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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Connecting to Thermocouples with Fewer Lead Wires

A simple technique has been devised to reduce the number of lead wires needed to connect an array of thermocouples to the instruments (e.g., voltmeters) used to read their output voltages. Because thermocouple wires are usually made of expensive metal alloys, reducing the number of lead wires can effect a considerable reduction in the cost of such an array. Reducing the number of wires also reduces the number of terminals and the amount of space needed to accommodate the wires.

Goldsby, Jon C.↗
NASA NTRS2012

Electromagnetic Nondestructive Evaluation of Wire Insulation and Models of Insulation Material Properties

Polymers have been widely used as wiring electrical insulation materials in space/air-craft. The dielectric properties of insulation polymers can change over time, however, due to various aging processes such as exposure to heat, humidity and mechanical stress. Therefore, the study of polymers used in electrical insulation of wiring is important to the aerospace industry due to potential loss of life and aircraft in the event of an electrical fire caused by breakdown of wiring insulation. Part of this research is focused on studying the mechanisms of various environmental aging process of the polymers used in electrical wiring insulation and the ways in which their dielectric properties change as the material is subject to the aging processes. The other part of the project is to determine the feasibility of a new capacitive nondestructive testing method to indicate degradation in the wiring insulation, by measuring its permittivity.

Bowler, Nicola↗
NASA NTRS2013

Integrated Electrical Wire Insulation Repair System

An integrated system tool will allow a technician to easily and quickly repair damaged high-performance electrical wire insulation in the field. Low-melt polyimides have been developed that can be processed into thin films that work well in the repair of damaged polyimide or fluoropolymer insulated electrical wiring. Such thin films can be used in wire insulation repairs by affixing a film of this low-melt polyimide to the damaged wire, and heating the film to effect melting, flow, and cure of the film. The resulting repair is robust, lightweight, and small in volume. The heating of this repair film is accomplished with the use of a common electrical soldering tool that has been modified with a special head or tip that can accommodate the size of wire being repaired. This repair method can furthermore be simplified for the repair technician by providing replaceable or disposable soldering tool heads that have repair film already "loaded" and ready for use. The soldering tool heating device can also be equipped with a battery power supply that will allow its use in areas where plug-in current is not available

Williams, Martha↗
NASA NTRS2014

A Thermal Analysis of a Hot-Wire Probe for Icing Applications

This paper presents a steady-state thermal model of a hot-wire instrument applicable to atmospheric measurement of water content in clouds. In this application, the power required to maintain the wire at a given temperature is used to deduce the water content of the cloud. The model considers electrical resistive heating, axial conduction, convection to the flow, radiation to the surroundings, as well as energy loss due to the heating, melting, and evaporation of impinging liquid and or ice. All of these parameters can be varied axially along the wire. The model further introduces a parameter called the evaporation potential which locally gauges the maximum fraction of incoming water that evaporates. The primary outputs of the model are the steady-state power required to maintain a spatially-average constant temperature as well as the variation of that temperature and other parameters along the wire. The model is used to understand the sensitivity of the hot-wire performance to various flow and boundary conditions including a detailed comparison of dry air and wet (i.e. cloud-on) conditions. The steady-state power values are compared to experimental results from a Science Engineering Associates (SEA) Multi-Element probe, a commonly used water-content measurement instrument. The model results show good agreement with experiment for both dry and cloud-on conditions with liquid water content. For ice, the experimental measurements under read the actual water content due to incomplete evaporation and splashing. Model results, which account for incomplete evaporation, are still higher than experimental results where the discrepancy is attributed to splashing mass-loss which is not accounted in the model.

Thermal Analysis↗
NASA NTRS2015

Ultrasonic Device for Assessing the Quality of a Wire Crimp

A system for determining the quality of an electrical wire crimp between a wire and ferrule includes an ultrasonically equipped crimp tool (UECT) configured to transmit an ultrasonic acoustic wave through a wire and ferrule, and a signal processor in communication with the UECT. The signal processor includes a signal transmitting module configured to transmit the ultrasonic acoustic wave via an ultrasonic transducer, signal receiving module configured to receive the ultrasonic acoustic wave after it passes through the wire and ferrule, and a signal analysis module configured to identify signal differences between the ultrasonic waves. The signal analysis module is then configured to compare the signal differences attributable to the wire crimp to a baseline, and to provide an output signal if the signal differences deviate from the baseline.

