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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Flowability of Crumbler Rotary Shear Size-Reduced Granular Biomass: An Experiment-Informed Modeling Study on the Angle of Repose

Biomass has potential as a carbon-neutral alternative to petroleum for chemical and energy products. However, complete replacement of fossil fuel is contingent upon efficient processes to eliminate undesirable characteristics of biomass, e.g., low bulk density, variability, and storage-induced quality problems. Mechanical size reduction via comminution is a processing operation to engineer favorable biomass flowability in handling. Crumbler rotary shear mill has been empirically demonstrated to produce more uniformly shaped particles with higher flowability than hammermilled biomass. This study combines modeling and experimentation to unveil fundamental understandings of the relation between granular particle characteristics and biomass flow behavior, which elucidate underlying mechanisms and guide selection of critical processing parameters. For this purpose, the impact of critical material attributes, including particle size (2–6 mm), particle shape (briquette, chip, clumped-sphere, cube, etc.), and surface roughness, on the angle of repose (AOR) of milled pine chips were investigated using discrete element method (DEM) simulations. Forest Concepts Crumbler rotary shear system is used to produce milled pine particles within the same size range considered in DEM simulations. AOR of different sets of these particles were measured experimentally to benchmark DEM results against experimental data. Specific energy consumption for the comminution of biomass with different particle size and moisture content are measured for technoeconomic analysis. Our results show that the smaller size (2 mm) of pine particle achieves better followability (i.e., smaller AOR) while the energy cost of comminution is significantly higher and bulk density is almost the same as the 6-mm pine particles. For the 2-mm particle size, Crumbles from veneer have better flow properties than Crumbles from chips. Contrarily, no significant difference was observed between the AOR of the two materials for the 6-mm particle size. Furthermore, from DEM simulations, mechanical interlocking between particles was found as a dominant factor in determining AOR of complex-shaped particles such as milled pine, which cannot be accurately captured by using simple particle shapes (e.g., mono-sphere) with a rolling resistance model. Conversely, clumped-sphere model alleviates this limitation without increasing computational cost significantly and can be used for accurate representation of biomass granular particles when simulating free-flow behavior.

09 BIOMASS FUELS↗
NASA NTRS1973

Friction losses in a lubricated thrust-loaded cageless angular-contract bearing

The NASA spinning torque apparatus was modified to measure the spinning torque on a cageless ball thrust bearing. Friction torque was measured for thrust loads varying from 44.5 to 403 newtons (10 to 90 lb) at speeds of 1000, 2000, and 3000 rpm. Tests were conducted with di-2-ethylhexyl sebacate and a synthetic paraffinic oil. These tests were run with either oil jet lubrication or with a thin surface film of lubricant only. An analytical model which included rolling resistance was developed and extended from previous models for spinning torque and lubricant rheology. The model was extended by the inclusion of rolling resistance. The computed values were in fair agreement with the experimental results and confirmed previous hypotheses that a thin lubricant film gives minimum bearing torque and an oil jet flow of a viscous lubricant will result in considerable rolling torque in addition to the torque due to ball spin.

Townsend, D. P.↗
DOE OSTI2021

Applicability of discrete element method with spherical and clumped particles for constitutive study of granular materials

Discrete element method (DEM) has been intensively used to study the constitutive behaviour of granular materials. However, to what extent a real granular material can be reproduced by virtual DEM simulations remains unclear. This study attempts to answer this question by comparing DEM simulations with typical features of experimental granular materials. Three groups of models with spherical and clumped particles are investigated from four perspectives: (i) deviatoric stress and volumetric behaviour; (ii) critical state behaviour; (iii) stress-dilatancy relationship; and (iv) the evolution of principal stress ratio against axial strain. The results demonstrate that DEM with spherical or clumped particles is capable of qualitatively describing macroscopic deviatoric stress responses, volumetric behaviour, and critical state behaviour observed in experiments for granular materials. On the other hand, some qualitative deviations between experiments and the investigated DEM simulations are also observed, in terms of the stress-dilatancy behaviour and principal stress ratio against axial strain, which are proven to be critical for constitutive modelling. The results demonstrate that DEM with spherical or clumped particles may not necessarily fully capture experimental features of granular materials even from a qualitative perspective. It is thus encouraged to thoroughly validate DEM with experiments when developing constitutive models based on DEM observations.

