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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
NASA NTRS2018

High Resolution Computed Tomography Inspection of Components Uncovers Root Causes of Vexing Failure Mysteries

During testing of actuators for fight programs, failures have occurred that required closure with an understanding of the root cause of the failure. For some InSight project actuators, intermittent changes of the winding resistance of the motors during temperature changes was extremely baffling. It was critical to determine the cause of the intermittent characteristic because the actuators were stock from a previous program and the company that provided the motors was no longer in business. Using an X-Ray Computed-Tomography (CT) method, the exact source of the intermittent failure was determined and completely understood – at dimensions of less than 20 microns. In another case, after the completion of an actuator’s life-test-to-failure, inspection was required to determine the source of the failure. The size of the actuator (10 mm diameter) required destructive means to get to the interior of the actuator for inspection, risking the loss of the source of the failure. Using CT imaging, the exact source of the failure was determined.

Johnson, Michael R.↗
NASA NTRS1997

Microstructure and Mechanical Properties of Vacuum Plasma Sprayed Cu-8Cr-4Nb

This paper compares the tensile properties of Cu-8Cr-4Nb material produced by VPS to material previously produced by extrusion. The microstructure of the VPS material is also presented. The combustion chamber liner of rocket motors represents an extreme materials application. The liner hot wall is exposed to a 2760 C (5000 F) flame while the cold side is exposed to cryogenic hydrogen liquid. Materials for use in the combustion chamber liner require a combination of high temperature strength, creep resistance, and low cycle fatigue resistance along with high thermal conductivity. The hot side is also subject to localized cycles between reducing and oxidizing environments that degrade the liner by a process called blanching. A new Cu-8 at.% Cr-4 at% Nb (Cu-8Cr-4Nb) alloy has been developed at NASA Lewis Research Center as a replacement for the currently used alloy, NARloy-z (Cu-3 wt.% Ag-0.5 wt.% Zr). The alloy is strengthened by a fine dispersion of Cr2Nb particles. The alloy has better mechanical properties than NARloy-Z while retaining most of the thermal conductivity of pure copper. The alloy has been successfully consolidated by extrusion and hot isostatic pressing (HIPing). However, vacuum plasma spraying (VPS) offers several advantages over prior consolidation methods. VPS can produce a near net shape piece with the profile of the liner. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the liner hot wall during the VPS deposition. The low oxygen VPS Cu-8Cr-4Nb exhibits a higher strength than Cu-8Cr-4Nb produced by extrusion at elevated temperatures and a comparable strength at room temperature. Moduli and ductility were not significantly different. However, the ability to produce parts to near-net shape and maintain the good elevated temperature tensile properties of the extruded Cu-8Cr-4Nb makes VPS an attractive processing method for fabricating rocket engine combustion liners.

Holmes, Richard↗
NASA NTRS1984

Insulation Material

Manufactured by Hitco Materials Division of Armco, Inc. a ceramic fiber insulation material known as Refrasil has been used extensively as a heat-absorbing ablative reinforcement for such space systems as rocket motor nozzles, combustion chambers, and re-entry shields. Refrasil fibers are highly porous and do not melt or vaporize until fibers exceed 3,100 degrees Fahrenheit. Due to these and other properties, Refrasil has found utility in a number of industrial high temperature applications where glass, asbestos and other materials fail. Hitco used this insulation to assist Richardson Co., Inc. in the manufacturing of hard rubber and plastic molded battery cases.

