jet Propulsion Laboratory and testing of a wide range of materials and formulations. These simulants were required to represent the physical and mechanical properties of cometary nuclei, based on the current understanding of the science community. Working with cryogenic simulants can be tedious and costly; thus MPACS is a suite of ambient simulants that yields a brittle failure mode similar to that of cryogenic icy materials. Here we describe our suite of comet simulants known as MPACS that will be used to test and validate the Biblade Comet Sampling System (Backes et al., in review).

Carey, Elizabeth M.↗

Dynamics and Control of a Disordered System in Space

In this paper, we present some ideas regarding the modeling, dynamics and control aspects of granular spacecraft. Granular spacecraft are complex multibody systems composed of a spatially disordered distribution of a large number of elements, for instance a cloud of N grains in orbit, with N greater than 10(exp 3). These grains can be large (Cubesat-size) or small (mm-size), and can be active, i.e., a fully equipped vehicle capable sensing their own position and attitude, and enabled with propulsion means, or entirely passive. The ultimate objective would be to study the behavior of the single grains and of large ensembles of grains in orbit and to identify ways to guide and control the shape of a cloud composed of these grains so that it can perform a useful function in space, for instance, as an element of an optical imaging system for astrophysical applications. This concept, in which the aperture does not need to be continuous and monolithic, would increase the aperture size several times compared to large NASA observatories such as ATLAST, allowing for a true Terrestrial Planet Imager that would be able to resolve exo-planet details and do meaningful spectroscopy on distant world. In the paper, we address the modeling and autonomous operation of a distributed assembly (the cloud) of large numbers of highly miniaturized space-borne elements (the grains). A multi-scale, multi-physics model is proposed of the dynamics of the cloud in orbit, as well as a control law for cloud shape maintenance, and preliminary simulation studies yield an estimate of the computational effort, indicating a scale factor of approximately N(exp 1.4) as a function of the number of grains. A granular spacecraft can be defined as a collection of a large number of space-borne elements (in the 1000s) designed and controlled such that a desirable collective behavior emerges, either from the interactions among neighboring grains, and/or between the grains and the environment. In this paper, each grain is considered to be a highly miniaturized spacecraft which has limited size and mass, hence it has limited actuation, limited propulsive capability, limited power, limited sensing, limited communication, limited computational resources, limited range of motion, limited lifetime, and may be expendable. The modeling and dynamics of clouds of vehicles is more challenging than with conventional vehicles because we are faced with a probabilistic vehicle composed of a large number of physically disconnected vehicles. First, different scales of motion occur simultaneously in a cloud: translations and rotations of the cloud as a whole (macro-dynamics), relative rotation and translation of one cloud member with respect to another (meso-dynamics), and individual cloud member dynamics (micro-dynamics). Second, the control design needs to be tolerant of the system complexity, of the system architecture (centralized vs. decentralized large scale system control) as well as robust to un-modeled dynamics and noise sources. Figure 1, top left, shows the kinematic parameters of a 1000 element cloud in orbit. The motion of the system is described with respect to a local vertical-local horizontal (LV-LH) orbiting reference frame (x,y,z)=F(sub ORF) of origin O(sub ORF) which rotates with mean motion omega and orbital semi-major axis R(sub 0). The orbital geometry at the initial time is defined in terms of its six orbital elements, and the orbital dynamics equation for point O(sub ORF) is propagated forward in time under the influence of the gravitational field of the primary and other external perturbations, described below. The origin of this frame coincides with the initial position of the center of mass of the system, and the coordinate axes are z along the local vertical, x toward the flight direction, and y in the orbit normal direction. The assumptions we used to model the dynamics are as follows: 1) The inertial frame is fixed at Earth's center. 2) The orbiting Frame ORF follows Keplerian orbit. 3) the cloud system dynamics is referred to ORF. 4) the attitude of each grain uses the principal body frame as body fixed frame. 5) the atmosphere is assumed to be rigidly rotating with the Earth. Regarding the grains forming the cloud: 1) each grain is modeled as a rigid body; 2) a simple attitude estimator provides attitude estimates, 3) a simple guidance logic commands the position and attitude of each grain, 4) a simple local feedback controller based on PD control of local states is used to stabilize the attitude of the vehicle. Regarding the cloud: 1) the cloud as a whole is modeled as an equivalent rigid body in orbit, and 2) an associated graph establishes agent connectivity and enables coupling between modes of motion at the micro and macro scales; 3) a simple guidance and estimation logic is modeled to estimate and command the attitude of this equivalent rigid body; 4) a cloud shape maintenance controller is based on the dynamics of a stable virtual truss in the orbiting frame. Regarding the environmental perturbations acting on the cloud: 1) a non-spherical gravity field including JO (Earth's spherical field) zonal component, J2 (Earth's oblateness) and J3 zonal components is implemented; 2) atmospheric drag is modeled with an exponential model; 3) solar pressure is modeled assuming the Sun is inertially fixed; and 4) the Earth's magnetic field is model using an equivalent dipole model. The equations of motion are written in a referential system with respect to the origin of the orbiting frame and the state is propagated forward in time using an incremental predictor-corrector scheme. A representative cloud with varying number of grains is simulated to identify the limitations in computation time as the number of grains grows. We derive a control law to track a desired surface in the ORF (equivalently to maintain a reference cloud shape) by defining an error from a desired surface shape, and designing a control law that is exponentially stable and reduces the tracking error to zero. Figure 1 (top right) shows a comparison of various requirements for simulation of single spacecraft vs. granular spacecraft, indicating the high degree of complexity that needs to be taken into consideration. The ORF components of control force required by one of the grains is, for this particular case, in the micro-Newton range. However, no attempt has been made yet to reconfigure (or re-orient) the cloud configuration internally, for which forces in the milli-Newton level are expected, depending on the time required to do the reconfiguration. Figure 1, bottom, shows the computation time as a function of the number of grains, indicating an order N(exp 1.43) scaling on a 8 Gb, 1067 MHz RAM MacOSX computer with a 3.06 GHz Intel Core 2 Duo processor. With this metric, the same simulation for a system of N=1000 grains would take 5.4 hours, and 146 hours (i.e., 6 days) for a system with N=10,000 grains. Therefore, efficient ways to simulate this complex system, where not only the time scales of natural system dynamics, but also the sampling times of the Guidance, Navigation, and Control are included, remain to be explored. Additional details on the cloud modeling, dynamics, and control will be described in the paper.

