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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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Structural Testing Technology Development: Cooperative Research and Development Final Report, CRADA Number CRD-06-00200

NREL is the only organization in the US that is accredited to conduct tests of wind turbine systems and components in accordance with International Electrotechnical Commission (IEC) test standards. The National Wind Technology Center houses the only full-scale wind turbine blade drivetrain test facilities in the US. To maintain these facilities, accreditation, and the acceptance of the wind industry, NREL must strive continuously to maintain and improve staff capabilities, procedures, facility and equipment. In addition, as wind turbines continue to increase in size, NREL must improve its capability to test the larger components associated with these new turbines. NREL is currently investigating methods to increase blade and drivetrain testing capabilities. Mitsubishi Power Systems (MPS) must also strive to meet the demands of the evolving wind energy industry by developing, proving and manufacturing new, cost-effective blades for its turbines. Mitsubishi has established a joint venture with TPI composites of Rhode Island for manufacturing blades to be installed on US wind turbines. There is an obvious advantage to test these prototype blades in a US facility. The NREL blade test facility is uniquely capable of fulfilling this need. In addition, NREL can provide other testing support to MPS through the use of its dynamometer facility for drivetrain testing and through the use of NREL’s field-testing capabilities for testing wind turbine systems. This CRADA provides the opportunity for both organizations to achieve critical goals in development of wind energy in the US. MPS obtains verification of its wind turbine components and system. NREL obtains improved test capabilities.

17 WIND ENERGY↗

Investigation of upper-surface-blowing nacelle integration at cruise speeds utilizing powered engine simulators

Various overwing nacelle designs were investigated on a representative four-engine short-haul aircraft configuration during a combined analytical and experimental program. Design conditions were a Mach number of 0.7 and a lift coefficient of 0.4. All nacelles had D-shaped nozzle exits and included a streamline-contoured design, a low boattail angle reference configuration, and a high boattail angle powered lift design. Testing was done with the design four-engine airplane configuration as well as with only inboard nacelles installed. Turbopowered engine simulators were used to provide realistic representation of nacelle flows. Performance trends are compared for the various nacelle designs. In addition, comparisons are presented between analytical and experimental pressure distributions and between flow-through and powered simulator results.

Meleason, E. T.↗

Survey of Experimental Results From One Year of PASP PLUS Orbital Operation

With PASP Plus as its primary payload, the APEX satellite was launched by a standard Pegasus rocket released from a NASA B-52 aircraft on 3 August 1994. A 70 deg inclination, 363 km X 2550 km orbit was achieved, allowing both investigation of space plasma effects on high-voltage operation in the perigee region and investigation of space radiation effects on array power output from passage through the inner radiation belt in the apogee region. Data gathering by PASP Plus was begun on 7 Aug 94 and ended on 11 Aug 95. In one year, PASP Plus collected an order of magnitude more data on environmental interactions on solar arrays than all previous space-borne photovoltaic experiments combined. The test arrays flown and the interactions-measuring and space-environment sensors of PASP Plus are described. The results of measurements of leakage current under test-array positive biasing and arc rates under negative biasing as a function of bias voltage, plasma density, array orientation, and other conditions are presented. The results of measurements of test-array power-output degradation caused by space radiation are also examined.

PHOTOVOLTAIC EFFECT↗

Experimental Validation of a High-Temperature Test Facility for Future Additive Manufactured Supercritical Carbon Dioxide Turbine Testing

For next-generation power plants to achieve high cycle efficiencies consistent with the Department of Energy's 65% efficiency target, turbomachinery capable of operating within high-temperature power cycles must be demonstrated. Pairing additively manufactured superalloy turbines with the supercritical carbon dioxide (sCO 2 ) power cycle could enable turbine inlet temperatures approaching 1300 °C while providing flexibility in turbine cooling strategies. Development of test facilities to characterize and validate such systems is crucial. In this study, a turbine test facility capable of achieving inlet conditions of 800 °C, 11 MPa, and 0.43 kg/s while accommodating complex auxiliary cooling flow requirements has been designed and constructed to support future testing of a Haynes 282 additively manufactured 30 kW turbine-generator system with advanced cooling channels. This facility enables characterization of aerodynamic performance, leakage, and windage losses. Details of the facility's construction and operation are presented, along with experimental validation tests using an orifice as an expansion device in place of the turbine. These tests confirm that the facility can reach the required conditions, distinguish regions of achievable steady and pseudo-steady conditions, and identify the heater power required for each point in the upcoming turbine campaign. The campaign confirmed that ISO 5167-2 can reliably predict orifice mass flow rates in extreme supercritical carbon dioxide conditions with deviations of 0.5–7.5%.

