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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

Failure Detector for Power-Factor Controller

New protective circuits have been developed for power-factor ac motor controllers. Circuits prevent direct current and consequent motor heating that would normally result from failure of solid-state switch in controller. Single-phase power-factor controller with short detector compensates for short-circuit failure in either direction by applying full power to motor. Controller with open detector compensates for open-circuit failure in either direction by turning off power to motor.

Nola, F. J.↗
DOE OSTI2019

Practical Challenges and Failure Modes During Fabrication of Haynes 230 Micro-Pin Solar Receivers for High Temperature Supercritical Carbon Dioxide Operation

Printed circuit heat exchangers (PCHX) fabricated from high nickel alloys have shown promise as primary heat exchangers, recuperators, and solar receivers for high temperature and pressure supercritical carbon dioxide power cycles. There are numerous challenges in fabricating these devices including forming channel features, joining via diffusion or transient liquid phase bonding, and brazing/welding of headers. Commercial entities are understandably hesitant to share propriety best practices, and both commercial and non-commercial entities working on these components tend not to publically share failures and mistakes. However, sharing of this information could prevent similar costly errors and further the understanding of the coupled manufacturing, materials and mechanics issues in creating these components. Thus, in this paper, we document the challenges, failures, and mitigation methods uncovered in fabrication of prototype micro-pin based solar thermal receivers constructed of Haynes 230 and fabricated through a combination of photochemical machining (PCM), wire electrical discharge machining (EDM), transient liquid phase (TLP) bonding, vacuum brazing, and gas tungsten arc welding (GTAW). The receiver is designed to absorb concentrated solar fluxes greater than 140 W cm-2, while heating supercritical carbon dioxide from 550 °C to 720 °C at a pressure of 20 MPa to 25 MPa. The prototype receiver consists of a thin (~ 450 µm), Haynes 230 coversheet bonded to a 15 cm × 15 cm Haynes 230 micro-pin plate. The pieces are joined using a TLP bonding process with a nickel-phosphorus interlayer. Prior to bonding, micro-pins with height ~150 µm and diameter 300 µm are fabricated using PCM in the plate, and through slot features are made using wire EDM. Finally, flow headers are joined to the microchannel plate through a combination of vacuum brazing and GTAW. During hydrostatic proof testing, the prototype device failed when the coversheet delaminated from the pin array at a pressure of 290 bar. A failure analysis including scanning electron microscopy (SEM) to view failure sites and energy-dispersive X-ray spectroscopy (EDS) to evaluate elemental analysis of the failed areas was conducted. The failure modes can be broadly categorized as (1) failures potentially relating to reliquification of the transient liquid phase bonds between the micro-pins plate and coversheet during post-processing, (2) failures related to manufacturing defects, and (3) failures attributed to design.

14 SOLAR ENERGY↗
DOE OSTI2024

Planarization of p -GaN surfaces on MOCVD grown V-defect engineered GaN-based LEDs

The large polarization barriers between the quantum wells and quantum barriers in long-wavelength GaN-based light-emitting diodes (LEDs) inhibit their performance by requiring excess driving voltages to reach standard operating current densities. Lateral injection of carriers directly into quantum wells is required to circumvent this issue. V-defects are naturally occurring inverted hexagonal defects with semipolar {$10\bar{1}1$}-plane sidewalls generated on surface depressions from threading dislocations. LEDs engineered to intentionally generate V-defects below the active region of the LED can achieve lateral carrier injection through the V-defect sidewalls and have already been able to demonstrate world record wall-plug efficiencies for LEDs in the green-red wavelengths. V-defects can be enlarged during kinetically limited growth where the growth rate of the c-plane GaN is faster than that of their sidewalls, leaving them unfilled. We report on the metal organic chemical vapor deposition growth conditions required to fill in V-defects with p-GaN during epitaxial growth of the LED post the active region. Circular transmission length measurements of Pd/Au contacts processed on p-GaN surfaces with various amounts of unfilled V-defects showed no significant difference in their sheet resistance and specific contact resistance. J–V measurements of LEDs grown with varying unfilled V-defect densities showed no significant difference in the forward bias regime. However, in the reverse bias regime, catastrophic breakdown occurred at markedly lower voltages for samples with larger unfilled V-defect densities. This suggests that unfilled V-defects may act as hotspots for device failure, and planarizing LED surfaces may help prevent early degradation of LED devices.