58 GEOSCIENCES↗
NASA NTRS2022

NASA White Paper - Terramechanics for LTV Modeling and Simulation

Simulating the interaction between wheel and soil is critical to the overall rover dynamics. This paper presented simple models for wheel soil interaction including the rolling resistances on the wheel due to soil compression and bull- dozing and the maximum tractive force between wheel and soil. Summary of typical lunar soil properties were presented in this paper and the wheel resis- tance model implementation and integration were also discussed. Integrating the wheel resistance model with the rover simulation will improve its dynamics and wheel slip models and enable the capability simulate the situation where wheel got stuck in the soil.

Terramechanics↗
DOE OSTI2021

USAMP Low-Cost Mg Sheet Component Development and Demonstration Project

The overarching objective of this USAMP project was to develop and demonstrate door panels made from magnesium (Mg) sheet with a cost penalty over conventional steel stampings of no more than $\$5.50$/kg saved. The technical approach integrated experiments with advanced computational tools based on Integrated Computational Materials Engineering (ICME) methods to develop new alloy chemistries and their thermomechanical processing that promise improved formability and lower forming temperatures. A penultimate task before finally forming the stampings was to incorporate actual microstructure into models that would enable formability simulations. This approach would, for the first time, account for individual magnesium grains moving in an anisotropic fashion unlike that for aluminum or steel that have isotropic properties upon which the current simulation tools are based. In separate activities, new coatings and lubricants to facilitate forming and improved corrosion protection and joining strategies, were developed to ensure that the door could be produced with stated product requirements. A technical cost model, which included parts production, assembly, and paint for a door specifically designed for Mg sheet, showed the cost penalty to be between $\$4.26$ to $\$6.60$/kg saved, which enveloped the project’s cost targets. The cost of the coated Mg sheet was identified as the key driver for the cost penalty. The mass of the Mg-intensive door was 7.9 kg, which was 54% less than the baseline steel door.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Low-Cost Magnesium Alloy Sheet Component Development and Demonstration Project

The overarching objective of this USAMP project was to develop and demonstrate door panels made from magnesium (Mg) sheet with a cost penalty over conventional steel stampings of no more than $5.50/kg saved. The technical approach integrated experiments with advanced computational tools based on Integrated Computational Materials Engineering (ICME) methods to develop new alloy chemistries and their thermomechanical processing that promise improved formability and lower forming temperatures. A penultimate task before finally forming the stampings was to incorporate actual microstructure into models that would enable formability simulations. This approach would, for the first time, account for individual magnesium grains moving in an anisotropic fashion unlike that for aluminum or steel that have isotropic properties upon which the current simulation tools are based. In separate activities, new coatings and lubricants to facilitate forming and improved corrosion protection and joining strategies, were developed to ensure that the door could be produced with stated product requirements. A technical cost model, which included parts production, assembly, and paint for a door specifically designed for Mg sheet, showed the cost penalty to be between 4.26 USD to 6.60 USD/kg saved, which enveloped the project’s cost targets. The cost of the coated Mg sheet was identified as the key driver for the cost penalty. The mass of the Mg-intensive door was 7.9 kg, which was 54% less than the baseline steel door.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Identifying rolling resistance and air resistance simultaneously for an electric truck

Accurately estimating rolling and air resistance is essential for predicting the energy consumption of vehicles. This study presents a field-based approach using a rolldown test to simultaneously determine rolling and air resistance coefficients. Unlike prior methods that frequently used simulations or models, we employ a goal programming methodology to improve precision and evaluate the actual vehicle and environmental conditions. Our methodology was tested using a Class 8 Freightliner eCascadia on a surveyed road section, ensuring controlled conditions for data collection. By analyzing the time–velocity relationship across multiple test runs, we derived resistance coefficients for both loaded and unloaded conditions. The study confirms that rolling resistance is largely independent of velocity at low speeds but exhibits a nonlinear dependency at higher speeds. Additionally, road surface conditions, tire condition, axle configuration, aerodynamic properties, and weather conditions significantly impact resistance values, emphasizing the need for real-world testing rather than relying solely on standardized projections. Our results align with existing literature while demonstrating the efficacy of the goal programming approach in refining resistance estimates. This work contributes to improved vehicle energy modeling, offering practical insights for fleet operators and policymakers seeking accurate energy consumption predictions for electric trucks operating under varying environmental conditions.