42 ENGINEERING↗

Baseline Experimental Results on the Effect of Oil Temperature on Shrouded Meshed Spur Gear Windage Power Loss

Rotorcraft gearbox efficiencies are reduced at increased surface speeds due to viscous and impingement drag on the gear teeth. This windage power loss can affect overall mission range, payload, and frequency of transmission maintenance. Experimental and analytical studies on shrouding for single gears have shown it to be potentially effective in mitigating windage power loss. Efficiency studies on unshrouded meshed gears have shown the effect of speed, oil viscosity, temperature, load, lubrication scheme, etc. on gear windage power loss. The open literature does not contain experimental test data on shrouded meshed spur gears. Gear windage power loss test results are presented on shrouded meshed spur gears at elevated oil inlet temperatures and constant oil pressure both with and without shrouding. Shroud effectiveness is compared at four oil inlet temperatures. The results are compared to the available literature and follow-up work is outlined.

gear↗

KRUSTY Experiment: Reactivity Insertion Accident Analysis

The centerpiece of the Kilopower Project, i.e., the Kilowatt Reactor Using Stirling TechnologY (KRUSTY) test, consists of the development and testing of a ground technology demonstration of a small fission power system based on a 1-kW(electric) space science power requirement. The KRUSTY test was authorized by the U.S. Department of Energy’s (DOE’s) National Nuclear Security Administration Nevada Field Office. Authorization was obtained by adding an amendment to the existing regulatory documents for the National Criticality Experiments Research Center to cover the KRUSTY experiment. This amendment was reviewed and approved by the DOE. The most important safety question for the experiment was the addition of over 2 $ of excess reactivity to the reactor system. This amount of excess reactivity meant that the analyst could postulate accidents where the reactor went prompt critical, leading to physical shock or melting of the fuel. This paper analyzes these accidents using computer calculations and examines the controls used to mitigate them. The estimation of the impacts both on accident progression and consequences of reactivity insertion events was a significant part of obtaining approval for the KRUSTY experiment. The regulatory approval of KRUSTY was one of the first to be obtained for a completely new reactor concept in many decades.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Pressure distributions on a 0.04-scale model of the Space Shuttle Orbiter's forward fuselage in the Langley unitary plan wind tunnel

Pressure distribution tests on a 0.04-scale model of the forward fuselage of the Space Shuttle Orbiter are presented without analysis. The tests were completed in the Langley Unitary Plan Wind Tunnel (UPWT). The UPWT has two different test sections operating in the continuous mode. Each test section has its own Mach number range. The model was tested at angles of attack from -2.5 deg to 30 deg and angles of sideslip from -5 deg to 5 deg in both test sections. The test Reynolds number was 6.6 x 10 to the 6th power per meter. The tests were conducted in support of the development of the Shuttle Entry Air Data System (SEADS). In addition to modeling the 20 SEADS pressure orifices, the wind-tunnel model was also instrumented with orifices to match Development Flight Instrumentation (DFI) port locations currently existing on the Space Shuttle Orbiter Columbia (OV-102). This DFI simulation has provided a means for comparisons between reentry flight pressure data and wind-tunnel data.

Bradley, P. F.↗

Device and method for frictionally testing materials for ignitability

Test apparatus for determining ignition characteristics of various metal in oxidizer environments simulating operating conditions for materials is invented. The test apparatus has a chamber through which the oxidizing agent flows, and means for mounting a stationary test sample therein, a powered, rotating shaft in the chamber rigidly mounts a second test sample. The shaft is axially movable to bring the samples into frictional engagement and heated to the ignition point. Instrumentation connected to the apparatus provides for observation of temperatures, pressures, loads on and speeds of the rotating shaft, and torques whereby components of stressed oxygen systems can be selected which will avoid accidental fires under working conditions.

