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NASA NTRSDate not supplied

Thin-wall Internal Channel Geometry and Surface Enhancements for Heat Exchangers using Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations, surface texture, and post-processing surface enhancements for specific application requirements. One possible application area of AM are components using thin-wall (~1 mm) microchannel heat exchangers for subsystems across aerospace and industrial applications. Laser Powder Bed Fusion (L-PBF) is a common process for complex internal channels but the build diameter is limited to approximately 600 mm. Laser Powder Directed Energy Deposition (LP-DED) is being evaluated to produce thin-wall microchannel heat exchangers at scales beyond the L-PBF process. Successful deployment of the LP-DED technology requires characterization of geometric features from the process and potential improvements to the surface using post-processing. Surface texture, inclusive of roughness and waviness, is one of the critical attributes of AM that effects the friction factor and pressure drop within a heat exchanger and lacks data for the LP-DED process. This presentation will provide an overview of the characterization work completed of the LP-DED process for thin-walls and small channel geometry representative of various high performance alloys including NASA HR-1 and GRCop-42. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various internal channel geometry, geometric build features, and resulting surface texture will be provided along with a summary of conclusions from these experiments. This study presents characterization of 2.5 mm microchannels using LP-DED, mechanisms that cause the surface texture which include powder adherence and material droop, and angled walls have a significant impact on the thickness and surface texture. Results will also be presented on various surface enhancement processes that allow for tuning of the wetting surface for friction factor, heat transfer, or fatigue life performance requirements.

Additive Manufacturing↗

NASA NTRS2004

A Comparison of Transportation Systems for Human Missions to Mars

There are many ways to send humans to Mars. Credible technical reports can be traced to the 1950's. More recently, NASA has funded major studies that depict a broad variety of trajectories, technologies, stay times, and costs. Much of this data is still valid with direct application to today's exploration planning. This paper presents results comparing these studies with particular emphasis on the in-space transportation aspects of the mission. Specifically, comparisons are made on propulsion systems used for getting the crew and mission equipment from Earth orbit to Mars orbit, descending and ascending from the surface, and returning to Earth orbit. Areas of comparison for each of these phases include crew size, mission mass, propellant mass, delta v, specific impulse, transit time, surface stay time, aero-braking, and others. Data is analyzed to demonstrate either strong trends toward particular technologies or diverging solutions.

Bipropellants↗

NASA NTRS1976

Monitoring of environmental effects of coal strip mining from satellite imagery

This paper evaluates satellite imagery as a means of monitoring coal strip mines and their environmental effects. The satellite imagery employed is Skylab EREP S-190A and S-190B from SL-2, SL-3 and SL-4 missions; a large variety of camera/film/filter combinations has been reviewed. The investigation includes determining the applicability of satellite imagery for detection of disturbed acreage in areas of coal surface mining as well as the much more detailed monitoring of specific surface-mining operations, including: active mines, inactive mines, highwalls, ramp roads, pits, water impoundments and their associated acidity, graded areas and types of grading, and reclamed areas. Techniques have been developed to enable mining personnel to utilize this imagery in a practical and economic manner, requiring no previous photo-interpretation background and no purchases of expensive viewing or data-analysis equipment. To corroborate the photo-interpretation results, on-site observations were made in the very active mining area near Madisonville, Kentucky.

Brooks, R. L.↗

DOE OSTI2020

Modeling of SRS Aluminum-clad Spent Nuclear Fuel in Standard DOE Sealed Canisters

At the Savannah River Site (SRS), approximately 7 MTHM of aluminum-clad spent nuclear fuel is currently in wet storage at L-basin. A significant portion of this fuel is slated to be dried and sealed in DOE standard canisters for long-term storage. This report will focus on a few fuel types, which should bound all other fuel stored at SRS. These consist of the reference fuel assembly, the MURR fuel and the HFIR fuel. These bound a hypothetical maximum scenario for MTR box fuel, a maximum for decay heat in an assembly, and a maximum for the aluminum surface area, respectively. The geometry for the packages were created from DOE specifications for storage of each of the fuels. As long as the minimum time from reactor discharge to sealed storage is 3 years, then the highest temperatures which occur within the sealed canisters do not exceed 100° C for all scenarios considered here. In the geometry considered, while the HFIR fuel has a large surface area, the packaging configuration leaves large void areas, such that the aluminum surface to free volume ratio is about 30% less than an ATR or MURR packaging configuration.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1992