47 OTHER INSTRUMENTATION↗
NASA NTRS2005

Conceptual Design and Dynamics Testing and Modeling of a Mars Tumbleweed Rover

The NASA Langley Research Center has been developing a novel concept for a Mars planetary rover called the Mars Tumbleweed. This concept utilizes the wind to propel the rover along the Mars surface, bringing it the potential to cover vast distances not possible with current Mars rover technology. This vehicle, in its deployed configuration, must be large and lightweight to provide the ratio of drag force to rolling resistance necessary to initiate motion from rest on the Mars surface. One Tumbleweed design concept that satisfies these considerations is called the Eggbeater-Dandelion. This paper describes the basic design considerations and a proposed dynamics model of the concept for use in simulation studies. It includes a summary of rolling/bouncing dynamics tests that used videogrammetry to better understand, characterize, and validate the dynamics model assumptions, especially the effective rolling resistance in bouncing/rolling dynamic conditions. The dynamics test used cameras to capture the motion of 32 targets affixed to a test article s outer structure. Proper placement of the cameras and alignment of their respective fields of view provided adequate image resolution of multiple targets along the trajectory as the test article proceeded down the ramp. Image processing of the frames from multiple cameras was used to determine the target positions. Position data from a set of these test runs was compared with results of a three dimensional, flexible dynamics model. Model input parameters were adjusted to match the test data for runs conducted. This process presented herein provided the means to characterize the dynamics and validate the simulation of the Eggbeater-Dandelion concept. The simulation model was used to demonstrate full scale Tumbleweed motion from a stationary condition on a flat-sloped terrain using representative Mars environment parameters.

Calhoun Philip C.↗
NASA NTRS1992

Evaluation of electrolytic tilt sensors for measuring model angle of attack in wind tunnel tests

The results of a laboratory evaluation of electrolytic tilt sensors as potential candidates for measuring model attitude or angle of attack in wind tunnel tests are presented. The performance of eight electrolytic tilt sensors was compared with that of typical servo accelerometers used for angle-of-attack measurements. The areas evaluated included linearity, hysteresis, repeatability, temperature characteristics, roll-on-pitch interaction, sensitivity to lead-wire resistance, step response time, and rectification. Among the sensors being evaluated, the Spectron model RG-37 electrolytic tilt sensors have the highest overall accuracy in terms of linearity, hysteresis, repeatability, temperature sensitivity, and roll sensitivity. A comparison of the sensors with the servo accelerometers revealed that the accuracy of the RG-37 sensors was on the average about one order of magnitude worse. Even though a comparison indicates that the cost of each tilt sensor is about one-third the cost of each servo accelerometer, the sensors are considered unsuitable for angle-of-attack measurements. However, the potential exists for other applications such as wind tunnel wall-attitude measurements where the errors resulting from roll interaction, vibration, and response time are less and sensor temperature can be controlled.

Wong, Douglas T.↗
DOE OSTI2020

Granular packings with sliding, rolling, and twisting friction

Intuition tells us that a rolling or spinning sphere will eventually stop due to the presence of friction and other dissipative interactions. The resistance to rolling and spinning or twisting torque that stops a sphere also changes the microstructure of a granular packing of frictional spheres by increasing the number of constraints on the degrees of freedom of motion. We perform discrete element modeling simulations to construct sphere packings implementing a range of frictional constraints under a pressure-controlled protocol. Mechanically stable packings are achievable at volume fractions and average coordination numbers as low as 0.53 and 2.5, respectively, when the particles experience high resistance to sliding, rolling, and twisting. Only when the particle model includes rolling and twisting friction were experimental volume fractions reproduced.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Development and Demonstration of a Fuel-Efficient, Class 8 Tractor & Trailer Engine System (SuperTruck II)

