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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Overview of the NASA LISA Laser System Development

NASA Goddard Space Flight Center (GSFC) is developing the Laser System (LS) for the Laser Interferometer Space Antenna (LISA) mission, led by the European Space Agency (ESA) with a launch date of 2035. The LS under development at NASA GSFC consists of the Laser Head (LH), the Frequency Reference System (FRS), and the Power Monitor (PMON) Detector Assemblies. Since late 2017, we have been developing various models to advance the technology readiness level (TRL) for the LH from prototype (TRL4) to a system model demonstration in a relevant environment (TRL6). For the LH and FRS, the models further breakdown into the optical and electronics modules where the LH is made up of the Laser Optical Module (LOM) and the Laser Electronics Module (LEM) and the FRS consists of the FRS Optical Reference Cavity (FRS-O) and the FRS Electronics (FRS-E). The LS development follows the established NASA process in demonstrating the performance requirements [1] through the TRL4 effort and then advancing the form factor and package design to meet relevant environment requirements and qualifying the TRL6 design through rigorous testing and performance verification for space applications. The LOM for the LH is a main oscillator power amplifier (MOPA) with wavelength of 1064 nm and nominal output power of 2 Watt throughout the mission. The low-power, low-noise main oscillator (MO) is a custom micro non-planar ring oscillator (µNPRO) [2] that is phase modulated then amplified by the forward pumped ytterbium-dope fiber power amplifier (PA) stage to meet the output power requirement. The FRS is baselined on the GRACE Follow-On (GFO) [3] approach with updated FRS-E design to work with the LH-LEM. The PMON is located on the Optical Bench Assembly (OBA) [4] that samples a small portion of the LH output signal and provides the feedback signal to the LH-LEM for relative intensity noise (RIN) control. In this paper, we will report on the latest status of the LH testing and system level tests, explain the other subsystems involved in the test campaigns, and discuss the path to bring each LS subsystem to TRL6. We will also present the NASA GSFC roadmap in advancing the LISA LS to TRL6+ and plans for future system level testing as well as the preparation for space flight development to meet the LISA launch date of 2035.

amplifier↗
DOE OSTI2023

Friction Stir Scribe Joining of CFRP to Aluminum (Abstract)

The objective of this project is to develop and demonstrate friction stir scribe (FSS) joining of carbon fiber reinforced polymer (CFRP) to aluminum on light-duty vehicle body-in-white (BIW) joints. The project will also overcome the major obstacles of implementing FSS technology in a fully 3-D production robotic work cell and demonstrate the required CFRP-aluminum joint strengths in industrially relevant light-duty, BIW components. Specifically the project will develop the critical process technology, models and tools necessary to advance the FSS method through experimentation, validation at the laboratory scale, and integration into a production-like robotic environment. The ultimate goal is to demonstrate the technology on industrially relevant components based on process development and numerical simulation performed at scale.

42 ENGINEERING↗
DOE OSTI2024

Technology Development and Integration for Volume Production of High Purity Rare Earth Metals from Phosphate Processing

Under this project and in collaboration with Pacific Northwest National Laboratory (PNNL), Oak Ridge National Laboratory (ORNL), Florida International University (FIU), and Mosaic, the FIPR Institute successfully developed and demonstrated on laboratory batch scale a complete processing technology for production of high-purity rare earth elements (REE) in the form of mixed rare earth oxides (MREO) and rare earth metals (REM) using phosphoric acid sludge (a byproduct from phosphate mining) as the REE feedstock. Based on the research results, a technical research plan has been developed with expanded team members to elevate the technology readiness level (TRL) of the subject technology from 4 to 6 by conducting continuous testing of the processing flowsheet with the ultimate goal of producing about 900 tons per year of REM using the phosphate mining byproduct. Those 900 tons of REM would contain approximately 180 tons of Y, 120 tons of Nd, 50 tons of Gd, 37 tons of Dy, 33 tons of Sm, and 31 tons of Pr, meeting the US demand of roughly 39%, 6%, 42%, 48%, 101% and 7% for these elements, respectively. The advanced technologies for REE separation and purification involves three technology companies: K-Technologies, Inc. would test their continuous-ion-exchange/continuous-ion chromatography technologies on both the REE leachate and solvent extraction concentrate for 4 production of high-purity individual or binary REM. Rare Earth Salts would test their innovative electrochemical technology on the REE leachate or re-dissolved MREO in dilute acid for production of high-purity individual or binary REM. Rare Earth Technologies, Inc. would evaluate their advanced chromatographic separation technology on the dissolved MREO product for production of high-purity individual or binary REM.