Benz, F. J.↗

A Large Hemi-Anechoic Enclosure for Community-Compatible Aeroacoustic Testing of Aircraft Propulsion Systems

A large hemi-anechoic (absorptive walls and acoustically hard floor) noise control enclosure has been erected around a complex of test stands at the NASA Lewis Research Center in Cleveland, Ohio. This new state-of-the-art Aeroacoustic Propulsion Laboratory (APL) provides an all-weather, semisecure test environment while limiting noise to acceptable levels in surrounding residential neighborhoods. The 39.6 m (130 ft) diameter geodesic dome structure houses the new Nozzle Aeroacoustic Test Rig (NATR), an ejector-powered M = 0.3 free jet facility for acoustic testing of supersonic aircraft exhaust nozzles and turbomachinery. A multi-axis, force-measuring Powered Lift Facility (PLF) stand for testing of Short Takeoff Vertical Landing (STOVL) vehicles is also located within the dome. The design of the Aeroacoustic Propulsion Laboratory efficiently accomodates the research functions of two separate test rigs, one of which (NATR) requires a specialized environment for taking acoustic measurements. Absorptive fiberglass wedge treatment on the interior surface of the dome provides a hemi-anechoic interior environment for obtaining the accurate acoustic measurements required to meet research program goals. The APL is the first known geodesic dome structure to incorporate transmission-loss properties as well as interior absorption into a free-standing, community-compatible, hemi-anechoic test facility.

Cooper, Beth A.↗

Test and Verification Approach for the NASA Constellation Program

This viewgraph presentation is a test and verification approach for the NASA Constellation Program. The contents include: 1) The Vision for Space Exploration: Foundations for Exploration; 2) Constellation Program Fleet of Vehicles; 3) Exploration Roadmap; 4) Constellation Vehicle Approximate Size Comparison; 5) Ares I Elements; 6) Orion Elements; 7) Ares V Elements; 8) Lunar Lander; 9) Map of Constellation content across NASA; 10) CxP T&V Implementation; 11) Challenges in CxP T&V Program; 12) T&V Strategic Emphasis and Key Tenets; 13) CxP T&V Mission & Vision; 14) Constellation Program Organization; 15) Test and Evaluation Organization; 16) CxP Requirements Flowdown; 17) CxP Model Based Systems Engineering Approach; 18) CxP Verification Planning Documents; 19) Environmental Testing; 20) Scope of CxP Verification; 21) CxP Verification - General Process Flow; 22) Avionics and Software Integrated Testing Approach; 23) A-3 Test Stand; 24) Space Power Facility; 25) MEIT and FEIT; 26) Flight Element Integrated Test (FEIT); 27) Multi-Element Integrated Testing (MEIT); 28) Flight Test Driving Principles; and 29) Constellation s Integrated Flight Test Strategy Low Earth Orbit Servicing Capability.

Strong, Edward↗

Rehabilitation of the Rocket Vehicle Integration Test Stand at Edwards Air Force Base

Since initial use in 1958 for the X-15 rocket-powered research airplane, the Rocket Engine Test Facility has proven essential for testing and servicing rocket-powered vehicles at Edwards Air Force Base. For almost two decades, several successful flight-test programs utilized the capability of this facility. The Department of Defense has recently demonstrated a renewed interest in propulsion technology development with the establishment of the National Aerospace Initiative. More recently, the National Aeronautics and Space Administration is undergoing a transformation to realign the organization, focusing on the Vision for Space Exploration. These initiatives provide a clear indication that a very capable ground-test stand at Edwards Air Force Base will be beneficial to support the testing of future access-to-space vehicles. To meet the demand of full integration testing of rocket-powered vehicles, the NASA Dryden Flight Research Center, the Air Force Flight Test Center, and the Air Force Research Laboratory have combined their resources in an effort to restore and upgrade the original X-15 Rocket Engine Test Facility to become the new Rocket Vehicle Integration Test Stand. This report describes the history of the X-15 Rocket Engine Test Facility, discusses the current status of the facility, and summarizes recent efforts to rehabilitate the facility to support potential access-to-space flight-test programs. A summary of the capabilities of the facility is presented and other important issues are discussed.