Source record↗
NASA NTRS2020

Status of Analysis and Manufacturability of Superconducting Wires with Low AC Losses

Superconductors can carry an order-of-magnitude higher current than room temperature copper wires and can do so with two orders-of-magnitude lower alternating current (AC) electrical losses. These advantages underlie our estimates that turboelectric propulsion of large aircraft can be enabled by superconducting machines. However, even the much smaller losses of superconductors pose thermal management issues at the low temperatures required for superconductivity, and predicting those losses and validating the predictions has been a developing process at NASA Glenn Research Center over the last decade. Since Glenn’s earliest assessments of the feasibility of fully superconducting machines for turboelectric propulsion, the available models of AC losses in superconductors have changed significantly, as well as the state of development of superconducting wire for the coils of electric machines. While the models available to us have improved significantly, the value of the AC losses predicted by these models have only increased as more fidelity was developed. The fabrication of medium temperature superconducting wires (Tc near 40 K) has advanced, and wires can be produced with finer filaments and tighter twisting than a decade ago. However, the ideal wire configurations, developed decades ago for low temperature superconductors (Tc < 25 K), still elude manufacturers of medium and high temperature (Tc > 77 K) superconductors. This report discusses the developments, the current limitations, and the expectations that future configurations of superconducting wire can yet be produced that will provide suitably low AC losses for the aircraft propulsion application. The report presents a basic discussion of the types of AC losses in superconductors, followed by a discussion of the evolution of our understanding of the practical consequences of those AC losses. Next, there is a discussion of the superconducting wire configurations that have been developed, which were partially guided by that understanding. A brief discussion of the modes of removing the heat produced by the losses is presented. Lastly, a comparison is presented between losses in currently available MgB2 wire and other important cases, including copper at room temperature, copper at liquid hydrogen temperature, and expected future MgB2 wire. Room temperature copper has 100 times the loss of today’s MgB2 and 300 times the expected loss of future MgB2. That implies we can expect much higher efficiency from fully superconducting machines than from machines with copper stators, and high efficiency targets remain the driver behind investment in MgB2 development and medium temperature superconductor research.

superconducting motors↗
DOE OSTI2024

Aluminum Ultra-conductors for Energy-Efficient Aerospace Busbar Applications (Abstract)

In this project, we will develop aluminum ultra-conductors with graphene additives demonstrating enhanced electrical conductivity at 90 °C compared to electric grade aluminum alloy AA1100 (43% IACS at 90 °C). While ultra-conductivity has been developed in copper and copper alloys, it is yet to be reported extensively in aluminum-based materials. This project will scale initial work done at PNNL on aluminum ultra-conductors using shear-assisted processing and extrusion (ShAPETM), a novel solid phase processing technique. Ultra-conductors are an emerging class of composites, comprised of a metal substrate with small quantities of nanocrystalline additives such as graphene or carbon nanotubes that demonstrate enhanced conductivity at relevant operating temperatures. Aluminum ultra-conductors can improve efficiency and power density while reducing the demand for copper in a wide range of applications, such as power transmission cables and electric motors. Busbars are an important component in aerospace systems that require lightweight and high-current power distribution including both future electric vertical take-off and landing (eVTOL) aircrafts and current aircraft electrical systems. We will accelerate aluminum ultra-conductor composite formulation development using combinatorial synthesis and testing methods aided by process/microstructure modeling, developed previously at PNNL. Eaton will test the properties of the ShAPE aluminum ultra-conductor feedstock (used to make the busbars) in relevant operating conditions (20 – 90 °C), predict the improvement in busbar performance when manufactured with ultra-conductors over commercial conductors (such as AA1100), and perform technoeconomic analysis to evaluate the potential for commercialization of ShAPE aluminum ultra-conductors. The project is expected to have a budget of $\$375$K, with $\$300$K in federal funding and $\$75$K in-kind cost-share contribution from Eaton over a period of performance of 24 months. Of the $\$300$K of federal funds, $\$140$K is allocated for CRADA activities that generate intellectual property (IP), and the remaining $\$160$K is reserved for modeling, material testing, characterization, travel, and reporting-related activities.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Actively Controlled Louver for Human Spacecraft Radiator Ultraviolet (UV), Dust, and Freeze Protection

