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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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Major accomplishments for the months of January, February and March 2020 in the fields of Fuels Development Qualification, High Temperature Materials Development, Graphite and GRC Modeling and Validation.
Laser metal additive manufacturing technologies enable the fabrication of geometrically and compositionally complex parts unachievable by conventional manufacturing methods. However, the certification and qualification of additively manufactured parts are greatly hindered by the stochastic melt flow instabilities intrinsic to the process, which has not been explicitly revealed by direct observation. Here, we report the mechanisms of the melt flow instabilities in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-resolution synchrotron X-ray imaging. Here we identified powder/droplet impact, significant keyhole oscillation, and melting-mode switching as three major mechanisms for causing melt flow instabilities. We demonstrated the detrimental consequences of these instabilities brought to the process, and presented new understanding on the melt flow evolution and keyhole oscillation. This work provides critical insights into process instabilities during laser metal additive manufacturing, which may guide the development of instability mitigation approaches. The results reported here are also important for the development and validation of high-fidelity computational models.
This is a qualification report for the high-temperature irradiation-resistant thermocouple (HTIR-TC) developed by Nuclear Energy Enabling Technologies Advanced Sensors and Instrumentation program. Utilizing the Advanced Gas Reactor (AGR) 5/6/7 test conducted in the Advanced Test Reactor (ATR) at Idaho National Laboratory, the HTIR-TCs measured temperatures upwards of 1500°C during accident conditions. The HTIR TCs are thus qualified to perform and withstand an 18-month refueling cycle typical of nuclear power plants at the normal operating temperature, with a drift of less than ±1%. The HTIR-TC is also qualified for incorporating into a test fixture during new fuels tests.
Existing robotic rover technologies at Sandia National Laboratories (SNL) can be applied toward the realization of a robotic lunar rover mission in the near term. Recent activities at the SNL-RVR have demonstrated the utility of existing rover technologies for performing remote field geology tasks similar to those envisioned on a robotic lunar rover mission. Specific technologies demonstrated include low-data-rate teleoperation, multivehicle control, remote site and sample inspection, standard bandwidth stereo vision, and autonomous path following based on both internal dead reckoning and an external position location update system. These activities serve to support the use of robotic rovers for an early return to the lunar surface by demonstrating capabilities that are attainable with off-the-shelf technology and existing control techniques. The breadth of technical activities at SNL provides many supporting technology areas for robotic rover development. These range from core competency areas and microsensor fabrication facilities, to actual space qualification of flight components that are designed and fabricated in-house.
FY-92 accomplishments centered on conceptual design and analyses for 25, 50, and 75 K engines with emphasis on the 50 K engine. During the first period of performance, flow and energy balances were prepared for each of these configurations and thrust-to-weight values were estimated. A review of fuel technology and key data from the Rover/NERVA program established a baseline for proven reactor performance and areas of enhancement to meet near-term goals. Studies were performed of the criticality and temperature profiles for probable fuel and moderator loadings for the three engine sizes, with a more detailed analysis of the 50 K size. During the second period of performance, analyses of the 50 K engine continued. A chamber/nozzle contour was selected and heat transfer and fatigue analyses were performed for likely construction materials. Reactor analyses were performed to determine component radiation heating rates, reactor radiation fields, water immersion poisoning requirements, temperature limits for restartability, and a tie-tube thermal analysis. Finally, a brief assessment of key enabling technologies was made, with a view toward identifying development issues and identification of the critical path toward achieving engine qualification within 10 years.
Two 22-cells 19Ah Nickel-Hydrogen (Ni-H2) Single Pressure Vessel (SPV) Qual batteries, one each from EPI/Joplin and EPI/Butler, were designed and procured. The two batteries differ in the cell encapsulation technology, stack preload, and activation procedure. Both the Butler and Joplin batteries met the specified requirements when subjected to qualification testing and completed 2100 and 1300 LEO cycles respectively, with nominal performance. This paper discusses advantages, design features, testing procedures, and results of the two single pressure vessel Ni-H2 batteries.