Comparison of surface fluxes and conductances at two contrasting sites within the FIFE area

Surface flux measurements from two contrasting sites within the FIFE study area are analyzed. The seasonal variation of midday latent heat fluxes and surface conductances at the two sites was found to be very similar even though the ratio of their average total leaf area indices was greater than two to one. Concurrent measurements made at another six flat sites within the FIFE area confirmed the independence of latent heat flux with respect to leaf area index. The surface conductance stress function related to specific humidity deficit was the same for the two sites, whereas the solar radiation stress function showed a difference of 30 percent at a solar radiation input of 300 W/sq m and the soil moisture stress function showed a difference of 16 percent when half the extractable soil moisture had been taken up. However, when the stress functions were combined to determine the surface conductance, these differences virtually canceled out.

Stewart, J. B.↗

NASA NTRS2007

NASA CEV Reference GN&C Architecture

The Orion Crew Exploration Vehicle (CEV) will be the first human spacecraft built by NASA in almost 3 decades and will be the first vehicle to perform both Low Earth Orbit (LEO) missions and lunar missions since Apollo. The awesome challenge of designing a Guidance, Navigation, and Control (GN&C) system for this vehicle that satisfies all of its various mission requirements is countered by the opportunity to take advantage of the improvements in algorithms, software, sensors, and other related GN&C technology over this period. This paper describes the CEV GN&C reference architecture developed to support the overall NASA reference configuration and validate the driving requirements of the Constellation (Cx) Architecture Requirements Document (CARD, Reference 1) and the CEV System Requirements Document (SRD, Reference 2). The Orion GN&C team designed the reference architecture based on the functional allocation of GN&C roles and responsibilities of CEV with respect to the other Cx vehicles, such as the Crew Launch Vehicle (CLV), Earth Departure Stage (EDS), and Lunar Surface Area Module (LSAM), across all flight phases. The specific challenges and responsibilities of the CEV GN&C system from launch pad to touchdown will be introduced along with an overview of the navigation sensor suite, its redundancy management, and flight software (FSW) architecture. Sensors will be discussed in terms of range of operation, data utility within the navigation system, and rationale for selection. The software architecture is illustrated via block diagrams, commensurate with the design aspects.

Tamblyn, Scott↗

NASA NTRS2014

The Situational Awareness Sensor Suite for the ISS (SASSI): A Mission Concept to Investigate ISS Charging and Wake Effects

The complex interaction between the International Space Station (ISS) and the surrounding plasma environment often generates unpredictable environmental situations that affect operations. Examples of affected systems include extravehicular activity (EVA) safety, solar panel efficiency, and scientific instrument integrity. Models and heuristically‐derived best practices are well‐suited for routine operations, but when it comes to unusual or anomalous events or situations, especially those driven by space weather, there is no substitute for real‐time monitoring. Space environment data collected in real‐time (or near‐real time) can be used operationally for both real‐time alarms and data sources in assimilative models to predict environmental conditions important for operational planning. Fixed space weather instruments mounted to the ISS can be used for monitoring the ambient space environment, but knowing whether or not (or to what extent) the ISS affects the measurements themselves requires adequate space situational awareness (SSA) local to the ISS. This paper presents a mission concept to use a suite of plasma instruments mounted at the end of the ISS robotic arm to systematically explore the interaction between the Space Station structure and its surrounding environment. The Situational Awareness Sensor Suite for the ISS (SASSI) would be deployed and operated on the ISS Express Logistics Carrier (ELC) for long‐term "survey mode" observations and the Space Station Remote Manipulator System (SSRMS) for short‐term "campaign mode" observations. Specific areas of investigation include: 1) ISS frame and surface charging during perturbations of the local ISS space environment, 2) calibration of the ISS Floating Point Measurement Unit (FPMU), 3) long baseline measurements of ambient ionospheric electric potential structures, 4) electromotive force-induced currents within large structures moving through a magnetized plasma, and 5) wake‐induced ion waves in both electrostatic (i.e. particles) and electromagnetic modes. SASSI will advance the understanding of plasma‐boundary interaction phenomena, demonstrate a suite a sensors acting in concert to provide effective SSA, and validate and/or calibrate existing ISS space environment instruments and models.