This paper examines the use of actively controlled louvers to attenuate UV and dust, as well as mitigate freezing concerns for human spacecraft radiators during Artemis missions. Artemis missions to the lunar orbit or surface will expose the radiators to high energy UV radiation and dust, which will degrade the radiator’s coating emissivity and consequently reduce heat rejection performance. In addition, subfreezing environmental temperatures during transit to lunar orbit and nighttime on lunar south pole can rupture coolant tubes, reduce heat rejection performance, and worst-case scenario result in a Loss of Mission (LOM). Louver technology would be a promising solution to maintaining radiator performance and integrity for Artemis missions, but heritage louvers are passively controlled. This technology needs maturing to active control, or motor actuation, to achieve faster thermal response times. Actively controlled louver design considerations are discussed in this paper. The analysis that follows shows actively controlled louvers can attenuate high energy UV radiation and dust, as well as protect the coolant from freezing.

Louver↗
NASA NTRS2023

Actively Controlled Louver for Human Spacecraft Radiator Ultraviolet (UV), Dust, and Freeze Protection

This paper examines the use of actively controlled louvers to attenuate UV and dust, as well as mitigate freezing concerns for human spacecraft radiators during Artemis missions. Artemis missions to the lunar orbit or surface will expose the radiators to high energy UV radiation and dust, which will degrade the radiator’s coating emissivity and consequently reduce heat rejection performance. In addition, subfreezing environmental temperatures during transit to lunar orbit and nighttime on lunar south pole can rupture coolant tubes, reduce heat rejection performance, and worst-case scenario result in a Loss of Mission (LOM). Louver technology would be a promising solution to maintaining radiator performance and integrity for Artemis missions, but heritage louvers are passively controlled. This technology needs maturing to active control, or motor actuation, to achieve faster thermal response times. Actively controlled louver design considerations are discussed in this paper. The analysis that follows shows actively controlled louvers can attenuate high energy UV radiation and dust, as well as protect the coolant from freezing.

Louver↗
NASA NTRS2012

High-Altitude MMIC Sounding Radiometer for the Global Hawk Unmanned Aerial Vehicle

Microwave imaging radiometers operating in the 50-183 GHz range for retrieving atmospheric temperature and water vapor profiles from airborne platforms have been limited in the spatial scales of atmospheric structures that are resolved not because of antenna aperture size, but because of high receiver noise masking the small variations that occur on small spatial scales. Atmospheric variability on short spatial and temporal scales (second/ km scale) is completely unresolved by existing microwave profilers. The solution was to integrate JPL-designed, high-frequency, low-noise-amplifier (LNA) technology into the High-Altitude MMIC Sounding Radiometer (HAMSR), which is an airborne microwave sounding radiometer, to lower the system noise by an order of magnitude to enable the instrument to resolve atmospheric variability on small spatial and temporal scales. HAMSR has eight sounding channels near the 60-GHz oxygen line complex, ten channels near the 118.75-GHz oxygen line, and seven channels near the 183.31-GHz water vapor line. The HAMSR receiver system consists of three heterodyne spectrometers covering the three bands. The antenna system consists of two back-to-back reflectors that rotate together at a programmable scan rate via a stepper motor. A single full rotation includes the swath below the aircraft followed by observations of ambient (roughly 0 C in flight) and heated (70 C) blackbody calibration targets located at the top of the rotation. A field-programmable gate array (FPGA) is used to read the digitized radiometer counts and receive the reflector position from the scan motor encoder, which are then sent to a microprocessor and packed into data files. The microprocessor additionally reads telemetry data from 40 onboard housekeeping channels (containing instrument temperatures), and receives packets from an onboard navigation unit, which provides GPS time and position as well as independent attitude information (e.g., heading, roll, pitch, and yaw). The raw data files are accessed through an Ethernet port. The HAMSR data rate is relatively low at 75 kbps, allowing for real-time access over the Global Hawk high-data-rate downlink. Once on the ground, the raw data are unpacked and processed through two levels of processing. The Level 1 product contains geo-located, time-stamped, calibrated brightness temperatures for the Earth scan. These data are then input to a lD variational retrieval algorithm to produce temperature, water vapor, and cloud liquid water profiles, as well as several derived products such as potential temperature and relative humidity.

