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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Additive manufacturing of carbon fiber-reinforced thermoset composites via in-situ thermal curing

Fiber-reinforced polymer composites are lightweight structural materials widely used in the transportation and energy industries. Current approaches for the manufacture of composites require expensive tooling and long, energy-intensive processing, resulting in a high cost of manufacturing, limited design complexity, and low fabrication rates. Here, we report rapid, scalable, and energy-efficient additive manufacturing of fiber-reinforced thermoset composites, while eliminating the need for tooling or molds. Use of a thermoresponsive thermoset resin as the matrix of composites and localized, remote heating of carbon fiber reinforcements via photothermal conversion enables rapid, in-situ curing of composites without further post-processing. Rapid curing and phase transformation of the matrix thermoset, from a liquid or viscous resin to a rigid polymer, immediately upon deposition by a robotic platform, allows for the high-fidelity, freeform manufacturing of discontinuous and continuous fiber-reinforced composites without using sacrificial support materials. This method is applicable to a variety of industries and will enable rapid and scalable manufacture of composite parts and tooling as well as on-demand repair of composite structures.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Parametric Cost Modeling of a Mid-Lift-to-Drag Ratio Vehicle for Human Mars Entry, Descent, and Landing

Cost is one of the biggest obstacles to sending humans to Mars. However, spacecraft costs are typically estimated after the preliminary vehicle and mission concepts have been designed. By automating the cost estimation process, the effect of any change in vehicle or mission design on the mission cost can be determined more rapidly. This paper uses the tool SAPE-C (Systems Analysis for Planetary Entry, Descent, and Landing-Cost). SAPE-C integrates the cost modeling software SEER-H (System Estimation and Evaluation of Resources-Hardware) with a number of systems analysis tools and enables large design tradespace exploration early in the design process. SAPE-C is used to analyze several tradespaces of the Mid-Lift-to-Drag ratio rigid entry vehicle for human Mars missions. Key findings include quantifying the impacts of payload, vehicle length, and main engine specific impulse on the overall cost of the vehicle, and how the payload per lander and number of landers affects the cost of a campaign to Mars.

Mid L/D↗
NASA NTRSDate not supplied

Parametric Cost Modeling of a Mid-Lift-to-Drag Ratio Vehicle for Human Mars Entry, Descent, and Landing

Cost is one of the biggest obstacles to sending humans to Mars. However, spacecraft costs are typically estimated after the preliminary vehicle and mission concepts have been designed. By automating the cost estimation process, the effect of any change in vehicle or mission design on the mission cost can be determined more rapidly. This paper uses the tool SAPE-C (Systems Analysis for Planetary Entry, Descent, and Landing-Cost). SAPE-C integrates the cost modeling software SEER-H (System Estimation and Evaluation of Resources-Hardware) with a number of systems analysis tools and enables large design tradespace exploration early in the design process. SAPE-C is used to analyze several tradespaces of the Mid-Lift-to-Drag ratio rigid entry vehicle for human Mars missions. Key findings include quantifying the impacts of payload, vehicle length, and main engine specific impulse on the overall cost of the vehicle, and how the payload per lander and number of landers affects the cost of a campaign to Mars.

Paul D Friz↗
NASA NTRSDate not supplied

Parametric Cost Modeling of a Mid-Lift-to-Drag Ratio Vehicle for Human Mars Entry, Descent, and Landing

Cost is one of the biggest obstacles to sending humans to Mars. However, spacecraft costs are typically estimated after the preliminary vehicle and mission concepts have been designed. By automating the cost estimation process, the effect of any change in vehicle or mission design on the mission cost can be determined more rapidly. This paper uses the tool SAPE-C (Systems Analysis for Planetary Entry, Descent, and Landing-Cost). SAPE-C integrates the cost modeling software SEER-H (System Estimation and Evaluation of Resources-Hardware) with a number of systems analysis tools and enables large design tradespace exploration early in the design process. SAPE-C is used to analyze several tradespaces of the Mid-Lift-to-Drag ratio rigid entry vehicle for human Mars missions. Key findings include quantifying the impacts of payload, vehicle length, and main engine specific impulse on the overall cost of the vehicle, and how the payload per lander and number of landers affects the cost of a campaign to Mars.