Jones, Daniel S.↗

An Overview of the Nuclear Electric Xenon Ion System (NEXIS) Activity

The Nuclear Electric Xenon Ion System (NEXIS) research and development activity within NASA's Project Prometheus, was one of three proposals selected by NASA to develop thruster technologies for long life, high power, high specific impulse nuclear electric propulsion systems that would enable more robust and ambitious science exploration missions to the outer solar system. NEXIS technology represents a dramatic improvement in the state-of-the-art for ion propulsion and is designed to achieve propellant throughput capabilities >= 2000 kg and efficiencies >= 78% while increasing the thruster power to >= 20 kW and specific impulse to >= 6000 s. The NEXIS technology uses erosion resistant carbon-carbon grids, a graphite keeper, a new reservoir hollow cathode, a 65-cm diameter chamber masked to produce a 57-cm diameter ion beam, and a shared neutralizer architecture to achieve these goals. The accomplishments of the NEXIS activity so far include performance testing of a laboratory model thruster, successful completion of a proof of concept reservoir cathode 2000 hour wear test, structural and thermal analysis of a completed development model thruster design, fabrication of most of the development model piece parts, and the nearly complete vacuum facility modifications to allow long duration wear testing of high power ion thrusters.

ion thrusters↗

Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines

To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.

33 ADVANCED PROPULSION SYSTEMS↗

Wind energy developments in the 20th century

Wind turbine systems for generating electrical power have been tested in many countries. Representative examples of turbines which have produced from 100 to 1250 kW are described. The advantages of wind energy consist of its being a nondepleting, nonpolluting, and free fuel source. Its disadvantages relate to the variability of wind and the high installation cost per kilowatt of capacity of wind turbines when compared to other methods of electric-power generation. High fuel costs and potential resource scarcity have led to a five-year joint NASA-NSF program to study wind energy. The program will study wind energy conversion and storage systems with respect to cost effectiveness, and will attempt to estimate national wind-energy potential and develop techniques for generator site selection. The studies concern a small-systems (50-250 kW) project, a megawatt-systems (500-3000 kW) project, supporting research and technology, and energy storage. Preliminary economic analyses indicate that wind-energy conversion can be competitive in high-average-wind areas.

Vargo, D. J.↗

Advanced Energy Harvesting Control Schemes for Marine Renewable Energy Devices

The Advanced Energy Harvesting Control Schemes for Marine Renewable Energy Devices (Project) investigated, analyzed and modeled advanced turbine control schemes with the objective of increasing the energy harvested by hydrokinetic turbines in turbulent flow. Ocean Renewable Power Company (ORPC) implemented and validated a feedforward controller to increase power capture; and applied and tested the controls on ORPC’s RivGen® Power Systems in Igiugig, Alaska. Assessments of performance improvements were made for the RivGen® in the Igiugig environment and for ORPC’s TidGen® Power System in a reference tidal environment. Annualized Energy Production (AEP) and Levelized Cost of Energy (LCOE) improvements associated with implementation of the recommended control methodology were made for the TidGen® Power System in the DOE reference tidal environment. System Performance Advancement (SPA) goals were selected for the project. SPA targets were to improve Power to Weight Ratio (PWR) and system Availability, with the intention of reducing Levelized Cost of Electricity (LCOE). This project focused primarily reducing in PWR. Reductions in PWR of 25.5% were achieved. Reductions of 20.3% in LCOE were achieved. This project evaluated four types of controllers which were tested in simulation, emulation, a laboratory flume, and the field. The adaptive Kω2 controller performs similarly to the non-adaptive version of the same controller and may be useful in tidal channels where the mean velocity is continually evolving. Trends in simulation were largely verified through experiments, which also provided the opportunity to test assumptions about turbine responsiveness and control resilience to varying scales of turbulence. Laboratory experiments provided an essential stepping stone between simulation and implementation on a field-scale turbine. Experiments also demonstrated that using “energy loss” as a metric to differentiate between well-designed controllers operating at an optimal tip-speed ratio set-point is difficult, which anticipated the outcome from field experiments. The clear message is that the feedforward Kω2 controller out-performs the feedback controllers in almost all aspects and modes of evaluation. The controllers proved a substantial improvement over the baseline performance of the TidGen® turbine, in terms of energy capture. The effects of noise-contaminated angular velocity signals were investigated and validated by simulation as an explanation for the performance limitations observed for TidGen® turbine operations in Eastport, Maine. Measurements of loads performed as part of the laboratory testing indicate that there are limited differences in average axial thrust force between control architectures. This suggests that none of the control strategies are likely to substantially affect loads on the turbine support structure. Velocity measurements during the ORPC RivGen® turbine deployment at Igiugig, Alaska, in 2014 were used to assess the variability of the river flow. Results suggest that the river flow is approximately steady, in the mean sense, at any particular location in the river, with random turbulent fluctuations that are around 10% of the mean flow. The mean flow in the center channel of the river is 2.5 m/s, with reductions near the riverbanks and in the shallows. Spectral analysis and lagged correlation results indicate that temporal fluctuations at a given point are dominated by large scale fluctuations, such that measurements at the turbine location are just as useful for inflow control implementation as upstream measurements. At this site, and likely at many other river sites, flow is generally steady at a given location, but flow varies dramatically between locations, particularly laterally across the river. The primary result is that a lateral change in position of a few meters results in changes to flow speed that far exceed the turbulence fluctuations at any given location. The turbulence is dominated by long time scales. Following final system tests, the RivGen® device was submerged and each evaluated controller was tested across a range of gain/set point values and filter configurations for a minimum of 5 minutes, with longer runs attempted for well-performing cases. In addition to testing controllers during the 2015 deployment season, LGL Alaska Research Associates Inc. (LGL) performed a fish monitoring study in compliance with Alaska Department of Fish and Game fisheries habitat permit for the project. During the season, LGL reviewed 10% of 179 one-hour blocks of footage (6 minutes on the hour) and documented a total of over 1200 fish in the vicinity of the RivGen® device, including over 800 salmon smolt and over 350 adult salmon. No evidence of adverse effects including passage delay by upstream migrating salmon was noted. This is an important result for future deployments and has a direct impact on commercial system designs.

