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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Net-Shape HIP Powder Metallurgy Components for Rocket Engines

True net shape consolidation of powder metal (PM) by hot isostatic pressing (HIP) provides opportunities for many cost, performance and life benefits over conventional fabrication processes for large rocket engine structures. Various forms of selectively net-shape PM have been around for thirty years or so. However, it is only recently that major applications have been pursued for rocket engine hardware fabricated in the United States. The method employs sacrificial metallic tooling (HIP capsule and shaped inserts), which is removed from the part after HIP consolidation of the powder, by selective acid dissolution. Full exploitation of net-shape PM requires innovative approaches in both component design and materials and processing details. The benefits include: uniform and homogeneous microstructure with no porosity, irrespective of component shape and size; elimination of welds and the associated quality and life limitations; removal of traditional producibility constraints on design freedom, such as forgeability and machinability, and scale-up to very large, monolithic parts, limited only by the size of existing HIP furnaces. Net-shape PM HIP also enables fabrication of complex configurations providing additional, unique functionalities. The progress made in these areas will be described. Then critical aspects of the technology that still require significant further development and maturation will be discussed from the perspective of an engine systems builder and end-user of the technology.

Bampton, Cliff↗
NASA NTRS2004

Thin-Film Solar Cells on Metal Foil Substrates for Space Power

Photovoltaic arrays have played a key role in power generation in space. The current technology will continue to evolve but is limited in the important mass specific power metric (MSP or power/weight ratio) because it is based on bulk crystal technology. The objective of this research is to continue development of an innovative photovoltaic technology for satellite power sources that could provide up to an order of magnitude saving in both weight and cost, and is inherently radiation-tolerant through use of thin film technology and thin foil substrates such as 5-mil thick stainless steel foil or 1-mil thick Ti. Current single crystal technology for space power can cost more than $300 per watt at the array level and weigh more than 1 kg/sq m equivalent to specific power of approx. 65 W/kg. Thin film material such as CuIn(1-x),Ga(x)S2, (CIGS2), CuIn(1-x), G(x)Se(2-y),S(y), (CIGSS) or amorphous hydrogenated silicon (a-Si:H) may be able to reduce both the cost and mass per unit area by an order of magnitude. Manufacturing costs for solar arrays are an important consideration for total spacecraft budget. For a medium sized 5kW satellite, for example, the array manufacturing cost alone may exceed $2 million. Moving to thin film technology could reduce this expense to less than $500 K. Previous work at FSEC demonstrated the potential of achieving higher efficiencies from CIGSS thin film solar cells on 5-mil thick stainless steel foil as well as initial stages of facility augmentation for depositing thin film solar cells on larger (6"x 4") substrates. This paper presents further progress in processing on metal foil substrates. Also, previous work at DayStar demonstrated the feasibility of flexible-thin-film copper-indium-gallium-diselenide (CIGS) solar cells with a power-to-weight ratio in excess of 1000 W/kg. We will comment on progress on the critical issue of scale-up of the solar cell absorber deposition process. Several important technical issues need to be resolved to realize the benefits of lightweight technologies for solar arrays, such as: monolithic interconnects, lightweight array structures, and new ultra-light support and deployment mechanisms. Once the technology has gained spaceflight certification it should find rapid acceptance in specific satellite markets.

Raffaelle, Ryne P.↗
NASA NTRS2006

Phosphate Reactions as Mechanisms of High-Temperature Lubrication

One of the major problems preventing the operation of advanced gas turbine engines at higher temperatures is the inability of currently used liquid lubricants to survive at these higher temperatures under friction and wear conditions. Current state-of-the-art organic liquid lubricants rapidly degrade at temperatures above 300 C; hence some other form of lubrication is necessary. Vapor-phase lubrication is a promising new technology for high-temperature lubrication. This lubrication method employs a liquid phosphate ester that is vaporized and delivered to bearings or gears; the vapor reacts with the metal surfaces, generating a solid lubricious film that has proven very stable at high temperatures. In this study, solid lubricious films were grown on cast-iron foils in order to obtain reaction and diffusion rate data to help characterize the growth mechanism. A phenomenological mathematical model of the film deposition process was derived incorporating transport and kinetic parameters that were coupled to the experimental data. This phenomenological model can now be reliably used as a predictive and scale-up tool for future vapor-phase lubrication studies.