Paul D Friz↗
NASA NTRSDate not supplied

TBIRD, a rapid prototyping approach for design, assembly, and test of a LEO-to-ground lasercom CubeSat

The TeraByte InfraRed Delivery (TBIRD) system is a 3U payload on a 6U CubeSat launched in May 2022 which has now demonstrated space to ground links of >1 Terabyte (TB) per pass at a max data rate of 200Gbps. As a CubeSat mission, the development of the TBIRD payload was focused on low SWaP and a “rapid prototyping” approach which accepted higher risks to accelerate the schedule and reduce costs. The optomechanical design process followed standard in-house processes to develop a system that would be robust to LEO environmental loads, with a focus on the stability of the transmit (Tx) and receive (Rx) channel performance metrics. The driving requirement of maintaining 20μrad pointing error between the TX and Rx channels forced specific attention to thermal and mechanical load changes over operational conditions, which drove major design decisions. This paper describes some of engineering challenges overcome and approaches used to make TBIRD a successful program, as well as some of the tradeoffs of rapid prototyping precision optical payloads. TBIRD successfully met and exceeded the total downlink requirements listed above, with a bandwidth of 200Gbps and a total downlink of 4.8TB of information in a single pass.

TBIRD↗
DOE OSTI2022

A Structural Design Approach Tailored for the Rapid Preliminary Design of Microreactor Components

High-temperature microreactors can play a role in developing reliable, portable energy sources for off-grid remote locations, microgrid concepts, and industrial process heat. Portability and passive safety criteria tend to skew microreactor structural component designs toward complex geometries, high thermal stresses, and design bases with large numbers of startup/shutdown cycles. Current design rules, as typified by Section III of the American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code, are less than optimal for these conditions, particularly for preliminary component designs where developers need to rapidly consider a large number of potential component configurations. This paper presents a design method targeted toward rapid, efficient evaluation of preliminary component designs using modern finite element analysis. The new method retains key connections with the ASME Code rules and design data while streamlining the design approach. This paper presents the design method, several verification examples illustrating the similarities and differences between the new method and the current ASME rules, and the application of the new approach to the evaluation of a test article mimicking key features of a heat pipe–cooled microreactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

A Limit to Accelerated Free-Sintering: Nano-Phase Separation Interferes With Organic Debinding

Nano-phase separating Ni–12 at. pct Ag powders are processed via high-energy ball milling and brought into a supersaturated state with a reduction of the grain size to the nanocrystalline scale, a combination that is designed to encourage rapid densification by phase separation upon heating. This unstable powder is then characterized by dilatometry, in-situ x-ray diffraction, thermogravimetry and microstructure analysis for sintering cycles up to 940 °C. However, these powder compacts exhibit excessive pore evolution and significant macroscopic swelling caused by removal of the organic process additives. This competition of organic removal with densification is known in nanocrystalline metals, but the present study adds an additional dimension of phase separation, which shifts the dominant swelling mechanism as the formation of the second phase traps the volatilizing organics and hinders the debinding process. The creep swelling and overall loss in relative density is then dominated by the creep deformation of the second Ag phase. The interference between organic removal and low-temperature onset of consolidation represents a new challenge to efforts aimed at rapid free sintering and should guide the design of rapidly sintering alloys; specifically, the present work emphasizes the need to select alloys that have their sintering-accelerating phase separation temperature above the range where gases are evolved.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Experience with the EURECA Packet Telemetry and Packet Telecommand system

The European Retrieval Carrier (EURECA) was launched on its first flight on the 31st of July 1992 and retrieved on the 29th of June 1993. EURECA is characterized by several new on-board features, most notably Packet telemetry, and a partial implementation of packet telecommanding, the first ESA packetised spacecraft. Today more than one year after the retrieval the data from the EURECA mission has to a large extent been analysed and we can present some of the interesting results. This paper concentrates on the implementation and operational experience with the EURECA Packet Telemetry and Packet Telecommanding. We already discovered during the design of the ground system that the use of packet telemetry has major impact on the overall design and that processing of packet telemetry may have significant effect on the computer loading and sizing. During the mission a number of problems were identified with the on-board implementation resulting in very strange anomalous behaviors. Many of these problems directly violated basic assumptions for the design of the ground segment adding to the strange behavior. The paper shows that the design of a telemetry packet system should be flexible enough to allow a rapid configuration of the telemetry processing in order to adapt it to the new situation in case of an on-board failure. The experience gained with the EURECA mission control should be used to improve ground systems for future missions.

