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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
NASA NTRSDate not supplied

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity↗
DOE OSTI2023

Organic Vacuum Pump Fluids for the Vacuum Pumping of Fusion Power Plants

Vacuum pumps are the heart of the fusion fuel cycle, but most currently proposed pumping technologies are not capable of handling the required flow rates and vacuum pressures. Oil-containing vacuum pumps can readily meet the flow requirements, but vacuum fluids will degrade in fusion-relevant environments due to contact with tritium and exposure to high-energy radiation. Here, in this study, we describe a methodology to screen vacuum fluid candidates and purify these candidate fluids post oxidation, post exposure to deuterium, and post exposure to gamma radiation (<7.5 MGy) to simulate a process in which vacuum fluids can be recovered and regenerated during the fusion fuel cycle. A series of oils, including a highly purified mineral oil, phenyl silicone oil, and a polyphenyl ether, are shown to be suitable candidates for vacuum pumping. Additionally, we describe a simple purification methodology to remove oxidized functionalities and the associated isotopologues induced by contact with deuterium from the candidate vacuum fluids This purification methodology can also be applied to radiological damage with moderate effect. Finally, we demonstrate that the sorbents can be regenerated through electromagnetic microwave digestion.

oxidation↗
NASA NTRS1992

Simulation of the synergistic low Earth orbit effects of vacuum thermal cycling, vacuum UV radiation, and atomic oxygen

In order to assess the low Earth orbit (LEO) durability of candidate space materials, it is necessary to use ground laboratory facilities which provide LEO environmental effects. A facility combining vacuum thermal cycling and vacuum ultraviolet (VUV) radiation has been designed and constructed at NASA Lewis Research Center for this purpose. This facility can also be operated without the VUV lamps. An additional facility can be used to provide VUV exposure only. By utilizing these facilities, followed by atomic oxygen exposure in an RF plasma asher, the effects of the individual vacuum thermal cycling and VUV environments can be compared to the effect of the combined vacuum thermal cycling/VUV environment on the atomic oxygen durability of materials. The synergistic effects of simulated LEO environmental conditions on materials were evaluated by first exposing materials to vacuum thermal cycling, VUV, and vacuum thermal cycling/VUV environments followed by exposure to atomic oxygen in an RP plasma asher. Candidate space power materials such as atomic oxygen protected polyimides and solar concentrator mirrors were evaluated using these facilities. Characteristics of the Vacuum Thermal Cycling/VUV Exposure Facility which simulates the temperature sequences and solar ultraviolet radiation exposure that would be experienced by a spacecraft surface in LEO are discussed. Results of durability evaluations of some candidate space power materials to the simulated LEO environmental conditions will also be discussed. Such results have indicated that for some materials, atomic oxygen durability is affected by previous exposure to thermal cycling and/or VUV exposure.

Dever, Joyce A.↗
NASA NTRS1959

Vacuum-Induction, Vacuum-Arc, and Air-Induction Melting of a Complex Heat-Resistant Alloy

The relative hot-workability and creep-rupture properties at 1600 F of a complex 55Ni-20Cr-15Co-4Mo-3Ti-3Al alloy were evaluated for vacuum-induction, vacuum-arc, and air-induction melting. A limited study of the role of oxygen and nitrogen and the structural effects in the alloy associated with the melting process was carried out. The results showed that the level of boron and/or zirconium was far more influential on properties than the melting method. Vacuum melting did reduce corner cracking and improve surface during hot-rolling. It also resulted in more uniform properties within heats. The creep-rupture properties were slightly superior in vacuum heats at low boron plus zirconium or in heats with zirconium. There was little advantage at high boron levels and air heats were superior at high levels of boron plus zirconium. Vacuum heats also had fewer oxide and carbonitride inclusions although this was a function of the opportunity for separation of the inclusions from high oxygen plus nitrogen heats. The removal of phosphorous by vacuum melting was not found to be related to properties. Oxygen plus nitrogen appeared to increase ductility in creep-rupture tests suggesting that vacuum melting removes unidentified elements detrimental to ductility. Oxides and carbonitrides in themselves did not initiate microcracks. Carbonitrides in the grain boundaries of air heats did initiate microcracks. The role of microcracking from this source and as a function of oxygen and nitrogen content was not clear. Oxygen and nitrogen did intensify corner cracking during hot-rolling but were not responsible for poor surface which resulted from rolling heats melted in air.