36 MATERIALS SCIENCE↗
NASA NTRS2006

A Fast Technology Infusion Model for Aerospace Organizations

A multi-year Fast Technology Infusion initiative proposes a model for aerospace organizations to improve the cost-effectiveness by which they mature new, in-house developed software and hardware technologies for space mission use. The first year task under the umbrella of this initiative will provide the framework to demonstrate and document the fast infusion process. The viability of this approach will be demonstrated on two technologies developed in prior years with internal Jet Propulsion Laboratory (JPL) funding. One hardware technology and one software technology were selected for maturation within one calendar year or less. The overall objective is to achieve cost and time savings in the qualification of technologies. At the end of the recommended three-year effort, we will have demonstrated for six or more in-house developed technologies a clear path to insertion using a documented process that permits adaptation to a broad range of hardware and software projects.

technology readiness level↗
NASA NTRS2003

Development Efforts Expanded in Ion Propulsion: Ion Thrusters Developed With Higher Power Levels

The NASA Glenn Research Center was the major contributor of 2-kW-class ion thruster technology to the Deep Space 1 mission, which was successfully completed in early 2002. Recently, NASA s Office of Space Science awarded approximately $21 million to Glenn to develop higher power xenon ion propulsion systems for large flagship missions such as outer planet explorers and sample return missions. The project, referred to as NASA's Evolutionary Xenon Thruster (NEXT), is a logical follow-on to the ion propulsion system demonstrated on Deep Space 1. The propulsion system power level for NEXT is expected to be as high as 25 kW, incorporating multiple ion thrusters, each capable of being throttled over a 1- to 6-kW power range. To date, engineering model thrusters have been developed, and performance and plume diagnostics are now being documented. The project team-Glenn, the Jet Propulsion Laboratory, General Dynamics, Boeing Electron Dynamic Devices, the Applied Physics Laboratory, the University of Michigan, and Colorado State University-is in the process of developing hardware for a ground demonstration of the NEXT propulsion system, which comprises a xenon feed system, controllers, multiple thrusters, and power processors. The development program also will include life assessments by tests and analyses, single-string tests of ion thrusters and power systems, and finally, multistring thruster system tests in calendar year 2005. In addition, NASA's Office of Space Science selected Glenn to lead the development of a 25-kW xenon thruster to enable NASA to conduct future missions to the outer planets of Jupiter and beyond, under the High Power Electric Propulsion (HiPEP) program. The development of a 100-kW-class ion propulsion system and power conversion systems are critical components to enable future nuclear-electric propulsion systems. In fiscal year 2003, a team composed of Glenn, the Boeing Company, General Dynamics, the Applied Physics Laboratory, the Naval Research Laboratory, the University of Wisconsin, the University of Michigan, and Colorado State University will perform a 6-month study that will result in the design of a 25-kW ion thruster, a propellant feed system, and a power processing architecture. The following 2 years will involve hardware development, wear tests, single-string tests of the thruster-power circuits and the xenon feed system, and subsystem service life analyses. The 2-kW-class ion propulsion technology developed for the Deep Space 1 mission will be used for NASA's discovery mission Dawn, which involves maneuvering a spacecraft to survey the asteroids Ceres and Vesta. The 6-kW-class ion thruster subsystem technology under NEXT is scheduled to be flight ready by calendar year 2006. The less mature 25- kW ion thruster system under HiPEP is expected to be ready for a flight advanced development program in calendar year 2006.

Patterson, Michael J.↗
NASA NTRS1996

Maximum ADPE Approach for a High Rate CCSDS Return Link Processing System

The earth observing system data and operations system (EDOS) multi-mission data processing and distribution system for the earth observing system is considered. The EDOS was based on the Consultative Committee for Space Data Systems (CCSDS) protocols. The development included the challenge of developing and demonstrating a 150 Mbps CCSDS return link processing capability for the support of the first EDOS delivery. The approach used general-purpose automated data processing equipment (ADPE) and minimized the use of customized hardware. The way in which the system was developed is described. The principle design decisions and the performance benchmark results are presented.