Nagarajan, Anitha↗
NASA NTRS1997

Replanning Using Hierarchical Task Network and Operator-Based Planning

In order to scale-up to real-world problems, planning systems must be able to replan in order to deal with changes in problem context. In this paper we describe hierarchical task network and operatorbased re-planning techniques which allow adaptation of a previous plan to account for problems associated with executing plans in real-world domains with uncertainty, concurrency, changing objectives.

HTN/operator-based planning↗
NASA NTRS2005

Family System of Advanced Charring Ablators for Planetary Exploration Missions

Advanced Ablators Program Objectives: 1) Flight-ready(TRL-6) ablative heat shields for deep-space missions; 2) Diversity of selection from family-system approach; 3) Minimum weight systems with high reliability; 4) Optimized formulations and processing; 5) Fully characterized properties; and 6) Low-cost manufacturing. Definition and integration of candidate lightweight structures. Test and analysis database to support flight-vehicle engineering. Results from production scale-up studies and production-cost analyses.

Congdon, William M.↗
NASA NTRS2008

Simultaneous Noncontact Precision Imaging of Microstructural and Thickness Variation in Dielectric Materials Using Terahertz Energy

This article describes a noncontact single-sided terahertz electromagnetic measurement and imaging method that simultaneously characterizes microstructural (egs. spatially-lateral density) and thickness variation in dielectric (insulating) materials. The method was demonstrated for two materials-Space Shuttle External Tank sprayed-on foam insulation and a silicon nitride ceramic. It is believed that this method can be used as an inspection method for current and future NASA thermal protection system and other dielectric material inspection applications, where microstructural and thickness variation require precision mapping. Scale-up to more complex shapes such as cylindrical structures and structures with beveled regions would appear to be feasible.

Roth, Don J.↗
NASA NTRS1981

Assessment of Advanced Coal Gasification Processes

This report represents a technical assessment of the following advanced coal gasification processes: AVCO High Throughput Gasification (HTG) Process; Bell Single-Stage High Mass Flux (HMF) Process; Cities Service/Rockwell (CS/R) Hydrogasification Process; Exxon Catalytic Coal Gasification (CCG) Process. Each process is evaluated for its potential to produce SNG from a bituminous coal. In addition to identifying the new technology these processes represent, key similarities/differences, strengths/weaknesses, and potential improvements to each process are identified. The AVCO HTG and the Bell HMF gasifiers share similarities with respect to: short residence time (SRT), high throughput rate, slagging and syngas as the initial raw product gas. The CS/R Hydrogasifier is also SRT but is non-slagging and produces a raw gas high in methane content. The Exxon CCG gasifier is a long residence time, catalytic, fluidbed reactor producing all of the raw product methane in the gasifier. The report makes the following assessments: 1) while each process has significant potential as coal gasifiers, the CS/R and Exxon processes are better suited for SNG production; 2) the Exxon process is the closest to a commercial level for near-term SNG production; and 3) the SRT processes require significant development including scale-up and turndown demonstration, char processing and/or utilization demonstration, and reactor control and safety features development.

coal gasification↗
NASA NTRS2008

Hydrogen Research for Spaceport and Space-Based Applications: Hydrogen Production, Storage, and Transport

The activities presented are a broad based approach to advancing key hydrogen related technologies in areas such as fuel cells, hydrogen production, and distributed sensors for hydrogen-leak detection, laser instrumentation for hydrogen-leak detection, and cryogenic transport and storage. Presented are the results from research projects, education and outreach activities, system and trade studies. The work will aid in advancing the state-of-the-art for several critical technologies related to the implementation of a hydrogen infrastructure. Activities conducted are relevant to a number of propulsion and power systems for terrestrial, aeronautics and aerospace applications. Hydrogen storage and in-space hydrogen transport research focused on developing and verifying design concepts for efficient, safe, lightweight liquid hydrogen cryogenic storage systems. Research into hydrogen production had a specific goal of further advancing proton conducting membrane technology in the laboratory at a larger scale. System and process trade studies evaluated the proton conducting membrane technology, specifically, scale-up issues.