The Ohio Aerospace Institute and the NASA Lewis Research Center are designing and building a solar-cell calibration facility, the Photovoltaic Engineering Testbed (PET) to fly on the International Space Station to test advanced solar cell types in the space environment. A wide variety of advanced solar cell types have become available in the last decade. Some of these solar cells offer more than twice the power per unit area of the silicon cells used for the space station power system. They also offer the possibilities of lower cost, lighter weight, and longer lifetime. The purpose of the PET facility is to reduce the cost of validating new technologies and bringing them to spaceflight readiness. The facility will be used for three primary functions: calibration, measurement, and qualification. It is scheduled to be launched in June of 2002.
Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heat shield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heat shield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heat shield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (>2000 W/sq. cm heat flux and >2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heat shield for Extreme Entry Environments (HEEET). Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions. Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions. Examples include: (1) Bounding aeroheating parameters (heat flux, pressure, shear and enthalpy) in ground facilities. How to certify TPS if environments can't be bounded or aeroheating parameters can't be simultaneously achieved. (2) Higher uncertainties in ground test environments (facility calibration and analytical predictions) at extreme conditions. (3) Testing in flows similar to planetary atmosphere composition (H2/He for Gas and Ice Giants). (4) Test sample size limitations for qualifying seam designs. (5) Lack of computational tools capable of simulating all significant aspects of TPS performance (including initiation and propagation of failures). This presentation will provide recommendations on how the EDL community can address these challenges and mitigate some of the risks involved in flying TPS materials at extreme conditions. Examples include: (1) Dedicated activity to understanding TPS failure modes. Develop computational tools capable of modelling fluid interaction with material's thermostructural response. Validate these tools through failure testing. A better understanding of failure mechanisms may eliminate the need to fully bound all aeroheating parameters in ground testing. (2) Enhancements to current testing facilities to simulate flight-like ablation mechanism (ex. testing in Nitrogen at Ames Interaction Heating Facility to limit oxidation in favor of more sublimation). (3) Improved characterization of test conditions with new diagnostic methods and determination of environment uncertainty through rigorous statistical analysis of available data. (4) Design margin policies that are directly tied to uncertainties in ground test environments and modelling fidelity
Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heatshield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heatshield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heatshield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (>2000 W/cm2 heat flux and >2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heatshield for Extreme Entry Environments (HEEET) [1]. Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions.Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions.
Historically, graphite has been used in numerous reactor technologies, including research/test reactors and, commercially, in advanced gas reactors. These non-metallic materials can play a key role as internal core structures, reflectors, or neutron moderators, making them important for deployment of certain advanced reactor technologies. This report explores the industry readiness for graphite material deployment, documenting Codes and Standards applicable to their design, qualification, and manufacturing. Discussions also examine the manufacturing processes, aging/degradation, inspection techniques, and disposal options. The report covers the current status, documents gaps, and proposes some conclusions about approaches to managing some of the current gaps.
The NASA's Evolutionary Xenon Thruster (NEXT) program is developing the next-generation ion propulsion system with significant enhancements beyond the state-of-the-art to provide future NASA science missions with enhanced capabilities at a low total development cost. A Long-Duration Test (LDT) was initiated in June 2005, to verify the NEXT propellant throughput capability to a qualification-level of 450 kg, 1.5 times the anticipated throughput requirement of 300 kg per thruster based on mission analyses. As of September 2, 2009, the thruster has accumulated 24,400 hr of operation with extensive durations at the following input powers: 6.9, 4.7, 1.1, and 0.5 kW. The thruster has processed 434 kg of xenon, surpassing the NASA Solar Technology Application Readiness (NSTAR) program thruster propellant throughput demonstrated during the extended life testing of the Deep Space 1 flight spare ion thruster and approaching the NEXT development qualification throughput goal of 450 kg. The NEXT LDT has demonstrated a total impulse of 16.1 10(exp 6zzz0 N s; the highest total impulse ever demonstrated by an ion thruster. A reduction in neutralizer flow margin has been the only appreciable source of thruster performance degradation. The behavior of the neutralizer is not easily predicted due to both erosion and deposition observed in previous wear tests. Spot-to-plume mode transition flow data and in-situ erosion results for the LDT neutralizer are discussed. This loss of flow margin has been addressed through a combination of a design change in the prototype-model neutralizer to increase flow margin at low emission current and to update the NEXT throttle table to ensure adequate flow margin as a function of propellant throughput processed. The new throttle table will be used for future LDT operations. The performance of the NEXT LDT neutralizer is consistent with that observed for long-life hollow cathodes. The neutralizer life-limiting failure modes are progressing as expected and the neutralizer data indicate none of the neutralizer failures are imminent.