Chemical vapor deposition↗
DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
NASA NTRS1972

Mercury contamination study for flight system safety

The effects and prevention of possible mercury pollution from the failure of solar electric propulsion spacecraft using mercury propellant were studied from tankage loading of post launch trajector injection. During preflight operations and initial flight mode there is little danger of mercury pollution if proper safety precautions are taken. Any spillage on the loading, mating, transportation, or launch pad areas is obvious and can be removed by vacuum cleaning soil and chemical fixing. Mercury spilled on Cape Kennedy ground soil will be chemically complexed and retained by the sandstone subsoil. A cover layer of sand or gravel on spilled mercury which has settled to the bottom of a water body adjacent to the system operation will control and eliminate the formation of toxic organic mercurials. Mercury released into the earth's atmosphere through leakage of a fireball will be diffused to low concentration levels. However, gas phase reactions of mercury with ozone could cause a local ozone depletion and result in serious ecological hazards.

Gorzynski, C. S., Jr.↗
NASA NTRS1972

The application of elastohydrodynamic lubrication in gear tooth contacts.

It is shown that in the early stages of design, scoring and fatigue failure of gear contact surfaces can be prevented by the following means: improving load capacity with the aid of tip relief, or by improved surface finish; by giving special care to the location and application of the lubricant in high-speed or high-load gear applications; by determining the thickness of the elastohydrodynamic film from an analysis for the worst temperature, speed, and load conditions, and selecting the appropriate lubricant from this analysis; by using an additive in the case of frequent repeated startup and shutdown conditions; by taking the expected temperature, speed, and load in the selection of an extreme pressure additive; and by systematically testing any new transmission or gear box design.

Townsend, D. P.↗
NASA NTRS1975

Experiment definition phase shuttle laboratory: LDRL-10.6 experiment

Progress is reported in the development of the space shuttle laboratory laser data relay link. The system transmittance of various surfaces was considered in order to examine the coating tradeoffs for the beryllium mirrors. The results of six coating combinations considered are summarized. It is recommended that silver coatings be used throughout the system. Design of the pre-expander and a preliminary alignment procedure implemented to align all optical elements to the reference mechanical axis (the rotational axis of the outer gimbal bearing located between the two Gregorian telescopes) are included. The local oscillator subsystem, consisting of the laser, Stark cell, Stark cell electronics, power supply, starting circuit, and conditioning optics were completed and installed in the optimechanical subsystem and operation against a 10.6 micrometer source was attempted. Preliminary measurements of the HgCdTe mixer showed that this critical element was inoperative and in subsequent tests the receiver front end electronics had also failed. Possible reasons for these failures and corrective action and steps to prevent future recurrence are discussed.

Source record↗
NASA NTRS1976

Dual output variable pitch turbofan actuation system

An improved actuating mechanism was provided for a gas turbine engine incorporating fan blades of the variable pitch variety, the actuator adapted to rotate the individual fan blades within apertures in an associated fan disc. The actuator included means such as a pair of synchronizing ring gears, one on each side of the blade shanks, and adapted to engage pinions disposed thereon. Means were provided to impart rotation to the ring gears in opposite directions to effect rotation of the blade shanks in response to a predetermined input signal. In the event of system failure, a run-away actuator was prevented by an improved braking device which arrests the mechanism.

Griswold, R. H., Jr.↗
NASA NTRS1983

U.S. planetary protection program - Implementation highlights

The implementation of the United States planetary protection program, intended to prevent the contamination of the celestial bodies in the solar system during their exploration, in recent interplanetary projects is reviewed. The shift in planetary protection policy from that of absolute sterilization to a probabilistic approach is noted. Attention is then given to the use of microbiological assay, organic materials inventory, microbial burden reduction, contamination control, trajectory biasing and the analysis and identification of contaminating processes for purposed of planetary protection for the Pioneer 10 and 11, Viking and Voyager projects. The success of these measures, as demonstrated by the prevention of accidental planetary impact and the failure to detect terrestrial organisms by the Viking life detection experiments, is pointed out.