Brown, Shannon T.↗
NASA NTRS1986

Heat- and Radiation-Resistant Lubricants for Metals

Protective and lubricating coatings formed in situ. Orthophthalonitrile reacts with metal-surface asperities at high frictional temperatures to form lubricating films of metal phthalocyanine. Compounds also formed with hot metal fragments torn from asperities. Bearing surfaces better protected from scoring, and fragments rendered less harmful to base fluids. Lubricants useful as additives to oils and greases in gears, transmissions, motors, and other machines where rubbing loads between metal parts may be severe. Because of their low volatility and lack of requirement for air or moisture, lubricants also useful in vacuums.

Lawton, E. A.↗
NASA NTRS1988

Glass Artworks

Several NASA technologies have played part in growth and cost containment of studio glass art, among them a foam type insulation developed to meet a need for lightweight material that would reduce flame spread in aircraft fire. Foam comes in several forms and is widely used by glass artists, chiefly as an insulator for the various types of ovens used in glass working. Another Spinoff is alumina crucibles to contain molten glass. Before alumina crucibles were used, glass tanks were made of firebrick which tended to erode under high temperatures and cause impurities; this not only improved quality but made the process more cost effective. One more NASA technology that found its way into glass art working is a material known as graphite board, a special form of graphite originally developed for rocket motor applications. This graphite is used to exact compound angles and creates molds for poured glass artworks of dramatic design.

Source record↗
DOE OSTI2020

Comparison of electro-thermal performance of advanced cooling techniques for electric vehicle motors

Permanent magnet synchronous motors are commonly used in the powertrain of electric vehicles because of their high power and torque densities. Attempts to increase power and torque densities beyond the state-of-the-art often suffer from thermal limitations of the adopted winding-wire insulation class. In this paper, overall effectiveness of four different cooling technologies, namely conventional stator jacket cooling, embedded circular and rectangular cooling channels within stator core, and direct winding heat exchangers have been studied numerically. Here, by realizing temperature dependent magnetic and material properties, winding and core losses, a two-way coupling algorithm has been utilized to study the detailed electro-magnetic and thermal performance of BMW i3 motor with aforementioned cooling techniques. The numerical results illustrated that the direct winding heat exchangers approach provides better electro-thermal performance in comparison to the other cooling techniques analyzed. On the contrary, embedded rectangular and circular channel in stator core adversely affect the electro-magnetic performance and overall efficiency of the motor, despite their superior thermal performance compared to the jacket cooling

42 ENGINEERING↗
NASA NTRS1962

NASA Scout ST-1 Flight-Test Results and Analyses, Launch Operations, and Test Vehicle Description