Krimchansky, Alexander↗
DOE OSTI2026

Pitfalls in parameters: practical process development in chemical vapor processing of SiC

Vapor processing of high-value materials, such as silicon carbide (SiC), is of interest for many industries, including aerospace and energy production. Chemical vapor infiltration (CVI) of additively manufactured components is an especially attractive manufacturing process currently in development. Here, a novel development workflow is demonstrated with the H 2 –CH 3 SiCl 3 gas system for SiC to accelerate the process optimization of CVI SiC. A combination of calculated thermodynamics and high-throughput experimental chemical vapor deposition (CVD) coatings substantially reduced the experiments required with slow CVI processes. The computational results accurately predicted changes in the thermodynamic conditions tested, while CVD coatings – characterized by Raman spectroscopy – addressed changes in kinetic parameters. This workflow is also applicable to other vapor-processing systems, such as pyrolytic carbon, ZrC, or Si 3 N 4 .

Lamm, Benjamin W. [Oak Ridge National Laboratory (↗
NASA NTRS2024

Hawaiʻi Urban Development: Mapping Urban Infrastructure and Linkages to Wastewater Impacts across Hawaiʻi

Coastal ecosystems and human health across the Hawaiʻian islands are under threat from cesspools and other unpermitted wastewater infrastructure. Cesspools, or home sewage systems that hold wastewater effluent in porous concrete containers underground, discharge raw, untreated sewage directly into waterways. In fact, it is estimated that approximately 88,000 cesspools release 55 million gallons of raw sewage into Hawaiʻi’s waterways each day. Our partners, The Nature Conservancy, Hawaiʻi Regional Office (TNC) and University of Hawaiʻi, Mānoa (UHM), are heavily involved with the implementation and impact of Act 125, which was passed in 2017 by Hawaiʻi State Legislature to help combat these effects. This requires the conversion of cesspools to be upgraded and either converted to approved onsite disposal systems or connected to a sewer system so that the wastewater may be treated and to avoid leaching into the groundwater. Thus, identifying and locating cesspool and other unpermitted wastewater infrastructure is key to state and partner goals. Utilizing NASA Earth observations including Landsat 7 Enhanced Thematic Mapper Plus (ETM+), Landsat 8 Operational Land Imager (OLI), and Landsat 9 OLI-2 imagery, as well as pre-classified Sentinel-2 Multispectral Instrument (MSI) imagery in Esri’s Living Atlas, our team showcased the various perspectives that wastewater pollution research can use to assist in identifying and tracking urban development and concrete condition. This process was demonstrated by utilizing supervised object-based classification models, calculating various urban indices, and finding building size estimates to calculate effluent levels. Additionally, providing our partners with a GIS Methodology that can be built on to reach their future needs.

urban classification↗
NASA NTRSDate not supplied

Adaptation of Metal Additive Manufacturing Processes for the International Space Station

The In-Space Manufacturing (ISM) project at NASA Marshall Space Flight Center, in a partnership with the company, Made in Space, has previously investigated 3D printing of polymer materials on-orbit. In recent years, the project has begun exploring the potential for metal additive manufacturing (AM) on future space missions to reduce logistics and enable point-of-use manufacturing for sparing and repair. This presentation will provide an overview of constraints for demonstrating a manufacturing process on the International Space Station (ISS) as well as trades of available metal AM processes and their potential for in-space use. There are currently two processes in development as payloads for an ISS technology demonstration: wire+arc additive manufacturing (the Vulcan payload from Made in Space, Inc.) and bound metal deposition (the Fabrication Laboratory from Techshot, Inc). An update on both of these systems, results to date, and future development efforts will be presented. Relevant modeling work to evaluate operation of certain aspects of the processes in a microgravity environment will also be summarized.