Barengoltz, J.↗
NASA NTRS1983

Precedency control and other semantic integrity issues in a workbench database

Most database systems model the current state of a system of real world discrete and simple entities together with their relationships. By examining instead a database system that is a workbench and models more complicated entities, a fresh perspective is gained. Specifically, semantic integrity is analysed. Four aspects distinct from physical integrity are identified, namely - access, failure, concurrency and precedency. Access control is shown to be the consequence of semantic interdependency between data and its matching semantic routines. Failure, concurrency precedency controls are concerned with preventing processes interfering with each other. Precedency is a new concept in the database context. It expresses a constraint between processes that act on the database. As processes create, update and delete entities they in general obey a partial ordering imposed by the semantics of their actions. Precedency control ensures that data remains consistent with respect to this partial order.

Dampney, C. N. G.↗
NASA NTRS1987

Proof that timing requirements of the FDDI token ring protocol are satisfied

The fiber distributed data interface (FDDI) is an ANSI draft proposed standard for a 100 Mbit/s fiber-optic token ring. The FDDI timed token access protocol provides dynamic adjustment of the load offered to the ring, with the goal of maintaining a specified token rotation time and of providing a guaranteed upper bound on time between successive arrivals of the token at a station. FDDI also provides automatic recovery when errors occur. The bound on time between successive token arrivals is guaranteed only if the token rotates quickly enough to satisfy timer requirements in each station when all ring resources are functioning properly. Otherwise, recovery would be initiated unnecessarily. The purpose of this paper is to prove that FDDI timing requirements are satisfied, i.e., the token rotates quickly enough to prevent initiation of recovery unless there is failure of a physical resource or unless the network management entity within a station initiates the recovery process.

Johnson, Marjory J.↗
NASA NTRS1987

Design Criteria for Controlling Stress Corrosion Cracking

This document sets forth the criteria to be used in the selection of materials for space vehicles and associated equipment and facilities so that failure resulting from stress corrosion will be prevented. The requirements established herein apply to all metallic components proposed for use in space vehicles and other flight hardware, ground support equipment, and facilities for testing. These requirements are applicable not only to items designed and fabricated by MSFC (Marshall Space Flight Center) and its prime contractors, but also to items supplied to the prime contractor by subcontractors and vendors.

Franklin, D. B.↗
NASA NTRS2000

Development of a High Output Fluorescent Light Module for the Commercial Plant Biotechnology Facility

To maximize the use of available resources provided onboard the International Space Station, the development of an efficient lighting 1 system is critical to the overall performance of the CPBF. Not only is it important to efficiently generate photon energy, but thermal loads on the CPBF Temperature and Humidity Control System must be minimized. By utilizing optical coatings designed to produce highly diffuse reflectance in the visible wavelengths while minimizing reflectance in the infrared region, the design of the fluorescent light module for the CPBF is optimized for maximum photon flux, spatial uniformity and energy efficiency. Since the Fluorescent Light Module must be fully enclosed to meet (ISS) requirements for containment of particulates and toxic materials, heat removal from the lights presented some unique design challenges. By using the Express Rack moderate C, temperature-cooling loop, heat is rejected by means of a liquid/air coolant manifold. Heat transfer to the manifold is performed by conduction using copper fins, by forced air convection using miniature fans, and by radiation using optically selective coatings that absorb in the infrared wavelengths. Using this combination of heat transfer mechanisms builds in redundancy to prevent thermal build up and premature bulb failure.

Turner, Mark↗
NASA NTRS2004

Hybrid Inflatable Pressure Vessel

Figure 1 shows a prototype of a large pressure vessel under development for eventual use as a habitable module for long spaceflight (e.g., for transporting humans to Mars). The vessel is a hybrid that comprises an inflatable shell attached to a rigid central structural core. The inflatable shell is, itself, a hybrid that comprises (1) a pressure bladder restrained against expansion by (2) a web of straps made from high-strength polymeric fabrics. On Earth, pressure vessels like this could be used, for example, as portable habitats that could be set up quickly in remote locations, portable hyperbaric chambers for treatment of decompression sickness, or flotation devices for offshore platforms. In addition, some aspects of the design of the fabric straps could be adapted to such other items as lifting straps, parachute straps, and automotive safety belts. Figure 2 depicts selected aspects of the design of a vessel of this type with a toroidal configuration. The bladder serves as an impermeable layer to keep air within the pressure vessel and, for this purpose, is sealed to the central structural core. The web includes longitudinal and circumferential straps. To help maintain the proper shape upon inflation after storage, longitudinal and circumferential straps are indexed together at several of their intersections. Because the web is not required to provide a pressure seal and the bladder is not required to sustain structural loads, the bladder and the web can be optimized for their respective functions. Thus, the bladder can be sealed directly to the rigid core without having to include the web in the seal substructure, and the web can be designed for strength. The ends of the longitudinal straps are attached to the ends of the rigid structural core by means of clevises. Each clevis pin is surrounded by a roller, around which a longitudinal strap is wrapped to form a lap seam with itself. The roller is of a large diameter chosen to reduce bending of the fibers in the strap. The roller also serves to equalize the load in the portions of the strap on both sides of the clevis pin. The lap seam is formed near the clevis by use of a tapered diamond stitch: This stitch is designed specifically to allow fibers in the stitch and strap to relax under load in such a manner that the load becomes more nearly evenly distributed among all fibers in the stitch region. Thus, the tapered diamond stitch prevents load concentrations that could cause premature failure of the strap and thereby increases the strength of the strap/structural-core joint. The lap seam can be rated at >90 percent of the strength of the strap material.