Krause, L. Habash↗

DOE OSTI2020

Advanced modeling of field enhanced thermionic emission

Shaped emitters are of interest to a broad range of applications in vacuum electronic devices. In particular, thermionic energy converters (TECs) take advantage of shaped emitters to increase the local surface field, thereby extracting more current for a given cathode temperature and applied voltage. However, modeling these devices is challenging; Warp [J.-L. Vay, D. P. Grote, R. H. Cohen, and A. Friedman, Comput. Sci. Discov. 5, 014019 (2012)] is a fully 3D particle-in-cell code capable of handling a wide range of physics problems and is well suited to modeling TECs. Additionally, recent improvements to Warp have enabled the accurate modeling of emitters with arbitrary curved surfaces. Specifically, the inclusion of subgrid resolution for computing the electrostatic potential and the ability to apply mesh refinement for specific areas of interest allow for a more accurate solution to the fields on these surfaces. These improvements coupled with Warp’s ability to handle variable particle weights make it an ideal candidate for simulating these complex devices. In this paper, the authors study the applicability of different subgrid configurations for simulating shaped emission surfaces and field convergence for different mesh-refinement techniques. They then implement a custom weighting algorithm that allows for uniform sampling of emission surfaces with a large variation in the surface electric field. They then use this algorithm to study emission for curved emitters in both the field-enhancement regime and the space-charge regime.

Edelen, Jonathan P. (ORCID:0000000215180652)↗

NASA NTRSDate not supplied

Experimental Characterization of Surface Roughness and Geometric Evaluations of Thin-Wall Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations and surface roughness based on specific application requirements. One possible application area of AM are components using thin-wall (<2 mm) microchannel heat exchangers for subsystems across aerospace, and industrial applications. AM offers the opportunity to significantly reduce the cost and lead time associated with fabricating these complex parts with internal features such as an array of cooling channels. Laser Powder Bed Fusion (L-PBF) has been continuously demonstrated as a technique to fabricate heat exchangers with internal geometric complexities. However, L-PBF is limited in the scale at which parts can be fabricated. Laser Powder Directed Energy Deposition (LP-DED) has been demonstrated as an AM technology to significantly increase the scale of which thin-wall microchannel heat exchangers could be manufactured. Successful deployment of the LP-DED technology requires critical understanding of the resulting features from the build process. Surface roughness is one of the critical areas that effects the friction factor and pressure drop within a heat exchanger and must be well understood. This presentation will provide an overview of the characterization work completed to understand the LP-DED process for thin-walls representative of hydrogen resistant alloy NASA HR-1 that would be used in a Hydrogen-environment application. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various geometric channel and geometric build features and resulting surface finish will be provided along with a summary of conclusions from these experiments. Results indicate that powder size is a major contributor and surface roughness varies between closed channel shapes and external surfaces.

Directed Energy Deposition↗

DOE OSTI2022

Development and Applications of an eReaxFF Force Field for Graphitic Anodes of Lithium-Ion Batteries

Graphene is one of the most promising materials for lithium-ion battery anodes due to its superior electronic conductivity, high surface area for lithium intercalation, fast ionic diffusivity and enhanced specific capacity. A reliable description of many battery processes requires an explicit description of electrochemical interactions involving electrons. A detailed atomistic modeling of electronic conduction and non-zero voltage simulations of graphitic materials require the inclusion of an explicit electronic degree of freedom. To enable large length- and time-scale simulations of electron conduction in graphitic anodes, we developed an eReaxFF force field concept describing graphitic materials with an explicit electron. The newly developed force field, verified against quantum chemistry-based data describing, amongst others, electron affinities and equation of states, reproduces the qualitative behavior of electron conductivity in pristine and imperfect graphitic materials at different applied temperatures and voltages. In addition, excess electron localization near a defect site estimated from eReaxFF simulations agree quite well with the corresponding density functional theory calculations. Here, our eReaxFF simulations show the initiation of lithium-metal-plating driven by electron transfer from the graphene surface to the exposed lithium ions demonstrating the method’s potential for studying lithium-graphene interactions with explicit electrons and explain many unresolved electrode and electrode-electrolyte interface processes.