Anderson, Tim↗
NASA NTRS2009

Determination of Chemical Kinetic Rate Constants of a Model for Carbothermal Processing of Lunar Regolith Simulant Using Methane

We have previously developed a chemical conversion model of the carbothermal processing of lunar regolith using methane to predict the rate of production of carbon monoxide. In this carbothermal process, gaseous methane is pyrolyzed as it flows over the hot surface of a molten zone of lunar regolith and is converted to carbon and hydrogen. Hydrogen is carried away by the exiting stream of gases and carbon is deposited on the melt surface. The deposited carbon mixes with the melt and reacts with the metal oxides in it to produce carbon monoxide that bubbles out of the melt. In our model, we assume that the flux of carbon deposited is equal to the product of the surface reaction rate constant gamma and the concentration of methane adjacent to the melt surface. Similarly, the rate of consumption of carbon per unit volume in the melt is equal to the product of the melt reaction rate constant k and the concentrations of carbon and metal oxide in the melt. In this paper, we describe our effort to determine gamma and k by comparison of the predictions from our model with test data obtained by ORBITEC (Orbital Technologies Corporation). The concentration of methane adjacent to the melt surface is a necessary input to the model. It is inferred from the test data by a mass balance of methane, adopting the usual assumptions of the continuously-stirred-tank-reactor model, whereby the average concentration of a given gaseous species equals its exit concentration. The reaction rates gamma and k have been determined by a non-linear least-squares fit to the test data for the production of carbon monoxide and the fraction of the incoming methane that is converted. The comparison of test data with our model predictions using the determined chemical kinetic rate constants provides a consistent interpretation of the process over the full range of temperatures, pressures, and methane flow rates used in the tests, thereby increasing our confidence to use the model for scale-up purposes.

Balasubramaniam, R↗
NASA NTRS2010

Performance Testing of Molten Regolith Electrolysis with Transfer of Molten Material for the Production of Oxygen and Metals on the Moon

Previously, we have demonstrated the production of oxygen by electrolysis of molten regolith simulants at temperatures near 1600 C. Using an inert anode and suitable cathode, direct electrolysis (no supporting electrolyte) of the molten silicate is carried out, resulting in the production of molten metallic products at the cathode and oxygen gas at the anode. Initial direct measurements of current efficiency have confirmed that the process offer potential advantages of high oxygen production rates in a smaller footprint facility landed on the moon, with a minimum of consumables brought from Earth. We now report the results of a scale-up effort toward the goal of achieving production rates equivalent to 1 metric ton O2/year, a benchmark established for the support of a lunar base. We previously reported on the electrochemical behavior of the molten electrolyte as dependent on anode material, sweep rate and electrolyte composition in batches of 20-200g and at currents of less than 0.5 A. In this paper, we present the results of experiments performed at currents up to 10 Amperes) and in larger volumes of regolith simulant (500 g - 1 kg) for longer durations of electrolysis. The technical development of critical design components is described, including: inert anodes capable of passing continuous currents of several Amperes, container materials selection, direct gas analysis capability to determine the gas components co-evolving with oxygen. To allow a continuous process, a system has been designed and tested to enable the withdrawal of cathodically-reduced molten metals and spent molten oxide electrolyte. The performance of the withdrawal system is presented and critiqued. The design of the electrolytic cell and the configuration of the furnace were supported by modeling the thermal environment of the system in an effort to realize a balance between external heating and internal joule heating. We will discuss the impact these simulations and experimental findings have on the design of a suitable prototype for lunar applications

Sibille, Laurent↗
NASA NTRS2010

Direct Electrolysis of Molten Lunar Regolith for the Production of Oxygen and Metals on the Moon