Yost, William T.↗
NASA NTRS2015

Fine-Filament MgB2 Superconductor Wire

Hyper Tech Research, Inc., has developed fine-filament magnesium diboride (MgB2) superconductor wire for motors and generators used in turboelectric aircraft propulsion systems. In Phase I of the project, Hyper Tech demonstrated that MgB2 multifilament wires (<10 micrometers) could reduce alternating current (AC) losses that occur due to hysteresis, eddy currents, and coupling losses. The company refined a manufacturing method that incorporates a magnesium-infiltration process and provides a tenfold enhancement in critical current density over wire made by a conventional method involving magnesium-boron powder mixtures. Hyper Tech also improved its wire-drawing capability to fabricate fine multifilament strands. In Phase II, the company developed, manufactured, and tested the wire for superconductor and engineering current density and AC losses. Hyper Tech also fabricated MgB2 rotor coil packs for a superconducting generator. The ultimate goal is to enable low-cost, round, lightweight, low-AC-loss superconductors for motor and generator stator coils operating at 25 K in next-generation turboelectric aircraft propulsion systems.

Cantu, Sherrie↗
NASA NTRSDate not supplied

Short Circuiting the Controller –Missteps in Maintenance and Inspection of Process and Wiring in STS-93

During the launch of the Chandra X-Ray Observatory in 1999, an in-flight anomaly occurred a few seconds after liftoff. A power fluctuation caused two Main Engine controllers to drop offline. Fortunately, due to redundancy, the Space Shuttle Columbia was able to successfully reach orbit and avoid an abort. After the successful deployment of Chandra and the safe return of the crew, in-vestigation revealed that the controller failure was due to a wire short in the pay-load bay. It was suspected that the Kapton insulation on the wire rubbed off against a burred screw head, the result of overtightening of the screw during a maintenance event 4 to 5 years prior to the STS-93 mission. Vibrations led the abraded wire to short during flight. The Space Shuttle Program was grounded for 4 months while a program-wide inspection and wire chafing mitigation effort of all orbiter wiring ensued.

Kristy S Yun↗
NASA NTRS2024

Preliminary Measurements of Partial Discharge Inception Voltage Degradation with Constant Temperature Aging of Magnet Wire Twisted Pairs for Electric Aircraft Motors

Electric aircraft require high reliability electric motors to meet the stringent safety standards of the aviation industry. Motor winding insulation lifetime and reliability models for electric aircraft applications are needed to enable design of high reliability and high-performance electric motors for aviation applications. Three primary stresses effect the lifetime of motor winding insulation: thermochemical, mechanical, and electrical. This paper presents preliminary experiments on twisted pairs of magnet wire targeting understanding the thermo-chemical degradation of motor winding insulation through constant temperature thermal aging. Three types of magnet wire twisted pairs where tested: polyimide insulated magnet wire, epoxy coated polyimide insulated magnet wire, and epoxy potted polyimide magnet wire. The degradation of the samples over time at temperature was tracked using partial discharge inception voltage measurements. These initial experiments were used for development of procedures and expertise in partial discharge testing and thermo-chemical aging to inform future testing. The preliminary nature of these experiments should be noted when viewing the results. Lessons learned from the experiments are documented.

Thomas Tallerico↗
DOE OSTI2015

Transverse Beam Halo Measurements at High Intensity Neutrino Source (HINS) using Vibrating Wire Monitor

The measurement and control of beam halos will be critical for the applications of future high-intensity hadron linacs. In particular, beam profile monitors require a very high dynamic range when used for the transverse beam halo measurements. In this study, the Vibrating Wire Monitor (VWM) with aperture 60 mm was installed at the High Intensity Neutrino Source (HINS) front-end to measure the transverse beam halo. A vibrating wire is excited at its resonance frequency with the help of a magnetic feedback loop, and the vibrating and sensitive wires are connected through a balanced arm. The sensitive wire is moved into the beam halo region by a stepper motor controlled translational stage. We study the feasibility of the vibrating wire for the transverse beam halo measurements in the low-energy front-end of the proton linac.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Method of fabricating high-density hermetic electrical feedthroughs using insulated wire bundles

A method of fabricating electrical feedthroughs coats of a plurality of electrically conductive wires with an electrically insulating material and bundles the coated wires together in a substantially parallel arrangement. The bundled coated wires are secured to each other by joining the electrically insulating material of adjacent wires together to form a monolithic block which is then cut transverse to the wires to produce a block section having opposing first and second sides with a plurality of electrically conductive feedthroughs extending between them.