16 TIDAL AND WAVE POWER↗

Polarization-type potential-induced degradation in bifacial PERC modules in the field

This study examines the susceptibility of bifacial glass/glass passivated emitter and rear cell (PERC) modules to potential-induced degradation-polarization (PID-p) in the field. While there are several studies showing PID-p occurring on both front and back faces of bifacial PERC in accelerated tests, we address the yet unclarified behavior in fielded modules. We examine the effects of mounting configuration; specifically, comparing modules mounted near ground and in elevated ground rack configurations. Modules with the cell circuit in -1500 V system voltage configuration, whether mounted on racks about 30 cm above the ground or elevated 2 m high showed mean degradation of 4.5% to 6% in power under standard test conditions over about 2.5 weeks as measured from the front side of the module. This extent of degradation remained sustained for a duration of about 6 months analyzed. Average daytime temperatures of modules in the various mounting configurations were similar and therefore judged to be insufficient to be a primary influence for the modest PID-p rate differences that we observed among mounting configurations. Increased leakage current in the morning suggests morning dew was sustained longer on modules near the ground measured over six months which would be expected to increase the PID-p rate over the long term. However, the main difference seen between the modules on the various mountings during the initial period with up to 6% mean degradation by PID-p was the approximately two times the irradiance from albedo on the rear of modules mounted in elevated ground rack compared to those on the near ground rack. This difference in incident albedo led to a modestly reduced rate of the development of PID-p of the modules on the elevated ground rack. The difference is attributed to the dissipation of PID-p-causing electrical charge by the albedo incident on the module rear. The behavior could be modeled by a sigmoidal equation with consideration of the differences in the insolation on the module rear.

14 SOLAR ENERGY↗

Tank Tests of 1/5.5-Scale Forward Dynamic Model of the Columbia XJL-1 Amphibian - Langley Tank Model 208, TED No. NACA 2336

Tests of a powered dynamic model of the Columbia XJL-1 amphibian were made in Langley tank no.1 to determine the hydrodynamic stability and spray characteristics of the basic hull and to investigate the effects of modifications on these characteristics. Modifications to the forebody chime flare, the step, and the afterbody, and an increase in the angle of incidence of the wing were included in the test program. The seaworthiness and spray characteristics were studied from simulated taxi runs in smooth and rough water. The trim limits of stability, the range of stable positions of the enter of gravity for take-off, and the landing stability were determined in smooth water. The aerodynamic lift, pitching moment, and thrust were determined at speeds up to take-off speed.

Havens, Robert F.↗

Analysis of the Phenix end-of-life natural convection test with SAS4A/SASSYS-1

From a reduced power and flow condition, the 2009 Phenix Natural Convection Test mimics a protected loss-of-heat sink event. The measured transient response of the Phenix reactor to such an event provides an important data set for validating safety analysis codes. A model of the Phenix reactor and primary coolant system was developed using the reactor safety analysis code system SAS4A/SASSYS-1. While the overall global response of the reactor was predicted reasonably well, there were some non-negligible discrepancies in the temperature predictions during the transient and work continues to improve the model. Some modeling issues have been identified, and will be addressed as improvements to the model continue. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