Sorensen, Erik Mose↗
DOE OSTI2015

Design and Validation Testing of TruckScan to Assay Large Sacks of Fukushima Radioactive Debris on a Truck

As a result of the March 2011 earthquake and resulting tsunami in Japan, there was a serious accident at the Fukushima Dai-ichi Nuclear Power Plant. This accident has contaminated soil and vegetation in a wide area around the plant. Decontamination projects over the last 4 years have resulted in large numbers of 1 cubic meter canvas bags of debris, commonly called Super Sacks [SS]. These are currently stored nearby where they were generated, but starting in 2015, they will be moved to various Interim Storage Facilities [ISF]. Trucks will typically carry 8-20 of these SSs. When the trucks arrive at the ISF they need to be rapidly sorted into groups according to radioactivity level, for efficient subsequent processing. Canberra Industries, Inc. [CI] has designed a new truck monitoring system 'TruckScan' for use at these ISFs. The TruckScan system must measure the entire truck loaded with multiple closely packed SSs, and generate a nuclide specific assay report showing the radioactivity in each individual SS. The Canberra-Japan office, along with Obayashi Corporation have performed validation testing to demonstrate to the regulatory authorities that the proposed technique was sufficiently accurate. These validation tests were conducted at a temporary storage area in Fukushima prefecture. Decontaminated waste of various representative types and of various levels of radioactivity was gathered and mixed to create homogeneous volumes. These volumes were sampled multiple times and assayed with laboratory HPGe detectors to determine the reference concentration of each pile. Multiple SSs were loaded from each pile. Some of the SSs were filled 50% full, others 75% full, and others 100% full, to represent the typical loading configuration of the existing SSs in the field. The content of the SSs are either sand, soil, or vegetation with densities ranging from 0.3 g/cc - 1.6 g/cc. These SSs with known concentrations of Cs-134 and Cs-137 were then loaded onto trucks in a variety of configurations, typical of how they might be on the real trucks. A partial system was installed at the site and used to assay these trucks with the various loading configurations. Whereas the full system will have 8 collimated 3 x 3'' NaI detectors, the test system only had two detectors; therefore the truck was moved and counted 4 times. The data were acquired and analyzed with the Canberra Genie software to determine the peak counts for both Cesium nuclides. That data was then analyzed with a prototype version of a Maximum Entropy algorithm, to determine the individual SS activity. The goal of the validation tests was to demonstrate that the system could detect 1000 Bq/kg in 15 seconds, and to determine how accurately it could quantify individual SSs. The validation tests demonstrated that the product would perform as predicted. The TruckScan results were consistent with the sample assay results [y = 1.0029 x, R{sup 2} = 0.914]. The Total Propagated Uncertainty, including both uncertainties from these tests and others that were estimated but not tested was 16.6% percent. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Ultrafast (1‐5 sec) Lamination of Perovskite Solar Cells With Self‐Encapsulation Using Rapid Joule Heating

Perovskite solar cells (PSCs) are traditionally fabricated using sequential layer‐by‐layer deposition, in which each layer of the device is processed on top of the preceding layer. This constrains the processing techniques and selection of transport layer materials that can be used in the solar cell. To overcome these challenges, two half‐cells can be processed independently and then diffusion‐bonded through a lamination process. However, current lamination processes for perovskite solar cells suffer from relatively long process times, which can limit throughput when moving toward high‐volume manufacturing. In this study, a custom platform was designed for rapid‐joule heating of perovskite materials and devices. This enabled more than a 99% reduction in lamination time from 26 min to 1 s. Perovskite samples that were laminated in 1 s exhibited comparable values of percent bonded area, interfacial toughness, grain domain size, and X‐ray diffraction spectra to those laminated in greater than 10 min. As a proof‐of‐concept, 18.3% efficient devices were successfully laminated in 5 s. A transient heat transfer model was developed to describe the relationship between the perovskite temperature and the electrical power supplied to the heaters, establishing a baseline for predicting processing conditions in large‐scale manufacturing systems. Ultra‐fast lamination provides a pathway toward scalable roll‐to‐roll or sheet‐to‐sheet manufacturing of PSCs.

heat transfer↗
DOE OSTI2024

AOI [1] Advanced Manufacturing of Ceramic Anchors with Embedded Sensors for Process and Health Monitoring of Coal Boilers