The first of a series of flight tests for the development of the four-stage, solid-propellant Scout vehicle was conducted at the NASA Wallops Station under the direction of the Langley Research Center. Vehicle designation for the test was NASA Scout ST-1. Performance characteristics of the vehicle and components were recorded during a high-altitude probe mission. Flight-simulation studies are presented and show that the accuracy of the guidance system during the flight was within control-system design specifications. The control system functioned normally during the flight with the exception of an overpowering of the reaction-control roll jets near burnout of the third-stage rocket motor. The resulting roll displacement of the vehicle is shown to have caused the monitor tracking radar which had been erroneously tracking a radar beacon in the vehicle on a side lobe to reorient to the major lobe of the receiving antenna. This tracking switch falsely indicated a violent turning maneuver on the monitor plot board and resulted in a hold-fire decision for the fourth-stage rocket motor. Although data for the final thrusting and coast phase of the flight were not obtained, the majority of the test objectives were achieved. In-flight thrust misalignment angles for the second- and third-stage rocket motors derived from control-system error data and for the first-stage motor determined from flight-simulation studies are presented. All rocket-motor thrust misalignment angles were well within the tolerances used for control-system design. Rocket-motor flight performance is presented, and velocity increments attained from the first three stages substantiated the predicted nominal performance. Operation of the rocket motors was satisfactory with the exception of high-level vibrations which were encountered during third-stage motor burning. Rolling moments which overpowered the reaction-control jets are also attributed to the burning characteristics of the third-stage motor. A discussion of the premature loss of the third-stage heat shield is given and shows that the heat-shield latching mechanism failed from pressure loads as the vehicle entered the transonic speed range. Although venting was provided to relieve the high negative pressures known to exist on the heat shield at these speeds, a field modification of the wiring tunnel had the same effect as opening the inside of the heat shield to ambient pressures. Consequently, the latching mechanism failed from pressure loads which were of about the same magnitude as the latching-mechanism yield loads. Skin temperatures were recorded at several locations on the vehicle and were generally in good agreement with theoretical values. Aerodynamic heating presented no problem during the flight since the maximum temperatures recorded during the flight were only about half the design values because of the high-launch-angle trajectory. Environmental vibrations recorded in the vicinity of the guidance package showed that no significant continuous amplitude levels above the general instrumentation noise level were present during first- and second-stage burning. Large vibration amplitudes were recorded during third-stage burning which coincided with the large roll disturbance experienced by the vehicle near burnout of the third-stage motor.

Scout Launch Vehicle↗
NASA NTRS1996

Development Of A Magnetic Directional-Solidification Furnace

Report describes development of directional-solidification furnace in which axial magnetic field is imposed by surrounding ring permanent magnets and/or electromagnets and pole pieces. Furnace provides controlled axial temperature gradients in multiple zones, through which ampoule containing sample of material to be solidified is translated at controlled speed by low-vibration, lead-screw, stepping-motor-driven mechanism. Intended for use in low-gravity (spaceflight) experiments on melt growth of high-purity semiconductor crystals.

Aldrich, Bill R.↗
NASA NTRS2010

Improved Creep Measurements for Ultra-High Temperature Materials

Our team has developed a novel approach to measuring creep at extremely high temperatures using electrostatic levitation (ESL). This method has been demonstrated on niobium up to 2300 C, while ESL has melted tungsten (3400 C). This method has been extended to lower temperatures and higher stresses and applied to new materials, including a niobium-based superalloy, MASC. High-precision machined spheres of the sample are levitated in the NASA MSFC ESL, a national user facility and heated with a laser. The samples are rotated with an induction motor at up to 30,000 revolutions per second. The rapid rotation loads the sample through centripetal acceleration, producing a shear stress of about 60 MPa at the center, causing the sample to deform. The deformation of the sample is captured on high-speed video, which is analyzed by machine-vision software from the University of Massachusetts. The deformations are compared to finite element models to determine the constitutive constants in the creep relation. Furthermore, the non-contact method exploits stress gradients within the sample to determine the stress exponent in a single test.

Hyers, Robert W.↗
NASA NTRS2018

Design, Fabrication, and Critical Current Testing of No-Insulation Superconducting Rotor Coils for NASA's High-Efficiency Megawatt Motor

NASA Glenn Research Center is developing a 1.4~MW high-efficiency electric machine for future electrified aircraft to reduce energy consumption, emissions, and noise. This wound-field, synchronous machine employs a self-cooled, superconducting rotor to achieve excellent specific power and efficiency. This paper discusses the fabrication of the no-insulation high temperature superconducting (HTS) coils and presents the lessons learned. The process is compared to the fabrication of conventionally insulated HTS coils. Testing of the coils' critical current at liquid nitrogen temperature is also presented. The influence of thermal cycling on the critical current and n-value is studied.