Navistar presents the SuperTruck II (ST II) Final Report to the Unites States Department of Energy (US DOE), which covers the five Budget Periods (BPs) from 10-1-2016 through 6-30-2022. For ST II, Navistar built on the achievements of the SuperTruck I (ST I) Program as a catalyst to continue critical research, design and development, testing, and operations to reach the ambitious goals of the ST II project. This approach allowed Navistar to continue contributing to the essential needs of our nation for safe, efficient, and cost-effective delivery of goods and services, as we reduced negative environmental effects and improved operational productivity. This document contains information specified in DOE F 4600.2, Final Scientific/Technical Report DOE F 241.3, B. SCIENTIFIC/TECHNICAL REPORTS, explaining how we met and exceeded program requirements. Throughout this Final Report, Navistar extracted information from documents prepared during the project that represent our management, design and development, building, and testing efforts to meet and exceed SuperTruck II project goals. Navistar followed Plan requirements to achieve / exceed Project Objectives: a) >100% improvement in vehicle freight efficiency (FE) (on ton-MPG basis) relative to 2009 baseline with stretch goal of 140% improvement [actual: 170%); b) >55% engine brake thermal efficiency (BTE) demonstrated in operational engine at a 65-mph cruise point on a dynamometer – ≥31% increase from 2009 baseline [actual: 55.20% of combined BTE) ; and c) development and implementation of commercially cost effective technologies (in terms of a simple payback). Technology selection / development path focused on developing technologies applicable for production within 3-year approach, while ensuring technology readiness and cost of ownership for end users. The Program was organized into five budget periods: Requirements / Technology Assessment and Initial Hardware Testing; Technology Development and Concept Readiness Demonstration; Technology Finalization and Validation Tractor / Trailer Fabrication, Integration and Commissioning Demonstration; and Fuel Economy (FE) and Brake Thermal Efficiency (BTE) and Program Completion. Leadership was provided by DOE, with tasks performed by laboratories (Argonne National Laboratory, Lawrence Livermore National Laboratory); partners at Bosch, TPI, Dana, and J.B. Hunt; , and support from University of Michigan and Clemson University. Navistar lead this team with Principal Investigator / Contracting Officer; Project Manager (PM); Vehicle, Engine, and Aftertreatment Engineers; Finance Manager, Technical Program Leads, and Legal/IP; and other key personnel. Work also included personnel in risk management; funding / budget / finance. Work involved analysis, development, testing, and down selection of individual/system engine, aftertreatment, and vehicle technologies, with integration of selected technologies into a prototype vehicle for demonstration of fuel-efficiency gain. Work also included component/integrated system level development of truck and trailer aerodynamics, base engine efficiency, advanced aftertreatment, combustion efficiency, waste heat recovery, hybrid powertrain, reduced rolling resistance, weight reduction, idle reduction, and driver feedback. As ST II progressed, Navistar performed computer-based modeling / simulations of technologies focused on the primary operational areas: Engine, Aftertreatment, and Vehicle. During the ST II Program, the COVID Virus outbreak unexpectedly challenged by the effects of, which affected staffing, scheduling, design, supplies, availability of materials, production procedures, and testing. The DOE responded by extending the program by three quarters to ensure that project tasks were completed for this vital project. Focus continued on analyzing, developing, testing, and down selecting individual-/system-level engine and vehicle technologies for integration of the final selected technologies into a prototype vehicle that would demonstrate fuel-efficiency gains made possible through these technologies. This included component/integrated system-level development of truck and trailer aerodynamics, base engine efficiency, advanced aftertreatment, combustion efficiency, waste heat recovery, solar power, distributed and intelligent vehicle power, hybrid powertrain, reduced rolling resistance, weight reduction, idle reduction, and driver feedback. Throughout the program, function, reliability, and performance at all levels were ensured through testing. Proof of this approach was demonstrated in multiple, on-road demonstrations: Scenario A (Flatland) Fuel Economy, Scenario B (Hilly) Fuel Economy, and City Cycle Tests. Other benefits derived from ST II included new/improved products, publications, patents, and next-step capabilities related to electric/hydrogen vehicles and autonomous driving.