Researchers at West Virginia University (WVU) developed methods to fabricate and test ceramic anchors with an embedded sensor technology for monitoring the health and processing conditions within pulverized coal (PC) and fluidized-bed combustion (FBC) boiler systems. The technology included the development of advanced manufacturing processes for 2D/3D printing electroceramic (conductive ceramic) sensor designs within the ceramic anchor microstructure during the manufacturing process. This advanced manufacturing process would allow for the precise control of local microstructure and composition in order to engineer layer-by-layer any protective and electrically active materials within the refractory anchor. This 3D printing technology would permit the rapid and controlled design of the refractory microstructure and embedded sensor design throughout the volume of the ceramic anchor. The work also included a method to interconnect the sensors to boiler shell through the anchor clamp, where the sensor signals will be processed by low-power electronics and transmitted wirelessly to a central processing hub. The end-goal of the program was to produce a ceramic anchor sensor system which would be ready for implementation within a coal boiler, and/or other similar refractory liner systems (such as that in the glass and metal manufacturing areas). The project objectives were to: 1) Define the chemical and microstructural stability, in addition to the electrical properties, of oxide and non-oxide ceramic composites to be embedded within the ceramic anchor compositions that may operate up to 1400ºC; 2) Develop and implement the 2D/3D printing technology to pattern and control the microstructure of the ceramic anchor and embedded sensor circuits; 3) Develop an interconnect technology which will permit easy installation of the ceramic anchors and signal collection at the boiler shell; 4) Develop low power analog electronics and wireless communication hardware to efficiently collect the sensor signal at each processing unit and transmit data to a central hub for data analysis; 5) Demonstrate the smart ceramic anchor system for temperature and liner fracture within a high-temperature processing unit, such as a boiler furnace or glass melting furnace floor/wall liner.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1988

Direct solution for thermal stresses in a nose cap under an arbitrary axisymmetric temperature distribution

The design of a nose cap for a hypersonic vehicle is an iterative process requiring a rapid, easy to use and accurate stress analysis. The objective of this paper is to develop such a stress analysis technique from a direct solution of the thermal stress equations for a spherical shell. The nose cap structure is treated as a thin spherical shell with an axisymmetric temperature distribution. The governing differential equations are solved by expressing the stress solution to the thermoelastic equations in terms of a series of derivatives of the Legendre polynomials. The process of finding the coefficients for the series solution in terms of the temperature distribution is generalized by expressing the temperature along the shell and through the thickness as a polynomial in the spherical angle coordinate. Under this generalization the orthogonality property of the Legendre polynomials leads to a sequence of integrals involving powers of the spherical shell coordinate times the derivative of the Legendre polynomials. The coefficients of the temperature polynomial appear outside of these integrals. Thus, the integrals are evaluated only once and their values tabulated for use with any arbitrary polynomial temperature distribution.

Davis, Randall C.↗
NASA NTRS2001

Rapid Prototyping Integrated With Nondestructive Evaluation and Finite Element Analysis

Most reverse engineering approaches involve imaging or digitizing an object then creating a computerized reconstruction that can be integrated, in three dimensions, into a particular design environment. Rapid prototyping (RP) refers to the practical ability to build high-quality physical prototypes directly from computer aided design (CAD) files. Using rapid prototyping, full-scale models or patterns can be built using a variety of materials in a fraction of the time required by more traditional prototyping techniques (refs. 1 and 2). Many software packages have been developed and are being designed to tackle the reverse engineering and rapid prototyping issues just mentioned. For example, image processing and three-dimensional reconstruction visualization software such as Velocity2 (ref. 3) are being used to carry out the construction process of three-dimensional volume models and the subsequent generation of a stereolithography file that is suitable for CAD applications. Producing three-dimensional models of objects from computed tomography (CT) scans is becoming a valuable nondestructive evaluation methodology (ref. 4). Real components can be rendered and subjected to temperature and stress tests using structural engineering software codes. For this to be achieved, accurate high-resolution images have to be obtained via CT scans and then processed, converted into a traditional file format, and translated into finite element models. Prototyping a three-dimensional volume of a composite structure by reading in a series of two-dimensional images generated via CT and by using and integrating commercial software (e.g. Velocity2, MSC/PATRAN (ref. 5), and Hypermesh (ref. 6)) is being applied successfully at the NASA Glenn Research Center. The building process from structural modeling to the analysis level is outlined in reference 7. Subsequently, a stress analysis of a composite cooling panel under combined thermomechanical loading conditions was performed to validate this process.

Abdul-Aziz, Ali↗
NASA NTRS2018

Planetary Probe Entry Models for Concurrent and Integrated Interplanetary Mission Design

There are many prospective mission opportunities involving atmospheric entry probes. The Planetary Science Deep Space SmallSat Studies (PSDS3) re-cently selected probe missions to Venus, Mars, and the outer planets as part of the 10 selected studies. Two of the six themes in the most recent New Fron-tiers call were a Saturn probe and a Venus in situ explorer. The 2013-2022 Planetary Science Decadal Survey includes probe missions at Venus, Mars, Saturn, Titan, Uranus, and Neptune. Across mission destinations and mission classes there is growing interest in planetary probes. While interplanetary trajectory specialists may like to use a broad sweep of low-fidelity solutions to find a wide array of trajectory options, probe specialists typically start off with mid- to high-fidelity point designs for the entry probe since the equations of motion for atmospheric probes require numerical integration and are so directly linked with some of the probe's subsystem design. Cur-rently, there are no alternatives to this design ap-proach as there are no tools capable of automatical-ly and concurrently designing interplanetary and atmospheric trajectories. Unfortunately, this makes us reliant on point designs in the early stages of the mission design process. The reliance on point de-signs for atmospheric probes hinders the flexibility of the design, making the design process cumber-some and restricting decision-making down the road. The research presented here addresses this problem by providing low-fidelity models for the automated, rapid design of atmospheric trajectories and probe's models which may be solved concur-rently with the interplanetary trajectory.