Studies over the last decade have shown radioisotope-based nuclear electric propulsion to be enhancing and, in some cases, enabling for many potential robotic science missions. Also known as radioisotope electric propulsion (REP), the technology offers the performance advantages of traditional reactor-powered electric propulsion (i.e., high specific impulse propulsion at large distances from the Sun), but with much smaller, affordable spacecraft. Future use of REP requires development of radioisotope power sources with system specific powers well above that of current systems. The US Department of Energy and NASA have developed an advanced Stirling radioisotope generator (ASRG) engineering unit, which was subjected to rigorous flight qualification-level tests in 2008, and began extended lifetime testing later that year. This advancement, along with recent work on small ion thrusters and life extension technology for Hall thrusters, could enable missions using REP sometime during the next decade.
The National Aeronautics and Space Administration (NASA) continues to evolve the human exploration approach for beyond low-Earth orbit and in a manner involving international, academic, and industry partners. The center of this approach is NASA’s Gateway program that will establish a permanent human presence in lunar orbit for human cislunar science, operations, and lunar surface access to eventually land the next American astronauts on the south pole of the Moon. In support of the effort, NASA’s Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall-effect thruster in support of the Gateway program. The project is managed by the NASA Glenn Research Center (GRC), supported by the NASA Jet Propulsion Laboratory (JPL) with development, qualification & flight hardware all supplied by L3 Harris Aerojet Rocketdyne (AR). Development of the 12-kW Hall thruster electric propulsion system began with maturation of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Units (TDUs). The technology development was then transitioned to AR via the AEPS contract, which built and tested two Engineering Test Unit (ETU) thrusters and multiple critical components. The project transitioned to the production of the three flight thrusters and entered qualification testing at the component and thruster levels.
The National Aeronautics and Space Administration (NASA) continues to evolve the human exploration approach for beyond low-Earth orbit and in a manner involving international, academic, and industry partners. The center of this approach is NASA’s Gateway program that will establish a permanent human presence in lunar orbit for human cislunar science, operations, and lunar surface access to eventually land the next American astronauts on the south pole of the Moon. In support of the effort, NASA’s Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall-effect thruster in support of the Gateway program. The project is managed by the NASA Glenn Research Center (GRC), supported by the NASA Jet Propulsion Laboratory (JPL) with development, qualification & flight hardware all supplied by L3 Harris Aerojet Rocketdyne (AR). Development of the 12-kW Hall thruster electric propulsion system began with maturation of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Units (TDUs). The technology development was then transitioned to AR via the AEPS contract, which built and tested two Engineering Test Unit (ETU) thrusters and multiple critical components. The project transitioned to the production of the three flight thrusters and entered qualification testing at the component and thruster levels.
Believe it or not, this has been a simplistic look at starting a checklist for SEE testing. Given a memory that has 68 operating modes, when a SEU occurs that changes the mode, just how do you determine what's going on? Laser and microbeam tests can help, but not easily for modern packaged devices. Expanding this approach to other more complex devices such as ADCs or processors as well as analog devices should be considered. The recommendation is to use the existing text standards as the starting point. Just make your own checklist for the device/technology/issues being considered. At HEART 2007, we presented some of the burgeoning challenges associated with single event effect(SEE) testing of modern commercial memories: a) Package, device complexity, test fixture, and data analysis issues were discussed; b) "Complete" SEE Characterization would take 15 years; c) Qualification test costs have a greater than 4 times increase over the last decade. In this talk, we continue to explore the roles of technology with an emphasis on the existing SEE Test Procedures and some of the concerns related to modern devices. The primary objective of the briefing is to provide some overarching guidance concerning the many considerations involved in the formulation of a SEE test plan provided in a " Checklist" format.we note that there is no such thing as a complete check list and that the best approach is to develop a flexible test plan that takes into account the device type and functions, the device technology, circuit and package design, and, of course, test facility and beam characteristics.