When considering the construction of a lunar base, the high cost ($ 100,000 a kilogram) of transporting materials to the surface of the moon is a significant barrier. Therefore in-situ resource utilization will be a key component of any lunar mission. Oxygen gas is a key resource, abundant on earth and absent on the moon. If oxygen could be produced on the moon, this provides a dual benefit. Not only does it no longer need to be transported to the surface for breathing purposes; it can also be used as a fuel oxidizer to support transportation of crew and other materials more cheaply between the surface of the moon, and lower earth orbit (approximately $20,000/kg). To this end a stable, robust (lightly manned) system is required to produce oxygen from lunar resources. Herein, we investigate the feasibility of producing oxygen, which makes up almost half of the weight of the moon by direct electrolysis of the molten lunar regolith thus achieving the generation of usable oxygen gas while producing primarily iron and silicon at the cathode from the tightly bound oxides. The silicate mixture (with compositions and mechanical properties corresponding to that of lunar regolith) is melted at temperatures near 1600 C. With an inert anode and suitable cathode, direct electrolysis (no supporting electrolyte) of the molten silicate is carried out, resulting in production of molten metallic products at the cathode and oxygen gas at the anode. The effect of anode material, sweep rate, and electrolyte composition on the electrochemical behavior was investigated and implications for scale-up are considered. The activity and stability of the candidate anode materials as well as the effect of the electrolyte composition were determined. Additionally, ex-situ capture and analysis of the anode gas to calculate the current efficiency under different voltages, currents and melt chemistries was carried out.

Sirk, Aislinn H. C.↗
NASA NTRS2011

Advances in the Lightweight Air-Liquid Composite Heat Exchanger Development for Space Exploration Applications

An advanced, lightweight composite modular Air/Liquid (A/L) Heat Exchanger (HX) Prototype for potential space exploration thermal management applications was successfully designed, manufactured, and tested. This full-scale Prototype consisting of 19 modules, based on recommendations from its predecessor Engineering Development unit (EDU) but with improved thermal characteristics and manufacturability, was 11.2 % lighter than the EDU and achieves potentially a 42.7% weight reduction from the existing state-of-the-art metallic HX demonstrator. However, its higher pressure drop (0.58 psid vs. 0.16 psid of the metal HX) has to be mitigated by foam material optimizations and design modifications including a more systematic air channel design. Scalability of the Prototype design was validated experimentally by comparing manufacturability and performance between the 2-module coupon and the 19-module Prototype. The Prototype utilized the thermally conductive open-cell carbon foam material but with lower density and adopted a novel high-efficiency cooling system with significantly increased heat transfer contact surface areas, improved fabricability and manufacturability compared to the EDU. Even though the Prototype was required to meet both the thermal and the structural specifications, accomplishing the thermal requirement was a higher priority goal for this first version. Overall, the Prototype outperformed both the EDU and the corresponding metal HX, particularly in terms of specific heat transfer, but achieved 93.4% of the target. The next generation Prototype to achieve the specification target, 3,450W would need 24 core modules based on the simple scaling factor. The scale-up Prototype will weigh about 14.7 Kg vs. 21.6 Kg for the metal counterpart. The advancement of this lightweight composite HX development from the original feasibility test coupons to EDU to Prototype is discussed in this paper.

Shin, E. Eugene↗
NASA NTRS2004

Study of Rapid-Regression Liquefying Hybrid Rocket Fuels

A report describes experiments directed toward the development of paraffin-based hybrid rocket fuels that burn at regression rates greater than those of conventional hybrid rocket fuels like hydroxyl-terminated butadiene. The basic approach followed in this development is to use materials such that a hydrodynamically unstable liquid layer forms on the melting surface of a burning fuel body. Entrainment of droplets from the liquid/gas interface can substantially increase the rate of fuel mass transfer, leading to surface regression faster than can be achieved using conventional fuels. The higher regression rate eliminates the need for the complex multi-port grain structures of conventional solid rocket fuels, making it possible to obtain acceptable performance from single-port structures. The high-regression-rate fuels contain no toxic or otherwise hazardous components and can be shipped commercially as non-hazardous commodities. Among the experiments performed on these fuels were scale-up tests using gaseous oxygen. The data from these tests were found to agree with data from small-scale, low-pressure and low-mass-flux laboratory tests and to confirm the expectation that these fuels would burn at high regression rates, chamber pressures, and mass fluxes representative of full-scale rocket motors.