25 ENERGY STORAGE↗

NASA NTRS2023

Lunar Dust Mitigation: A Guide and Reference: First Edition (2021)

On the surface of the Moon, lunar dust specifically presents unique challenges to operations long-term due to regolith particles’ ubiquitous presence in the lunar environment, potential to electrostatically charge and possible chemical reactivity. Whether to avoid exposure, try to remove or simply to tolerate lunar dust infiltrating a system becomes a complex question involving length of required service life, dust effects and critical risks, mass and complexity trades for the entire system. This publication provides a snapshot of advice from topical experts for specific areas of concern to systems targeted for deployment on the lunar surface. Following introductory overview commentary, dust mitigation approaches appropriate to the lunar surface are first addressed for typically static structures such as optical surfaces, radiators, and other thermal control surfaces, followed by regolith exposure concerns for communications equipment and non-optical sensors. The broad topic of mechanisms and mechanical assemblies is broken down to address relevant component level concerns, such as for bearings and for seals. “Soft goods” components of space suits (fabric) specific concerns are discussed, followed finally by brief coverage of human health issues and concerns, though the emphasis of this publication remains with components directly exposed to the harsh lunar surface environment. A description of some lunar surface hazard details, in particular characteristics of lunar surface dust, follows in Appendix A, and more detailed explanations of quantification issues for particulates are in Appendix B. The simple inertial removal of particles from a surface is discussed in Appendix C, followed by a summary of terrestrial best practices for dust mitigation recommended within select industries in Appendix D. The aggregated bibliography of references, while extensive and very useful, should not be construed to be exhaustive and can serve as a constructive start.

dust↗

NASA NTRS1986

Application of laser-velocimetry to the study of the flow around a two-dimensional airfoil

The experimental techniques employed by NASA researchers to obtain a high volume throughput of data in a study of high-lift multielement airfoils using a laser velocimeter (LV) are detailed. The two-dimensional LV system recorded mean velocity, turbulence intensities, Re shear stresses, skewness and kurtosis of the flow. A computer-controlled positioning mount for the LV allowed automated surveys of the flows with a 0.001 in. positioning accuracy. The flow was seeded with oil droplets and additional refinement of the wind tunnel controls permitted rapid speedup at selected areas of the flowfield over specific regions of the airfoil. Surface pressure taps furnished data for selecting regions for more detailed investigation. The data processing capabilities processed 30-40 samples every 10 min in an automated mode. Profiles of the data were computed automatically to furnish graphical displays on demand. Numerous samples of the data displays generated are provided.

Braden, J. A.↗

NASA NTRS1989

Measurement of the effects of particulate contamination on X-ray reflectivity

Because particles of sizes larger than a few tenths microns adversely affect high resolution X-ray telescopes by scattering and absorbing X-rays, the cleanliness required to maintain the about 1 percent overall calibration precision desired for the Advanced X-ray Astrophysics Facility (AXAF) is being investigated. At the grazing angles used for the AXAF mirrors, each particle shadows a surface area about 100 times its geometric area, necessitating glass occlusion specifications much more stringent than typically stipulated for visible-light particulate contamination. On test flats coated with gold, controlled levels of contamination have been deposited spanning the range from 5 x 10 to the -5th to 0.005 fractional area covered, and the absorption component of extinction has been measured over a range of grazing angles and X-ray energies to verify the predicted effects of particulate contamination.

Slane, P.↗

NASA NTRS2001

Materials Compatibility Testing in RSRM ODC: Free Cleaner Selection

Government regulations have mandated production phase-outs of a number of solvents, including 1,1,1-trichloroethane, an ozone-depleting chemical (ODC). This solvent was used extensively in the production of the Reusable Solid Rocket Motors (RSRMs) for the Space Shuttle. Many tests have been performed to identify replacement cleaners. One major area of concern in the selection of a new cleaner has been compatibility. Some specific areas considered included cleaner compatibility with non-metallic surfaces, painted surfaces, support materials such as gloves and wipers as well as corrosive properties of the cleaners on the alloys used on these motors. The intent of this paper is to summarize the test logic, methodology, and results acquired from testing the many cleaner and material combinations.