atmospheric probes↗
NASA NTRS2019

Experimental Design and Preliminary Analysis of a Mars CO2 Rapid Cycle Adsorption Pump

Temperature-swing adsorption pumps have been proposed as a method of acquiring and compressing Martian atmospheric CO2 for downstream processing. Most industrial applications and previous research targeted at space in-situ resource utilization (ISRU) utilize long (~hours) temperature swing periods, typically limited by the ability to transfer heat from a naturally insulating sorbent bed. A rapid cycle adsorption pump (RCAP) would reduce these periods to minutes, in the hope of increasing overall throughput. This paper details the design and preliminary experimental results from testing an RCAP in a simulated Martian environment. The test configuration features a central, liquid-cooled and heated heat transfer plate surrounded by symmetrical rectangular sorbent beds. Various bed thicknesses and commercially available Zeolite 13X sorbent particle sizes are evaluated to both determine performance and provide data for a parallel modeling effort. Discussions of multi-stage configurations and methods of boosting bed conductivity are included.

Rapid Cycle Adsorption↗
DOE OSTI2019

Automated Design and Analysis of a Variable Displacement Linkage Motor

Hydrostatic drives consisting of a variable displacement pump and a low speed high torque (LSHT) motor are frequently used in off-highway vehicles. A variable displacement traction motor is desirable because of the ability to downsize the pump and thereby run the hydrostat at higher efficiency, as well as the possibility of hybridization of the drivetrain. Currently on the market are fixed and discrete speed LSHT radial piston motors and high speed low torque variable displacement axial piston motors. The radial piston motors are displacement dense but are not continuously variable, whereas the axial piston motors are continuously variable but require gearboxes, introducing packaging and robustness concerns. The Variable Displacement Linkage Motor (VDLM) is a LSHT motor that is continuously variable. It offers several benefits over current LSHT motors in that it is highly efficient over its operating range, it has low torque ripple, and it is displacement dense due to its multi-lobed cam and radial packaging. As with the design of any motor, the process is iterative and must be performed whenever performance objectives change. This paper describes an automated method for rapid exploration of the solution space for a variable displacement motor with specific application to the VDLM. This method leads to a motor design that theoretically can achieve 97% efficiency with a torque ripple below 5% at full displacement.

42 ENGINEERING↗
DOE OSTI2021

NACHOS, a CubeSat-based high-resolution UV-Visible hyperspectral imager for remote sensing of trace gases: system overview and science objectives

Here, the Nano-satellite Atmospheric Chemistry Hyperspectral Observation System (NACHOS) is a high-throughput (f/2.9), high spectral resolution (~1.3 nm optical resolution, 0.6 nm sampling) Offner-design hyperspectral imager operating in the 300-500 nm spectral region. The 1.5U instrument payload (1U optical system, 0.5U electronics module) is hosted by a 1.5U LANL-designed CubeSat bus to comprise a 3U complete satellite. Spectroscopically similar to NASA’s Ozone Monitoring Instrument (OMI), which provides wide-field global mapping of ozone and other gases at coarse spatial resolution, NACHOS fills the complementary niche of targeted measurements at much higher spatial resolution. With 350 across-track spatial pixels and a 15-degree across-track field of view, NACHOS will provide spectral imaging at roughly 0.4 km per pixel from 500 km altitude. NACHOS incorporates highly streamlined gas-retrieval algorithms for rapid onboard processing, alleviating the need to routinely downlink massive hyperspectral data cubes. We will discuss the instrument design, challenges in achieving mechanical robustness to launch vibration in such a compact instrument, the onboard calibration system, and gas-retrieval data downlink strategy. We will also discuss potential science missions, including monitoring of NO 2 as an easily detected proxy for anthropogenic fossil-fuel greenhouse gases, monitoring lowlevel SO 2 degassing at pre-eruptive volcanoes, H 2 CO from wildfires, and characterization of aerosols. The long-term vision is for a many-satellite constellation that could provide both high spatial resolution and frequent revisits for selected targets of interest. As an initial technology demonstration of this vision, the NACHOS project is currently slated to launch two CubeSats in early 2022.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