36 MATERIALS SCIENCE↗
DOE OSTI2022

System and method for liquid crystal display system incorporating wire grid polarizers for large scale and large volume stereolithography

The present disclosure relates to a liquid crystal display (LCD) system. The system in one example has a light source for generating unpolarized light, and an LCD screen arranged in a path of transmittance of the unpolarized light. First and second wire grid polarizers are arranged adjacent to the LCD screen and each have a plurality of nano-scale wires, with the first and second wire grid polarizers have differing polarizations. A pitch of each of the nano-scale wires is no larger than one-third a wavelength of the unpolarized light from the light source. The wire grid polarizers create, in connection with operation of the LCD screen, a 2D light mask suitable for initiating the polymerization of an optically curable material.

Duoss, Eric B.↗
DOE OSTI2023

Superconducting wires for quench detection

A superconducting device includes a first superconducting wire configured to carry a first current in a superconducting state, and to generate thermal energy upon occurrence of a hot spot during conduction. The device includes a second superconducting wire, thermally coupled to and electrically isolated from the first superconducting wire. The second superconducting wire is configured to conduct a second current in a superconducting state below, but sufficiently near its critical surface to be quenched to a non-superconducting state upon conduction of the thermal energy from the first superconducting wire.

Van Der Laan, Daniel Cornelis↗
DOE OSTI2024

Modernizing the Legacy Fission Wire Measurement System for the Advanced Test Reactor-Critical Facility

Operational lifetime extensions of existing research reactors have emphasized the need for refurbishment, replacements, and upgrades to supporting equipment and instrumentation. The Advanced Test Reactor (ATR) at Idaho National Laboratory (INL), which entered service in 1967, has recently completed the sixth core internals change-out and has scheduled operations until at least 2040. Reactor maintenance and operational risk management is critically important in the research reactor community, however supporting measurement systems sometimes get overlooked when maintenance is planned. The Fission Wire Measurement System (FWMS) is a custom measurement system designed in the 1960s to measure the beta-particle activity of irradiated uranium-aluminum fission wires. This measurement is conducted to determine the fission rate profile of the Advanced Reactor Test Critical (ATR-C) facility. The ATR-C is an open-pool, low-power test reactor that was purpose driven to resemble ATR and is used to qualify experiment configurations and verify core models prior to full-power experiment irradiations in ATR. A power distribution measurement in ATR-C uses uranium-aluminum wires that are distributed throughout the ATR-C core to validate simulation and modeling results. These measurements require 340 to 1500 wires to be irradiated and measured within a 12-hour window. The activity of the wires is measured in the required time with the FWMS, which was put into service in 1965 at the Radiation Measurements Laboratory (RML). The system consists of 4 measurement channels and one reference channel, each with a 2-pi proportional gas flow detector and the measurement channels each have an automated sample changer. This legacy system is crucial to the continued operations of ATR and has undergone some minor hardware upgrades since 1965, however the system presently relies on custom control boards, custom gas ion chambers, analog amplifiers/discriminators, and a user interface (UI) for the system written in outdated code. Much of the equipment and software is custom with no commercial replacements or support and limited documentation. The existing control software requires an operating system that is no longer supported, creating more vulnerabilities to continued operations. A project is underway with a third-party vendor to design, build, and document a new control and data acquisition system (CDAS) for the FWMS. The new upgrade will replace the control system, computer, UI, sample changer motors, and main power supply while maintaining the interface with existing detector hardware. The upgraded system will be operated in parallel with the current hardware and software to conduct validation testing. This equipment upgrade demonstrates the commitment at ATR to ensuring successful operations and potential future research reactors at INL.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2020

An experimental investigation of the effectiveness of Ar-CO 2 shielding gas mixture for the wire arc additive process