Decker, R. F.↗
DOE OSTI2024

Vacuum insulated glazing, valve, flexible seal, and method for making vacuum insulated glazing

A vacuum insulated glazing includes first and second spaced apart glass panes having perimeter portions defining a vacuum space between the glass panes. A vacuum valve is positioned at the perimeter portions of the glass panes and includes a valve body extending between the perimeter portions of the glass panes, and having first and second ends and a fluid conduit extending from the first end to the second end of the valve body and in fluid communication with the vacuum space. A one-way valve in the fluid conduit permits fluid flow from the vacuum space, and prevents fluid flow into the vacuum space. A suction fitting is provided for connecting the valve body to a suction device. An end seal between the perimeter portions of the glass panes is provided for hermetically sealing the vacuum space. A valve for a VIG and a method of making a VIG are also disclosed.

Bhandari, Mahabir↗
NASA NTRS2023

Using Mylar-Insulated Cryopumping Panels to Improve Vacuum Level During Warm Temperature Testing at JSCs Large Thermal Vacuum Facilities

The Johnson Space Center’s Space Environment Simulation Lab (SESL) has both Chamber A, the world’s largest purpose-built thermal vacuum chamber capable of creating deep space conditions, and Chamber B, the largest human rated thermal vacuum chamber. A unique design feature of these chambers is the gaseous helium cryopumping panels within the liquid nitrogen shroud. This shroud is used to bring the chamber to cryogenic temperatures while the cryopumping panels trap gasses using their large surface area in order to create a high vacuum environment of 5*10^-6 Torr. In preparation for the James Webb Space Telescope (JWST) flight test, a series of functionals required the chamber to run at higher temperatures, and therefore did not need active cooling from the liquid nitrogen shroud. During testing, cryopumping panels were used to mitigate contamination during this main shroud warm-up. One of the cryopumping panels in Chamber A was covered with several layers of aluminized mylar in order to thermally protect the zone from the warmed shroud. This strategy was effective and became part of operations during JWST testing. Currently, Chamber B has requests for both commercial and NASA space suit tests at both high and low temperatures to accurately generate thermal models. High temperature tests would greatly benefit from simultaneous shroud warming and the high vacuum environment provided by the cryopumping panels. This paper will quantitatively define the thermal loads on the panels used in previous Chamber A warm up sequences. Additionally, this report will perform a thermal analysis to judge the feasibility of adding layers of aluminized mylar to the cryopumping panels of Chamber B.

Cryogenics↗
NASA NTRS2023

Using Mylar-Insulated Cryopumping Panels to Improve Vacuum Level During Warm Temperature Testing at JSC's Large Thermal Vacuum Facilities

The Johnson Space Center’s Space Environment Simulation Lab (SESL) has both Chamber A, the world’s largest purpose-built thermal vacuum chamber capable of creating deep space conditions, and Chamber B, the largest human rated thermal vacuum chamber. A unique design feature of these chambers is the gaseous helium cryopumping panels within the liquid nitrogen shroud. This shroud is used to bring the chamber to cryogenic temperatures while the cryopumping panels trap gasses using their large surface area in order to create a high vacuum environment of 5*10^-6 Torr. In preparation for the James Webb Space Telescope (JWST) flight test, a series of functionals required the chamber to run at higher temperatures, and therefore did not need active cooling from the liquid nitrogen shroud. During testing, cryopumping panels were used to mitigate contamination during this main shroud warm-up. One of the cryopumping panels in Chamber A was covered with several layers of aluminized mylar in order to thermally protect the zone from the warmed shroud. This strategy was effective and became part of operations during JWST testing. Currently, Chamber B has requests for both commercial and NASA space suit tests at both high and low temperatures to accurately generate thermal models. High temperature tests would greatly benefit from simultaneous shroud warming and the high vacuum environment provided by the cryopumping panels. This paper will quantitatively define the thermal loads on the panels used in previous Chamber A warm up sequences. Additionally, this report will perform a thermal analysis to judge the feasibility of adding layers of aluminized mylar to the cryopumping panels of Chamber B.