Zukouski, Russ↗
NASA NTRSDate not supplied

Modeling of Multicomponent Trace Contaminant Adsorption on Activated Carbon

Modeling of multicomponent trace contaminant adsorption on activated carbon for spacecraft life support applications presents challenges due to the very low contaminant concentrations in cabin air coupled with very strong adsorption of heavier components such as cyclic polydimethylsiloxanes. Both gas-phase and solid-phase micropore mass transfer resistances can be important, and competitive interactions between adsorbed components can result in behavior such as roll-up where lighter components displaced by heavier components have a higher concentration at the outlet than at the inlet. This paper describes the further development of a dynamic trace contaminant adsorption model based on Ideal Adsorbed Solution Theory (IAST). Alternative 1-dimensional and 2-dimensional versions of the model are described with different mass transfer resistance and driving force assumptions. Optimization of solution methods for speed and stability is also described. Mass balance equations are scaled to provide sensitivity over the wide range of component concentrations in cabin air. Model parameters are estimated from isotherm and breakthrough test data on single adsorbate and binary adsorbate systems. Multicomponent results are compared against predictions of a heritage model used extensively by NASA for trace contaminant control system (TCCS) carbon bed sizing. Finally, efforts to implement the model in a second software platform for wider access are described.

Kevin E Lange↗
NASA NTRS1973

Model support roll balance and roll coupling

The design concepts of two specialized wind tunnel model support mechanisms are described. The forced oscillation roll balance mechanism was designed to meet the specific requirement to measure aerodynamic forces and moments to permit determination of the damping-in-roll parameters of winged configurations. A variable speed motor is used to oscillate the model by means of an offset crank. The oscillating motion is resisted by a torsion spring to provide a restoring torque and is attached to the section forward of the strain-gage balance. This spring action allows the model to be oscillated at a frequency for velocity resonance, whereby the mechanical spring and any aerodynamic spring balance. This spring action allows the model to be oscillated at a frequency for velocity resonance, whereby the mechanical spring and any aerodynamic spring balance out the model inertia. The only torque then required to oscillate the model at that particular frequency is equal to that due to aerodynamic damping. The second mechanism, a roll coupling for remotely rotating a model, was designed to invert or roll a model about its longitudinal axis when mounted for testing.

Sharpes, R. E.↗
NASA NTRS2010

History of Space Shuttle Main Engine Turbopump Bearing Testing at the Marshall Space Flight Center

The Space Shuttle is propelled into orbit by two solid rocket motors and three liquid fed main engines. After the solid motors fall away, the shuttle engines continue to run for a total time of 8 minutes. These engines are fed propellants by low and high pressure turbopumps. A critical part of the turbopump is the main shaft that supports the drive turbine and the pump inducer and impeller. Rolling element bearings hold the shaft in place during rotation. If the bearings were to fail, the shaft would move, allowing components to rub in a liquid oxygen or hydrogen environment, which could have catastrophic results. These bearings are required to spin at very high speeds, support radial and axial loads, and have high wear resistance without the benefit of a conventional means of lubrication. The Rocketdyne built Shuttle turbopumps demonstrated their capability to perform during launches; however, the seven hour life requirement was not being met. One of the limiting factors was the bearings. In the late 1970's, an engineering team was formed at the Marshall Space Flight Center (MSFC), to develop a test rig and plan for testing the Shuttle s main engine high pressure oxygen turbopump (HPOTP) bearings. The goals of the program were to better understand the operation of bearings in a cryogenic environment and to further develop and refine existing computer models used to predict the operational limits of these bearings. In 1982, testing began in a rig named the Bearing and Seal Material Tester or BSMT as it was commonly called. The first testing investigated the thermal margin and thermal runaway limits of the HPOTP bearings. The test rig was later used to explore potential bearing improvements in the area of increased race curvatures, new cage materials for better lubrication, new wear resistant rolling element materials, and other ideas to improve wear life. The most notable improvements during this tester s time was the incorporation of silicon nitride balls and bronze filled polytetrafluoroethylene (PTFE) cage inserts into the bearings and the anchoring of the SHABERTH bearing model and SINDA thermal computer model for cryogenic bearing analysis. In the mid 1990's, Pratt and Whitney (P&W) won the contract to deliver new high pressure turbopumps for the Shuttle s engines. P&W used two new bearing materials for the rings, Cronidur 30 and AISI 9310 steel and testing was needed on these new materials. A test rig had been designed and delivered to MSFC for testing hydrostatic bearings but with the need by Pratt to validate their bearings, the rig was reconfigured for testing of two ball bearings or a ball bearing and a roller bearing. The P&W bearings are larger than the Rocketdyne bearings and could not be installed in the BSMT. This new test rig was called the LH2 test rig and began operation in 1995. The LH2 test rig accumulated 75,000 seconds of run time in hydrogen. This test rig was valuable in two areas: validating the use of silicon nitride balls and rollers in Alternate Turbopump Development (ATD) bearings, which Pratt eventually used, and in proving the robustness of the balls and rollers after river marks appeared on the surface of the rolling elements. Individual test reports have been presented at conferences and symposiums throughout the years. This paper is a comprehensive report of all the bearing testing done at Marshall. It represents thousands of hours of dedication and labor in all engineering and technical fields that made this program a success.