Raboin, Jasen↗
DOE OSTI2021

The Influence of the Instantaneous Collapse of Tailings Pond on Downstream Facilities

To evaluate the evolutionary processes guiding the formation of the tailings‐water mixtures produced by the instantaneous collapse of tailings ponds and the influence of these on downstream facilities, a 2D simulation model with reasonable boundary and working conditions derived from actual engineering practice was built in this study, and the relationship between dam‐break elevation and impact on downstream facilities was also analyzed to determine the relevant mechanism of influence. Computational results indicated that lowering the dam‐break elevation caused the maximum velocity and flooding depth, along with the flooded area at monitoring points, to gradually increase. The occurrence times of maximum velocity and flooding depth were also gradually moved forward as the breaking elevation was reduced; this effect is directly related to the increase in the total potential energy at the lower break elevations. Further simulations of sand‐prevent dams with different heights located downstream from a tailings pond were carried out to identify methods for mitigating the impact of dam failure. The results revealed that increasing the height of the sand‐prevent dam reduced the production of tailings mixtures. Based on the results, the construction of a sand‐prevent dam with a crest elevation equal to that of the starter dam was recommended.

Wang, Sha (ORCID:0000000324875445)↗
NASA NTRS2021

Mid-Air Range-Visual-Inertial Estimator Initialization for Micro Air Vehicles

Monocular Visual-Inertial Odometry (VIO) has become ubiquitous for navigation of autonomous Micro Air Vehicles (MAVs). Yet, state-of-the-art VIO is still very failure- prone, which can have dramatic consequences. To prevent this, VIO must be able to re-initialize in mid-air, either during a free fall or on a constant horizontal velocity trajectory after attitude control has been re-established. However, for both of these trajectories, the visual scale cannot be observed with VIO batch initializers because of the absence of acceleration change. We propose to use a small and lightweight laser range finder and a scene facet model to initialize vision-based navigation at the right scale under any motion condition and over any scene structure. This new range constraint is integrated into a visual-inertial bundle adjustment initializer. We demonstrate in simulation and real data how this approach can address mid-air state estimation failure in real-time and analyze the sensitivity of estimators to initial state errors.

Brockers, Roland↗
NASA NTRS2006

Closed-Loop Evaluation of an Integrated Failure Identification and Fault Tolerant Control System for a Transport Aircraft

Formal robustness analysis of aircraft control upset prevention and recovery systems could play an important role in their validation and ultimate certification. Such systems developed for failure detection, identification, and reconfiguration, as well as upset recovery, need to be evaluated over broad regions of the flight envelope or under extreme flight conditions, and should include various sources of uncertainty. To apply formal robustness analysis, formulation of linear fractional transformation (LFT) models of complex parameter-dependent systems is required, which represent system uncertainty due to parameter uncertainty and actuator faults. This paper describes a detailed LFT model formulation procedure from the nonlinear model of a transport aircraft by using a preliminary LFT modeling software tool developed at the NASA Langley Research Center, which utilizes a matrix-based computational approach. The closed-loop system is evaluated over the entire flight envelope based on the generated LFT model which can cover nonlinear dynamics. The robustness analysis results of the closed-loop fault tolerant control system of a transport aircraft are presented. A reliable flight envelope (safe flight regime) is also calculated from the robust performance analysis results, over which the closed-loop system can achieve the desired performance of command tracking and failure detection.

Shin, Jong-Yeob↗