Edward Waters College is submitting a final report covering the grant period from January 1999 - April 30, 2000. The Teacher re-certification program at Edward Waters College created a high quality professional development opportunity for middle and high school science teachers which will contribute to the improvement of science education and the use of innovation technologies in the classroom for years to come. The following goals and objectives were met and exceeded during the grant period. 1) A focused and relevant educational technology curriculum based on National Science Education Standard and state-of-the art educational resources that are accepted as one of the qualifications for re-certification in the scientific discipline in Duval County, Florida. 2) The program goal was to recertify 40 middle and high school science teachers over a two- year period. This goal was met and exceeded the projected number by recertifying over 80 middle and high school science and math teachers over a two-year period. 3) Teachers that were recertified were given an opportunity to public information that they developed on EWC's Web page or develop a web page of their own. Area schools were made aware of this information through various forms of communication with the teachers in Duval County School District, i.e., flyers sent from EWC to participants, school newspapers, word of mouth, etc. 4) A multimedia technology resource lab is available at EWC for use as a "Learning Lab" for class field trips by Duval County teachers.
The Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and the NASA Glenn Research Center are developing a high-efficiency Stirling Radioisotope Generator (SRG) for NASA space science missions. The SRG is being developed for multimission use, including providing electric power for unmanned Mars rovers and deep space missions. On Mars, rovers with SRGs would be used for missions that might not be able to use photovoltaic power systems, such as exploration at high Martian latitudes and missions of long duration. The projected SRG system efficiency of 23 percent will reduce the required amount of radioisotope by a factor of 4 or more in comparison to currently used Radioisotope Thermoelectric Generators. The Department of Energy recently named Lockheed Martin as the system integration contractor. Lockheed Martin has begun to develop the SRG engineering unit under contract to the Department of Energy, and has contract options to develop the qualification unit and the first flight units. The developers expect the SRG to produce about 114 Wdc at the beginning of mission, using two opposed Stirling convertors and two General Purpose Heat Source modules. STC previously developed the Stirling convertor under contract to the Department of Energy and is now providing further development as a subcontractor to Lockheed Martin. Glenn is conducting an in-house technology project to assist in developing the convertor for space qualification and mission implementation. A key milestone was recently reached with the accumulation of 12 000 hr of long-term aging on two types of neodymium-iron boron permanent magnets. These tests are characterizing any possible aging in the strength or demagnetization resistance of the magnets used in the linear alternator. Preparations are underway for a thermal/vacuum system demonstration and unattended operation during endurance testing of the 55-We Technology Demonstration Convertors. In addition, Glenn is developing a charging system for the convertors to ensure clean fills of the helium working fluid and to monitor levels of any possible contaminants at different test intervals. Possible oxidation effects depend on the level of any oxygen contamination-regenerator materials and displacer radiation shields are now being evaluated for possible oxidation effects.
Three promising thermal technology development initiatives, vapor compression thermal control system, electronics cooling, and electrohydrodynamics applications are outlined herein. These technologies will provide thermal engineers with additional tools to meet the thermal challenges presented by increased power densities and reduced architectural options that will be available in future spacecraft. Goddard Space Flight Center and the University of Maryland are fabricating and testing a 'proto- flight' vapor compression based thermal control system for the Ultra Long Duration Balloon (ULDB) Program. The vapor compression system will be capable of transporting approximately 400 W of heat while providing a temperature lift of 60C. The system is constructed of 'commercial off-the-shelf' hardware that is modified to meet the unique environmental requirements of the ULDB. A demonstration flight is planned for 1999 or early 2000. Goddard Space Flight Center has embarked upon a multi-discipline effort to address a number of design issues regarding spacecraft electronics. The program addressed the high priority design issues concerning the total mass of standard spacecraft electronics enclosures and the impact of design changes on thermal performance. This presentation reviews the pertinent results of the Lightweight Electronics Enclosure Program. Electronics cooling is a growing challenge to thermal engineers due to increasing power densities and spacecraft architecture. The space-flight qualification program and preliminary results of thermal performance tests of copper-water heat pipes are presented. Electrohydrodynamics (EHD) is an emerging technology that uses the secondary forces that result from the application of an electric field to a flowing fluid to enhance heat transfer and manage fluid flow. A brief review of current EHD capabilities regarding heat transfer enhancement of commercial heat exchangers and capillary pumped loops is presented. Goddard Space Flight Center research efforts applying this technique to fluid management and fluid pumping are discussed.