simulation↗

Development of Machine-Learned Interatomic Potentials to Predict Structure, Transport, and Reactivity in Platinum-Based Fuel Cells

Machine-learned interatomic potentials (MLIPs) have rapidly progressed in accuracy, speed, and data efficiency in recent years. However, training robust MLIPs in multicomponent systems remains a challenge. In this work, we train an MLIP to describe hydrated Nafion ionomers and platinum catalysts, which are important components of fuel cells, by constructing a diverse training set to describe the bulk polymer and interfacial catalyst–polymer interactions well. We use our trained MLIP to study the properties of the platinum–Nafion system, including polymer structure, proton mobility in a bulk Nafion polymer and near a platinum-Nafion interface, and reactions near and far from the interface, finding excellent results for structure and reactions contained within our training set. Transport seems to be well described, with both vehicular transport and Grotthuss hopping captured, although converged calculations of diffusivities were not computed because they require calculations of tens of nanoseconds that are challenging with current state-of-the-art MLIPs. The combined insights that this model provides can be leveraged to optimize fuel cell performance, and the approach can be applied to other chemical processes and devices where structure, transport, and reactivity all contribute to the overall observed performance.

33 ADVANCED PROPULSION SYSTEMS↗

AST Critical Propulsion and Noise Reduction Technologies for Future Commercial Subsonic Engines: Separate-Flow Exhaust System Noise Reduction Concept Evaluation

This report describes the work performed by General Electric Aircraft Engines (GEAE) and Allison Engine Company (AEC) on NASA Contract NAS3-27720 AoI 14.3. The objective of this contract was to generate quality jet noise acoustic data for separate-flow nozzle models and to design and verify new jet-noise-reduction concepts over a range of simulated engine cycles and flight conditions. Five baseline axisymmetric separate-flow nozzle models having bypass ratios of five and eight with internal and external plugs and 11 different mixing-enhancer model nozzles (including chevrons, vortex-generator doublets, and a tongue mixer) were designed and tested in model scale. Using available core and fan nozzle hardware in various combinations, 28 GEAE/AEC separate-flow nozzle/mixing-enhancer configurations were acoustically evaluated in the NASA Glenn Research Center Aeroacoustic and Propulsion Laboratory. This report describes model nozzle features, facility and data acquisition/reduction procedures, the test matrix, and measured acoustic data analyses. A number of tested core and fan mixing enhancer devices and combinations of devices gave significant jet noise reduction relative to separate-flow baseline nozzles. Inward-flip and alternating-flip core chevrons combined with a straight-chevron fan nozzle exceeded the NASA stretch goal of 3 EPNdB jet noise reduction at typical sideline certification conditions.