manufacturing↗
DOE OSTI2022

Solvent Recovery and Management at the Savannah River Site H-Canyon Facility

NIOWAVE, Inc. is a domestic supplier of medical and industrial isotopes from uranium and radium. The Savannah River National laboratory (SRNL) is currently providing support to NIOWAVE, which plans to deploy a superconducting electron linear accelerator (LINAC) to fission uranium for Mo-99 production without the need for a nuclear reactor or HEU. The uranium from the Mo-99 production targets will be purified using a modified PUREX (Plutonium Uranium Reduction Extraction) solvent extraction process to recover the uranium in the product stream. The uranium will then be precipitated as an oxalate which is calcined to U 3 O 8 to fabricate pellets for new Mo-99 targets. In previous support provided to NIOWAVE, the SRNL demonstrated a solvent washing process to remove degradation products from the tributyl phosphate (TBP) solvent used in the modified PUREX process under development for uranium recovery. To supplement this technology demonstration, NIOWAVE requested the SRNL to provide summary information on the solvent recovery and management activities which are used at the Savannah River Site (SRS) H-Canyon facility. An existing reference document for the reprocessing of irradiated HEU fuels at the SRS was used as the primary reference for the solvent management activities; although, other reference documents were used to provide supplementary information. The information provided includes a brief summary of the solvent degradation issues which have been observed in the H-Canyon solvent extraction cycles and resulting process safety concerns. The solvent recovery processes for the three cycles of solvent extraction used in the H-Canyon were subsequently described including the process equipment which consists of the continuous and batch solvent washers, pumps, and tanks. A final section is provided on the monitoring and analysis of solvent quality based on the previous work performed at the SRNL for NIOWAVE and past research and development activities performed to support the solvent extraction processes in both the SRS F-Canyon and H-Canyon facilities.

07 ISOTOPE AND RADIATION SOURCES↗
NASA NTRS1972

Optical to optical interface device

The development, fabrication, and testing of a preliminary model of an optical-to-optical (noncoherent-to-coherent) interface device for use in coherent optical parallel processing systems are described. The developed device demonstrates a capability for accepting as an input a scene illuminated by a noncoherent radiation source and providing as an output a coherent light beam spatially modulated to represent the original noncoherent scene. The converter device developed under this contract employs a Pockels readout optical modulator (PROM). This is a photosensitive electro-optic element which can sense and electrostatically store optical images. The stored images can be simultaneously or subsequently readout optically by utilizing the electrostatic storage pattern to control an electro-optic light modulating property of the PROM. The readout process is parallel as no scanning mechanism is required. The PROM provides the functions of optical image sensing, modulation, and storage in a single active material.

Oliver, D. S.↗
NASA NTRS2001

Description of Selected Algorithms and Implementation Details of a Concept-Demonstration Aircraft VOrtex Spacing System (AVOSS)

A ground-based system has been developed to demonstrate the feasibility of automating the process of collecting relevant weather data, predicting wake vortex behavior from a data base of aircraft, prescribing safe wake vortex spacing criteria, estimating system benefit, and comparing predicted and observed wake vortex behavior. This report describes many of the system algorithms, features, limitations, and lessons learned, as well as suggested system improvements. The system has demonstrated concept feasibility and the potential for airport benefit. Significant opportunities exist however for improved system robustness and optimization. A condensed version of the development lab book is provided along with samples of key input and output file types. This report is intended to document the technical development process and system architecture, and to augment archived internal documents that provide detailed descriptions of software and file formats.

Hinton, David A.↗
DOE OSTI2023

Measuring Q₀ in LCLS-II Cryomodules Using Helium Liquid Level

The nitrogen-doped cavities used in the Linac Coherent Light Source II (LCLS-II) cryomodules have shown an unprecedented high Q₀ in vertical and cryomodule testing compared with cavities prepared with standard methods. While demonstration of high Q₀ in the test stand has been achieved, maintaining that performance in the linac is critical to the success of LCLS-II and future accelerator projects. The LCLS-II cryomodules required a novel method of measuring Q₀, due to hardware incompatibilities with existing procedures. Initially developed at Jefferson Lab during cryomodule acceptance testing before being used in the tunnel at SLAC, we use helium liquid level data to estimate the heat generated by cavities. We first establish the relationship between the rate of helium evaporation from known heat loads using electric heaters, and then use that relationship to determine heat from an RF load. Here we present the full procedure along with the development process, lessons learned, and reproducibility while demonstrating for the first time that world record Q₀ can be maintained within the real accelerator environment.

43 PARTICLE ACCELERATORS↗
NASA NTRSDate not supplied

Advancement of Novel Additively Manufactured Alloys for Space Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using the laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of these AM-enabled novel alloys, AM processing development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRS1982

A Module Experimental Process System Development Unit (MEPSDU)

Restructuring research objectives from a technical readiness demonstration program to an investigation of high risk, high payoff activities associated with producing photovoltaic modules using non-CZ sheet material is reported. Deletion of the module frame in favor of a frameless design, and modification in cell series parallel electrical interconnect configuration are reviewed. A baseline process sequence was identified for the fabrication of modules using the selected dendritic web sheet material, and economic evaluations of the sequence were completed.