Keen, Jill M.↗

NASA NTRSDate not supplied

Numerical Investigation of Combustor-Turbine Interactions with a Two-Stage High-Pressure Turbine Including Cooling Airflows

Combustor–turbine interactions (CTIs) are investigated by performing three-dimensional unsteady simulations using a realistic combustor and high-pressure turbine (HPT) configurations from the Energy Efficient Engine (E3) program. To understand CTIs, we compare the numerically predicted flow fields from single-component simulations (Step 1: the combustor + the first-stage stator of turbine; Step 2: the two-stage HPT imposing the time-averaged flow solution from Step 1 as the inflow boundary condition) and a fully coupled combustor–turbine simulation (Step 3) at the sea-level takeoff (SLTO) condition. In addition to three previous simulations where the cooling airflows inside the HPT had been neglected for all Step 1, Step 2, and Step 3, two new simulations of Step 2 and Step 3 take into account the cooling airflows using the source team approach. In this approach, to mimic the cooling airflows, we impose the source term at a specific area of a cooling airflow hole at the solid surfaces without making a mesh of each hole. The objective of this study is twofold. One is to investigate the effect of the presence of the cooling airflows on the aerodynamics of the combustor and HPT as well as the HPT performance. The second is to perform a detailed comparison among the calculated flowfields by two different numerical schemes, the central-difference with the standard Jameson–Schmidt–Turkel (CD-JST) scheme and the AUSM scheme. There is a noticeable difference in the hot-streak distributions at the first-stage stator. In addition, depending on the choice of the numerical scheme and the presence of the cooling airflows, an occurrence of shock waves appearing at the first-stage stator is greatly influenced. Thus, this has a noticeable impact on the HPT performance. It is shown that the estimated turbine efficiencies from Step 3 are about 7 % less than the ones from Step 2.

Combustor-turbine interaction↗

NASA NTRS2004

Determination of Aromatic Ring Number Using Multi-Channel Deep UV Native Fluorescence

The in situ detection of organic material on an extraterrestrial surface requires both effective means of searching a relatively large surface area or volume for possible organic carbon, and a more specific means of identifying and quantifying compounds in indicated samples. Fluorescence spectroscopy fits the first requirement well, as it can be carried out rapidly, with minimal or no physical contact with the sample, and with sensitivity unmatched by any other organic analytical technique. Aromatic organic compounds with know fluorescence signatures have been identified in several extraterrestrial samples, including carbonaceous chondrites, interplanetary dust particles, and Martian meteorites. The compound distributions vary among these sources, however, with clear differences in relative abundances by number of aromatic rings and by degree of alkylation. This relative abundance information, therefore, can be used to infer the source of organic material detected on a planetary surface.

Bhartia, R.↗

NASA NTRS2014

Automatic Aircraft Collision Avoidance System and Method

The invention is a system and method of compressing a DTM to be used in an Auto-GCAS system using a semi-regular geometric compression algorithm. In general, the invention operates by first selecting the boundaries of the three dimensional map to be compressed and dividing the three dimensional map data into regular areas. Next, a type of free-edged, flat geometric surface is selected which will be used to approximate terrain data of the three dimensional map data. The flat geometric surface is used to approximate terrain data for each regular area. The approximations are checked to determine if they fall within selected tolerances. If the approximation for a specific regular area is within specified tolerance, the data is saved for that specific regular area. If the approximation for a specific area falls outside the specified tolerances, the regular area is divided and a flat geometric surface approximation is made for each of the divided areas. This process is recursively repeated until all of the regular areas are approximated by flat geometric surfaces. Finally, the compressed three dimensional map data is provided to the automatic ground collision system for an aircraft.

Skoog, Mark↗

NASA NTRS1995

Approaches for averaging surface parameters and fluxes over heterogeneous terrain

Successful prediction of possible climate change depends on realistic parameterization of land surface processes in climate models. Such parameterizations must take appropriate account of the heterogeneities that are found in most earth surfaces. In this study, different averaging strategies for aggregating patch-scale heterogeneities to scales that are appropriate for mesoscale and climate model grids have been explored. A simple model for estimating area-average 'effective' surface flux parameters is evaluated. The model satisfies the energy balance equation and leads to a set of relationships between local and effective parameters in the governing equations for the surface energy balance. One outcome is that the resulting effective surface temperature is not a simple area-weighted average of component temperatures, but is a function of a specific combination of different resistances of the individual surface elements. A set of heterogeneous surfaces has been simulated to study the effective fluxes obtained using the described model. A comparison with results obtained by other investigators using different averaging methods is also performed.

Chehbouni, A.↗