Zilliac, Greg↗
NASA NTRS2012

Performance Assessment of Baseline Cells for the High Efficiency Space Power Systems Project

The Enabling Technology Development and Demonstration (ETDD) Program High Efficiency Space Power Systems (HESPS) Project, formerly the Exploration Technology Development Program (ETDP) Energy Storage Project is tasked with developing advanced lithium-ion cells for future NASA Exploration missions. Under this project, components under development via various in-house and contracted efforts are delivered to Saft America for scale-up and integration into cells. Progress toward meeting project goals will be measured by comparing the performance to these cells with cells of a similar format with Saft s state-of-the-art aerospace chemistry. This report discusses the results of testing performed on the first set of baseline cells delivered by Saft to the NASA Glenn Research Center. This build is a cylindrical "DD" geometry with a 10 Ah nameplate capacity. Testing is being performed to establish baseline cell performance at conditions relevant to ETDD HESPS Battery Key Performance Parameter (KPP) goals including various temperatures, rates, and cycle life conditions. Data obtained from these cells will serve as a performance baseline for future cell builds containing optimized ETDD HESPSdeveloped materials. A test plan for these cells was developed to measure cell performance against the high energy cell KPP goals. The goal for cell-level specific energy of the high energy technology is 180 Wh/kg at a C/10 discharge rate and 0 C. The cells should operate for at least 2000 cycles at 100 percent DOD with 80 percent capacity retention. Baseline DD cells delivered 152 Wh/kg at 20 C. This number decreased to 143.9 Wh/kg with a 0 C discharge. This report provides performance data and summarizes results of the testing performed on the DD cells.

Schneidegger, Brianne T.↗
NASA NTRS2012

Nuclear Thermal Propulsion (NTP): A Proven Growth Technology for Human NEO/Mars Exploration Missions

The nuclear thermal rocket (NTR) represents the next "evolutionary step" in high performance rocket propulsion. Unlike conventional chemical rockets that produce their energy through combustion, the NTR derives its energy from fission of Uranium-235 atoms contained within fuel elements that comprise the engine s reactor core. Using an "expander" cycle for turbopump drive power, hydrogen propellant is raised to a high pressure and pumped through coolant channels in the fuel elements where it is superheated then expanded out a supersonic nozzle to generate high thrust. By using hydrogen for both the reactor coolant and propellant, the NTR can achieve specific impulse (Isp) values of ~900 seconds (s) or more - twice that of today s best chemical rockets. From 1955 - 1972, twenty rocket reactors were designed, built and ground tested in the Rover and NERVA (Nuclear Engine for Rocket Vehicle Applications) programs. These programs demonstrated: (1) high temperature carbide-based nuclear fuels; (2) a wide range of thrust levels; (3) sustained engine operation; (4) accumulated lifetime at full power; and (5) restart capability - all the requirements needed for a human Mars mission. Ceramic metal "cermet" fuel was pursued as well, as a backup option. The NTR also has significant "evolution and growth" capability. Configured as a "bimodal" system, it can generate its own electrical power to support spacecraft operational needs. Adding an oxygen "afterburner" nozzle introduces a variable thrust and Isp capability and allows bipropellant operation. In NASA s recent Mars Design Reference Architecture (DRA) 5.0 study, the NTR was selected as the preferred propulsion option because of its proven technology, higher performance, lower launch mass, versatile vehicle design, simple assembly, and growth potential. In contrast to other advanced propulsion options, no large technology scale-ups are required for NTP either. In fact, the smallest engine tested during the Rover program - the 25,000 lbf (25 klbf) "Pewee" engine is sufficient when used in a clustered engine arrangement. The "Copernicus" crewed spacecraft design developed in DRA 5.0 has significant capability and a human exploration strategy is outlined here that uses Copernicus and its key components for precursor near Earth object (NEO) and Mars orbital missions prior to a Mars landing mission. The paper also discusses NASA s current activities and future plans for NTP development that include system-level Technology Demonstrations - specifically ground testing a small, scalable NTR by 2020, with a flight test shortly thereafter.

Borowski, Stanley K.↗
NASA NTRS2012

Design, Analysis and Testing of a PRSEUS Pressure Cube to Investigate Assembly Joints

Due to its potential to significantly increase fuel efficiency, the current focus of NASA's Environmentally Responsible Aviation Program is the hybrid wing body (HWB) aircraft. Due to the complex load condition that exists in HWB structure, as compared to traditional aircraft configurations, light-weight, cost-effective and manufacturable structural concepts are required to enable the HWB. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is one such structural concept. A building block approach for technology development of the PRSEUS concept is being conducted. As part of this approach, a PRSEUS pressure cube was developed as a risk reduction test article to examine a new integral cap joint concept. This paper describes the design, analysis and testing of the PRSEUS pressure cube test article. The pressure cube was required to withstand a 2P, 18.4 psi, overpressure load requirement. The pristine pressure cube was tested to 2.2P with no catastrophic failure. After the addition of barely visible impact damage, the cube was pressure loaded to 48 psi where catastrophic failure occurred, meeting the scale-up requirement. Comparison of pretest and posttest analyses with the cube test response agree well, and indicate that current analysis methods can be used to accurately analyze PRSEUS structure for initial failure response.