Scheidler, Justin J.↗
NASA NTRS2006

Cryogenic Cooling for Myriad Applications-A STAR Is Born

Cryogenics, the science of generating extremely low temperatures, has wide applicability throughout NASA. The Agency employs cryogenics for rocket propulsion, high-pressure gas supply, breathable air in space, life support equipment, electricity, water, food preservation and packaging, medicine, imaging devices, and electronics. Cryogenic liquid oxygen and liquid hydrogen systems are also replacing solid rocket motor propulsion systems in most of the proposed launch systems, a reversion to old-style liquid propellants. In the late 1980s, NASA wanted a compact linear alternator/motor with reduced size and mass, as well as high efficiency, that had unlimited service life for use in a thermally driven power generator for space power applications. Prior development work with free-piston Stirling converters (a Stirling engine integrated with a linear actuator that produces electrical power output) had shown the promise of that technology for high-power space applications. A dual use for terrestrial applications exists for compact Stirling converters for onsite combined heat and power units. The Stirling cycle is also usable in reverse as a refrigeration cycle suitable for cryogenic cooling, so this Stirling converter work promised double benefits as well as dual uses. The uses for cryogenic coolers within NASA abound; commercial applications are similarly wide-ranging, from cooling liquid oxygen and nitrogen, to cryobiology and bio-storage, cryosurgery, instrument and detector cooling, semiconductor manufacturing, and support service for cooled superconducting power systems.

Source record↗
NASA NTRS2010

Development and Acceptance Testing of the Dual Wheel Mechanism for the Tunable Filter Imager Cryogenic Instrument on the JWST

The James Webb Space Telescope (JWST) will carry four scientific instruments, one of which is the Tunable Filter Imager (TFI), which is an instrument within the Fine Guidance Sensor. The Dual Wheel (DW) mechanism is being designed, built and tested by COM DEV Ltd. under contract from the Canadian Space Agency. The DW mechanism includes a pupil wheel (PW) holding seven coronagraphic masks and two calibration elements and a filter wheel (FW) holding nine blocking filters. The DW mechanism must operate at both room temperature and at 35K. Successful operation at 35K comprises positioning each optical element with the required repeatability, for several thousand occasions over the five year mission. The paper discusses the results of testing geared motors and bearings at the cryogenic temperature. In particular bearing retainer design and PGM-HT material, the effects of temperature gradients across bearings and the problems associated with cooling mechanisms down to cryogenic temperatures. The results of additional bearing tests are described that were employed to investigate an abnormally high initial torque experienced at cryogenic temperatures. The findings of these tests, was that the bearing retainer and the ball/race system could be adversely affected by the large temperature change from room temperature to cryogenic temperature and also the temperature gradient across the bearing. The DW mechanism is now performing successfully at both room temperature and at cryogenic temperature. The life testing of the mechanism is expected to be completed in the first quarter of 2010.

Leckie, Martin↗
NASA NTRS1990

Technical Evaluation Motor no. 5 (TEM-5)

Technical Evaluation Motor No. 5 (TEM-5) was static test fired at the Thiokol Corporation Static Test Bay T-97. TEM-5 was a full scale, full duration static test fire of a high performance motor (HPM) configuration solid rocket motor (SRM). The primary purpose of TEM static tests is to recover SRM case and nozzle hardware for use in the redesigned solid rocket motor (RSRM) flight program. Inspection and instrumentation data indicate that the TEM-5 static test firing was successful. The ambient temperature during the test was 41 F and the propellant mean bulk temperature (PMBT) was 72 F. Ballistics performance values were within the specified requirements. The overall performance of the TEM-5 components and test equipment was nominal. Dissembly inspection revealed that joint putty was in contact with the inner groove of the inner primary seal of the ignitor adapter-to-forward dome (inner) joint gasket; this condition had not occurred on any previous static test motor or flight RSRM. While no qualification issues were addressed on TEM-5, two significant component changes were evaluated. Those changes were a new vented assembly process for the case-to-nozzle joint and the installation of two redesigned field joint protection systems. Performance of the vented case-to-nozzle joint assembly was successful, and the assembly/performance differences between the two field joint protection system (FJPS) configurations were compared.

Cook, M.↗