Wire arc additive manufacturing (AM) is the process by which a large, metallic structure is built layer-by-layer using a welding arc to melt a wire feedstock. A novel opportunity exists to alter the shielding gas composition to fabricate distinct geometrical features without altering the other AM parameters. In this paper, shielding gases with varied concentrations of Argon (Ar) and CO 2 was used to deposit three distinct geometric shapes (walls, infill, and overhang) using a wire-based additive manufacturing system utilizing the gas metal arc welding (GMAW) surface tension transfer (STT) process. Computer-aided design (CAD) models were sliced with a custom-built slicer, and the sliced algorithm was converted into optimal robotic toolpaths. A custom virtual instrument (VI) was built in LabVIEW to compare the temperature profiles on the surface during each deposition process. After each deposition, the geometric features were scanned, and the surface waviness value was evaluated. Tensile and Charpy impact coupons were extracted from the wall geometries in the longitudinal and transverse directions and tested. The results indicated that a higher CO 2 content produced higher melt pool temperatures to an extent, while lower contents of CO 2 resulted in a dimensionally accurate geometry. The data also indicated that the 2%/98% CO 2 /Ar blend produced scatter in tensile strength and the analysis of variance (ANOVA) shows significant difference. However, the intermediate range of CO 2 (5–10%) resulted in uniform tensile properties. Altogether, these results indicate that a 5%/95% CO 2 /Ar blend is the ideal shielding gas for lowering process temperatures and improving mechanical properties in wire arc additive manufacturing using the gas metal arc welding surface tension transfer process. Additionally, varying concentrations of Ar/CO 2 can be used within the same part in order to modify the local properties or process parameters such as strength, toughness, temperature, or dimensional features. This may improve overall manufacturing quality without sacrificing specific properties.

42 ENGINEERING↗
DOE OSTI2018

Monofilamentary In Situ Fe/MgB{sub 2} Superconducting Wires Fabricated by Pellet-in-Tube Method

Thin monofilamentary Fe/MgB{sub 2} superconducting wires without barriers are investigated by means of electrical transport measurements and surface and structural analysis methods. Small diameter wires are fabricated by pellet-in-tube method (PeIT) to obtain a high uniform initial filling density and heat treated as a function of various sintering temperatures and times. The results are discussed in terms of the grain connectivity, Fe{sub 2}B phase formation, and the relation between wire diameter and sintering conditions. We suggest that PeIT has a crucial importance to achieve homogeneous initial filling density, which leads to the fabrication of uniform long-length MgB{sub 2} wires.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Influence of Bias Current on Off-Diagonal Magnetoimpedance in Composite Wires

The off-diagonal magnetoimpedance in a composite wire consisting of a highly conductive inner core covered by a soft magnetic layer is studied theoretically. In the presence of bias current, the field dependence of the off-diagonal magnetoimpedance becomes asymmetric due to the combination of the circular magnetic field produced by the bias current and a helical anisotropy in the magnetic layer of the composite wire. The dependences of the asymmetric off-diagonal magnetoimpedance on the external field, frequency, and bias current are investigated. It is demonstrated that the off-diagonal magnetoimpedance in composite wires has high field sensitivity and exhibits nearly linear behavior at low external fields. The influence of the wire parameters such as the anisotropy axis angle, the magnetic layer thickness, and conductivity on the field sensitivity of the off-diagonal magnetoimpedance is analyzed. The results obtained may be useful for development of weak magnetic-field sensors.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Customized MgB{sub 2} Superconducting Wire Toward Practical Applications at Sam Dong in Korea

MgB{sub 2} superconducting wire from Sam Dong Co., Ltd. in Korea is suitable for various applications, including medical resonance imaging, fault current limiters, power cables, and transformers. So far, issues related to the wire production cost, current-carrying capacity, and conductor length (kilometers) are very important for further commercialization. Since 2014, our intensive research efforts have led to notable progress. Herein, we summarize and discuss our advanced research for achieving high-performance, scalable, and cost-effective MgB{sub 2} wires at Sam Dong. Based on our accumulated technical know-how, we will continue to fabricate more competitive and efficient MgB{sub 2} superconducting wires that will be suitable for the customer’s purposes.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Simulating the effects of underground nuclear explosions with an exploding wire

Exploding wires can deposit significant amounts of energy (1000’s of Joules on a nano-microsecond timescales) into a very confined space. Under the right conditions they can even produce neutrons. While most exploding wire studies have been performed in open air and to a lesser extent liquids we have started to investigate enclosing the wire element in solid matrices like concrete to mimic the effects of an underground nuclear explosion. The temperatures and pressures achieved are quite sufficient to induce structural cracking and localized flash melting in the enclosing media like a real underground nuclear detonation. As a result exploding wires would appear to form the perfect trigger for releasing confined chemical species including gases in geological media to study migration behavior in a controlled environment. Details of the apparatus and some illustrations of it potential will be given.

Underground Nuclear Explosions, Exploding Wires, X↗