Janardan, B. A.↗

Parametric Mass Modeling for Mars Entry, Descent and Landing System Analysis Study

This paper provides an overview of the parametric mass models used for the Entry, Descent, and Landing Systems Analysis study conducted by NASA in FY2009-2010. The study examined eight unique exploration class architectures that included elements such as a rigid mid-L/D aeroshell, a lifting hypersonic inflatable decelerator, a drag supersonic inflatable decelerator, a lifting supersonic inflatable decelerator implemented with a skirt, and subsonic/supersonic retro-propulsion. Parametric models used in this study relate the component mass to vehicle dimensions and mission key environmental parameters such as maximum deceleration and total heat load. The use of a parametric mass model allows the simultaneous optimization of trajectory and mass sizing parameters.

Samareh, Jamshid A.↗

BioSentinel: Leading the Way for Deep Space CubeSat Missions

Flagship science missions are not alone in Deep Space thanks to BioSentinel, a 6U spacecraft launched on Artemis-1. BioSentinel is one of the longest operating CubeSats beyond cislunar space. The subsystems and COTS components of the BioSentinel bus are a template for future deep space missions, and the lessons learned from over a year of operations will enable improved performance for the next missions. BioSentinel achieved its unprecedented performance for an SLS secondary payload due to preparation, planning, and a robust design. Pre-launch antenna and interface testing with both DSN and ESA confirmed command and data pathways and allowed for operational flexibility in the critical early hours post-deployment. Mission Operations simulations prior to launch identified potential risks and primed operators to respond in flight, preparing the team to react quickly to successfully detumble the spacecraft and enter a power-positive state. The spacecraft would not have survived without the inclusion of the trailblazing 3D-printed composite cold gas propulsion system. The non-standard tank geometry enabled efficient use of the limited space available in the CubeSat, as well as the capability to detumble the spacecraft and manage momentum, while providing sufficient margin to execute potential delta-V maneuvers. The Iris radio has operated for over 18 months with no significant issues. Initial Iris performance estimates have been accurate throughout the mission. BioSentinel continues to collect data on thermal conditions and to validate our performance models with real-world knowledge. We have received exemplary support from our DSN partners. Following the conclusion of the primary science mission, the Linear Energy Transfer (LET) Spectrometer continued to collect solar and galactic radiation data from its location in heliocentric orbit. The free space dataset offered by the BioSentinel LET is a valuable source of data for model validation and future mission planning. As the spacecraft travels farther from Earth it is poised to provide longitudinally distributed measurements of solar particle events during solar maximum. The lessons learned from BioSentinel suggest key areas to enhance performance. The ability to upload modified flight software can increase the stability of memory management. Additional heaters in the propulsion system design have already proven successful on the Starling mission. Streamlining mission operations can reduce costs, increase data return, and better utilize DSN time. Enhancements such as these will facilitate reliable, long-duration deep space exploration using the proven BioSentinel 6U CubeSat bus.

BioSentinel↗

Heat Pipe Enhanced Thermal Management System for GaN Switches in an Integrated Modular Motor Drive for Aircraft Propulsion

This paper presents the process of sizing a heat pipe enhanced thermal management system (TMS) for GaN switches in an integrated modular motor drive (IMMD) powering a 250 kW aircraft propulsion electric motor. A test setup mimicking the TMS and GaN switches assembly is constructed. The condenser chamber of the TMS is modeled in ANSYS Fluent while the GaN switches assembly is modeled in ANSYS Thermal allowing us to verify heat spreader temperature under test conditions and estimate GaN temperatures under test and actual application operating conditions.

DIRECT ENERGY CONVERSION↗