Gibson, Howard↗
NASA NTRS2005

Mars Tumbleweed Simulation Using Singular Perturbation Theory

The Mars Tumbleweed is a new surface rover concept that utilizes Martian winds as the primary source of mobility. Several designs have been proposed for the Mars Tumbleweed, all using aerodynamic drag to generate force for traveling about the surface. The Mars Tumbleweed, in its deployed configuration, must be large and lightweight to provide the ratio of drag force to rolling resistance necessary to initiate motion from the Martian surface. This paper discusses the dynamic simulation details of a candidate Tumbleweed design. The dynamic simulation model must properly evaluate and characterize the motion of the tumbleweed rover to support proper selection of system design parameters. Several factors, such as model flexibility, simulation run times, and model accuracy needed to be considered in modeling assumptions. The simulation was required to address the flexibility of the rover and its interaction with the ground, and properly evaluate its mobility. Proper assumptions needed to be made such that the simulated dynamic motion is accurate and realistic while not overly burdened by long simulation run times. This paper also shows results that provided reasonable correlation between the simulation and a drop/roll test of a tumbleweed prototype.

Raiszadeh, Behzad↗
NASA NTRS1992

Model flight tests of a spin-resistant trainer configuration

Powered, radio-controlled flight tests were conducted on a 1/4-scale model of a spin-resistant trainer configuration to determine the stall departure and spin resistance characteristics provided by an outboard wing leading-edge droop modification. The model was instrumented to provide quantitative as well as qualitative information on flight characteristics. Flight test results indicated that the unmodified configuration (wing leading-edge droop off) exhibited an abrupt, uncontrollable roll departure at the stall. With the outboard wing leading-edge droop installed, the modified configuration exhibited flight characteristics that were resistant to stall departure and spin entry. The stall departure and spin resistance characteristics of the modified configuration were demonstrated in flight maneuvers that included idle-power stalls, full-power stalls, sideslip stalls, and accelerated stalls.

Yip, Long P.↗
NASA NTRS2014

Absorption Voltages and Insulation Resistance in Ceramic Capacitors with Cracks

Time dependence of absorption voltages (V(sub abs)) in different types of low-voltage X5R and X7R ceramic capacitors was monitored for a maximum duration of hundred hours after polarization. To evaluate the effect of mechanical defects on V(sub abs)), cracks in the dielectric were introduced either mechanically or by thermal shock. The maximum absorption voltage, time to roll-off, and the rate of voltage decrease are shown to depend on the crack-related leakage currents and insulation resistance in the parts. A simple model that is based on the Dow equivalent circuit for capacitors with absorption has been developed to assess the insulation resistance of capacitors. Standard measurements of the insulation resistance, contrary to the measurements based on V(sub abs)), are not sensitive to the presence of mechanical defects and fail to reveal capacitors with cracks.

ceramic capacitor↗