Yovanof, Nicolette↗
NASA NTRS2012

Nuclear Thermal Rocket (Ntr) Propulsion: A Proven Game-Changing Technology for Future Human Exploration Missions

The NTR represents the next evolutionary step in high performance rocket propulsion. It generates high thrust and has a specific impulse (Isp) of approx.900 seconds (s) or more V twice that of today s best chemical rockets. The technology is also proven. During the previous Rover and NERVA (Nuclear Engine for Rocket Vehicle Applications) nuclear rocket programs, 20 rocket reactors were designed, built and ground tested. These tests demonstrated: (1) a wide range of thrust; (2) high temperature carbide-based nuclear fuel; (3) sustained engine operation; (4) accumulated lifetime; and (5) restart capability V all the requirements needed for a human mission to Mars. Ceramic metal cermet fuel was also pursued, as a backup option. The NTR also has significant growth and evolution potential. Configured as a bimodal system, it can generate electrical power for the spacecraft. Adding an oxygen afterburner nozzle introduces a variable thrust and Isp capability and allows bipropellant operation. In NASA s recent Mars Design Reference Architecture (DRA) 5.0 study, the NTR was selected as the preferred propulsion option because of its proven technology, higher performance, lower launch mass, simple assembly and mission operations. In contrast to other advanced propulsion options, NTP requires no large technology scale-ups. In fact, the smallest engine tested during the Rover program V the 25,000 lbf (25 klbf) Pewee engine is sufficient for human Mars missions when used in a clustered engine arrangement. The Copernicus crewed spacecraft design developed in DRA 5.0 has significant capability and a human exploration strategy is outlined here that uses Copernicus and its key components for precursor near Earth asteroid (NEA) and Mars orbital missions prior to a Mars landing mission. Initially, the basic Copernicus vehicle can enable reusable 1-year round trip human missions to candidate NEAs like 1991 JW and Apophis in the late 2020 s to check out vehicle systems. Afterwards, the Copernicus spacecraft and its 2 key components, now configured as an Earth Return Vehicle / propellant tanker, would be used for a short round trip (approx.18 - 20 months)/short orbital stay (60 days) Mars / Phobos survey mission in 2033 using a split mission approach. The paper also discusses NASA s current Foundational Technology Development activities and its pre-decisional plans for future system-level Technology Demonstrations that include ground testing a small (approx.7.5 klbf) scalable NTR before the decade is out with a flight test shortly thereafter.

Borowski, Stanley K.↗
NASA NTRS2012

Materials and Process Activities for NASA's Composite Crew Module

In January 2007, the NASA Administrator and Associate Administrator for the Exploration Systems Mission Directorate chartered the NASA Engineering and Safety Center (NESC) to design, build, and test a full-scale Composite Crew Module (CCM). The overall goal of the CCM project was to develop a team from the NASA family with hands-on experience in composite design, manufacturing, and testing in anticipation of future space exploration systems being made of composite materials. The CCM project was planned to run concurrently with the Orion project s baseline metallic design within the Constellation Program so that features could be compared and discussed without inducing risk to the overall Program. The materials and process activities were prioritized based on a rapid prototype approach. This approach focused developmental activities on design details with greater risk and uncertainty, such as out-of-autoclave joining, over some of the more traditional lamina and laminate building block levels. While process development and associated building block testing were performed, several anomalies were still observed at the full-scale level due to interactions between process robustness and manufacturing scale-up. This paper describes the process anomalies that were encountered during the CCM development and the subsequent root cause investigations that led to the final design solutions. These investigations highlight the importance of full-scale developmental work early in the schedule of a complex composite design/build project.

Polis, Daniel L.↗