Source record↗
DOE OSTI2021

Microchannel Reactor for Ethanol to Butene: CRADA 503 [Abstract only]

A key challenge facing most bioprocessing operations is that multiple unit operations are required, thereby resulting in complex, energy-intensive, and expensive processes. Further, biomass transportation costs drive the need for smaller, distributed processing plants. To incorporate the smaller scales desirable for biomass, novel processes must be developed with reduced capital costs. With over 20 years of experience in the development and commercialization of microchannel reactor technology, Oregon State University will partner with Pacific Northwest National Laboratory to demonstrate a microchannel reactor with lower capital costs for an alcohol-to-jet (ATJ) process technology that is currently being commercialized by LanzaTech. Ethanol can be produced from biomass feedstocks such as LanzaTech’s proprietary biochemical process using carbon from a number of possible feedstocks; syngas generated from biomass resources (e.g., MSW, organic industrial waste, agriculture waste) or reformed biogas, or from other biomass feedstocks such as corn kernel fiber. Ethanol then undergoes catalytic dehydration to form ethylene followed by a two-step oligomerization, hydrogenation, and fractionation to control the hydrocarbon product slate to the jet-range. Successful process development aided by a market pull for low carbon aviation fuel has spurred scale-up and commercial demonstration. However, Sustainable Aviation Fuel is a very price sensitive market and improved economics through process intensification will make the current ATJ process even more attractive. Recent efforts at PNNL have culminated in the development of a new catalyst technology for the conversion of ethanol to n-butene-rich olefins. A greater than 90% conversion, total olefin selectivity of 80-90% (n-butene selectivity ~60%), and good stability over a 100 hour test duration has been demonstrated at the bench scale. Producing butene-rich olefins directly from ethanol with high yield is new and impactful because the higher olefins can be selectively oligomerized to distillate-range hydrocarbons, thus eliminating one process step from the current ATJ process. Further, coupling the severely endothermic ethanol dehydration with exothermic C-C bond formation results in more energy efficient processing. Additional intensification and energy savings will stem from incorporating this new ethanol to n-butene catalyst technology within the ATJ process implemented using a microchannel reactor platform. Due to recent advances in microchannel manufacturing methods and associated cost reductions we believe the time is right to adapt this technology toward new commercial bioconversion applications.

02 PETROLEUM↗
NASA NTRSDate not supplied

Revisiting Building-Block Approaches for Structures

The building-block approach is a method for building confidence in designs, working from lower-level components to more complex assemblies, using knowledge gained at each step to inform higher fidelity representations. The goals of this paper are to revisit the basic techniques of the building-block approach as it applies to structural design and analysis and illustrate some best practices that should be considered when developing structural analysis models. The paper demonstrates the process of leveraging existing information to build confidence in the design/development of analysis models, followed by examples of how the building-block approach for analysis was used in NASA hardware and spacecraft development efforts. The paper will also discuss virtual testing and hybrid simulation techniques, which are showing promise for more efficient/cost-effective verification of aerospace structures.

Kenneth R. Hamm Jr.↗
NASA NTRSDate not supplied

Adaptation of Metal Additive Manufacturing Processes for the International Space Station

The In-Space Manufacturing (ISM) project at NASA Marshall Space Flight Center, in a partnership with the company, Made in Space, has previously investigated 3D printing of polymer materials on-orbit. In recent years, the project has begun exploring the potential for metal additive manufacturing (AM) on future space missions to reduce logistics and enable point-of-use manufacturing for sparing and repair. This paper provides an overview of constraints for demonstrating a manufacturing process on the International Space Station (ISS) as well as information on previous trades of available metal AM processes and their potential for in-space use. There are currently two processes in development as payloads for an ISS technology demonstration: wire+arc additive manufacturing (the Vulcan payload from Made in Space, Inc.) and bound metal additive manufacturing (the Fabrication Laboratory from Techshot, Inc). An update on both of these systems, key results to date, and future development efforts will be presented. Relevant modeling work, performed by NASA Ames Research Center, to evaluate operation of certain aspects of the bound metal AM process in a microgravity environment will also be summarized.

in-space manufacturing↗