Cryogenics↗
NASA NTRS2023

Using Mylar-Insulated Cryopumping Panels to Improve Vacuum Level During Warm Temperature Testing at JSC's Large Thermal Vacuum Facilities

Johnson Space Center’s Space Environment Simulation Lab (SESL) has both Chamber A, the world’s largest purpose-built thermal vacuum chamber capable of creating deep space conditions, and Chamber B, the largest human rated thermal vacuum chamber. A unique design feature of these chambers is the gaseous helium cryopumping panels within the liquid nitrogen shroud. This shroud is used to bring the chamber to cryogenic temperatures while the cryopumping panels trap gasses on its surface area to create a high vacuum environment of 5*10-6 Torr. In preparation for the James Webb Space Telescope (JWST) flight test, a series of functionals required the chamber to run at higher temperatures, and therefore did not need active cooling from the liquid nitrogen shroud. During testing, cryopumping panels were used to mitigate contamination during this main shroud warm-up. One of the cryopumping panels in Chamber A was covered with several layers of aluminized mylar to thermally protect the zone from the warmed shroud. This strategy was effective and became part of operations during JWST testing. Currently, Chamber B has requests for both commercial and NASA space suit tests at both high and low temperatures to validate thermal models. High temperature tests could benefit from reduced heater demand with an insulated shroud while still sustaining the high vacuum environment provided by the cryopumping panels. This paper will quantitatively define the thermal loads on the panels used in previous Chamber A warm up sequences. Additionally, this report will perform thermal analyses to assess the feasibility of adding layers of aluminized mylar to the cryopumping panels of Chamber B.

Cryogenics↗
DOE OSTI2022

Desalinating a Real Hyper-Saline Pre-Treated Produced Water via Direct-Heat Vacuum Membrane Distillation

Membrane distillation (MD) is an emerging thermal desalination technology capable of desalinating waters of any salinity. During typical MD processes, the saline feedwater is heated and acts as the thermal energy carrier; however, temperature polarization (as well as thermal energy loss) contributes to low distillate fluxes, low single-pass water recovery and poor thermal efficiency. An alternative approach is to integrate an extra thermal energy carrier as part of the membrane and/or module assembly, which can channel externally provided heat directly to the membrane-feedwater interface and/or along the feed channel length. This direct-heat delivery has been demonstrated to increase single-pass water recovery and enhance the overall thermal efficiency. We developed a bench-scale direct-heated vacuum MD (DHVMD) process to desalinate pre-treated oil and gas "produced water" with an initial total dissolved solids of 115,500 ppm at a feed temperature ranging between 24 and 32 degrees C. We evaluated both water flux and specific energy consumption (SEC) as a function of water recovery. The system achieved a 50% water recovery without significant scaling, with an average flux >6 kg m-2 hr-1 and a SEC as low as 2,530 kJ kg-1. The major species of mineral scales (i.e., NaCl, CaSO4, and SrSO4) that limited the water recovery to 68% were modeled in terms of thermodynamics and identified by scanning electron microscopy and energy-dispersive X-ray spectroscopy. In addition, we further developed and employed a physics-based process model to estimate temperature, salinity, water transport and energy flows for full-scale vacuum MD and DHVMD modules. Model results show that a direct-heat input rate of 3,600 W can increase single-pass water recovery from 2.1% to 3.1% while lowering the thermal SEC from 7,800 kJ kg-1 to 6,517 kJ kg-1 in an unoptimized module. Finally, the scaling up potential of DHVMD process is briefly discussed.

brine↗
DOE OSTI2022

Multistage Surface-Heated Vacuum Membrane Distillation Process Enables High Water Recovery and Excellent Heat Utilization: A Modeling Study

Surface-heated membrane distillation (MD) enhances the energy efficiency of desalination by mitigating temperature polarization (TP). However, systematic investigations of larger scale, multistage, surface-heated MD system with high water recovery and heat recycling are limited. Here, we explore the design and performance of a multistage surface-heated vacuum MD (SHVMD) with heat recovery through a comprehensive finite difference model. In this process, the latent heat of condensation is recovered through an internal heat exchanger (HX) using the retentate from one stage as the condensing fluid for the next stage and an external HX using the feed as the condensing fluid. Model results show that surface heating enhances the performance compared to conventional vacuum MD (VMD). Specifically, in a six-stage SHVMD process, 54.44% water recovery and a gained output ratio (GOR) of 3.28 are achieved with a surface heat density of 2000 W m –2 , whereas a similar six-stage VMD process only reaches 18.19% water recovery and a GOR of 2.15. Mass and energy balances suggest that by mitigating TP, surface heating increases the latent heat trapped in vapor. The internal and external HXs capture and reuse the additional heat, which enhances the GOR values. We show for SHVMD that the hybrid internal/external heat recovery design can have GOR value 1.44 times higher than that of systems with only internal or external heat recovery. Furthermore, by only increasing six stages to eight stages, a GOR value as high as 4.35 is achieved. The results further show that surface heating can reduce the energy consumption of MD for brine concentration. As a result, the multistage SHVMD technology exhibits a promising potential for the management of brine from industrial plants.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Design of a removable vacuum bellow restraint for RHIC vacuum vessels

In preparation for the rework of a RHIC Siberian snake for EIC, a DU7 cold section is being refurbished to replace the snake magnet before the RHIC run 25. There is a need to check the vacuum vessel leak tightness before tunnel installation, however the vacuum vessel original restraints have been removed. So there is a need to design a new removable bellow restraint for this vacuum testing. This report details the design and analysis done to ensure the safe operation of this bellow restraint.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Economic assessment of a multistage surface-heated vacuum membrane distillation process for the treatment of hypersaline produced water

Here, the treatment and disposal of hypersaline produced water remains a challenge, particularly for oil and gas producers in the Permian basin where production wells generate significant amounts of wastewater, and the traditional method of injecting wastewater into disposal wells is coming under increasing scrutiny. Here we investigate the viability of using solar energy to power a multi-stage, surface heated, vacuum membrane distillation (SHVMD) with energy recovery to treat hypersaline produced wastewater from Midland, Texas. Membrane distillation is a process that can desalinate waters with high total dissolved solids concentration, and when incorporated into a system with surface heating and energy recovery can achieve high water recovery rates. Model results show that a 6-stage SHVMD system with a 54.4 % water recovery rate and a gained output ratio (GOR) of 3.28 has the potential to be economically viable when used to treat hypersaline produced water in the Permian basin. Assuming energy costs of $\$0.03$/kWh thermal and $\$0.12$kWh electric , we estimate a project net present value (NPV) of $\$225,525$ and an internal rate of return (IRR) of 13.5 % when an air cooled condensor is used to cool the distillate and a NPV of $\$570,791$ and IRR of 24.52 % when a liquid coooling source is available.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Vacuum Pyrolysis of Hybrid Poplar Milled Wood Lignin with Fourier Transform-Ion Cyclotron Resonance Mass Spectrometry Analysis of Feedstock and Products for the Elucidation of Reaction Mechanisms

The pyrolysis of lignocellulosic materials is a promising technique to produce fuels and chemicals. It is well known that the most abundant products of lignin pyrolysis are oligomeric molecules, known as pyrolytic lignin (PL). The chemical composition of PL has been extensively studied; however, there is still an important debate whether these oligomers are produced directly from the lignin or from the recombination of monomeric pyrolytic products. Existing theories are unable to describe the effect of vacuum on the distribution of pyrolysis products. Hybrid poplar milled wood lignin (MWL) was initially isolated and thoroughly characterized by Fourier transform-ion cyclotron resonance mass spectrometry (FT-ICR MS). Chemical formulas were assigned to each oligomeric compound detected. The MWL was also subjected to vacuum pyrolysis in a modified pyroprobe at 250, 750, and 1000 mbar (absolute pressure), and the resulting liquid products were analyzed by FT-ICR MS. A new strategy to assign structural representations to the oligomeric PL products is proposed, based on the plausible pyrolysis reaction mechanisms of depolymerization/fragmentation applied to original MWL oligomer formulas. Our results support the hypothesis that PL is formed from the removal of moieties from primary lignin pyrolysis products with between three and five aromatic rings. This depolymerization/fragmentation allows the oligomers to reduce their molecular weights to the point where they can be removed from the reaction zone by direct vaporization. Furthermore, this phenomenon highlights the importance of pressure on removal mechanisms and their impact on the molecular weight of the resulting products from lignin pyrolysis.

09 BIOMASS FUELS↗