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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1972

Development of termination and utilization concepts for flat conductor cables. Volume 1: Development of low profile flat conductor cable connecting device and permanent splice

The development of low-profile flat conductor cable (FCC) connecting device and FCC permanent splice methods are discussed. The design goal for the low-profile connecting device was to mate and unmate FCC harness to a typical spacecraft component with a maximum height of 3/8 in. The results indicate that the design, fabrication, and processing of the low-profile connecting device are feasible and practical. Some redesign will be required to achieve the goal of 3/8 in. Also, failures were experienced subsequent to salt spray and humidity exposure. Five different FCC permanent splice methods were considered. Subsequent to evaluation of these five methods, two design concepts were chosen for development tests.

Source record↗
NASA NTRS1975

Search for solid conductors of Na(+) and K(+) ions: Five new conductors

Five conductors of three structure types were discovered which, as solids, can transport Na(+) or K(+) ions with conductivities of approximately .00001/(omega cm) at 300 K. These compounds are: (1) the pyrochlores NaTaWO6 and NaTa2O5F, both with an activation energy for conduction delta E of 21 kJ/mole; (2) the bodycentered cubic form of NaSbO3, with delta E = 42 kJ/mole; and (3) the niobates 2Na2O with 3Nb2O5 and 2K2O with 3Nb2O5, with the alkali ions probably in open layers of the incompletely determined structure; delta E = 17 kJ/mole. On the basis of approximately 40 structure types, some generalizations were made regarding the relation between structure and ionic transport.

Singer, J.↗
NASA NTRS1975

Search for solid conductors of Na/+/ and K/+/ ions - Five new conductors

Five new conductors of positive Na and K ions, for use as separators in high energy secondary batteries, have been discovered. They include: (1) the pyrochlores NaTaWO6 and NaTa2O5F; (2) the bcc form of NaSbO3; and (3) the niobates 2Na2O-3Nb2O5 and 2K2O-3Nb2O5, with the alkali ions probably in open layers of the completely determined structure. On the basis of approximately 40 structure types, generalizations have been made regarding the relation between structure and ionic transport.

Singer, J.↗
DOE OSTI2022

Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes: Preprint

This paper discusses steps taken to size a thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal FEA is used to determine optimum heat transfer coefficient of convective boundaries. Geometric details of fin-based surface area enhancement required to reach target combined overall heat transfer coefficient (U) and surface area (A) performance (UA) in W/K, is worked out for relevant boundaries and the resulting UA is verified in 3D thermal FEA. Thermal management system's UA (by extension specific power) sensitivity to coolant temperature is explored and temperature distribution plots of optimized machine components are presented and discussed.

additive manufacturing↗
NASA NTRS1970

Measuring the conductor spacing in flat conductor cables

Interference method produces a moire pattern having a shape correlated with the lead spacing. A continuous check of the spacing is possible if the material between the leads is translucent. Technique is quick, accurate, convenient, and simple to operate.

Angele, W.↗
NASA NTRS1972

Development of termination and utilization concepts for flat conductor cables. Volume 2: Utilization of small gage wire round conductor cables

The practical use of small-gage round wire for electrical wiring in manned air and space vehicle environments is discussed. The investigation consisted on a study of wire construction and candidate wire harness concepts, fabrication of small-gage wire harnesses, and verification of promising configurations by laboratory evaluation. The wire constructions selected for harness fabrication are described. Results of the laboratory evaluation are included.

Source record↗
DOE OSTI2022

Damage Evolution of Double-Sided Copper Conductor on Multi-layer Flexible Substrate Under Bending

Abstract—Thin-film conductors continue to play an important role in flexible electronics, and thus, the performance and reliability of such conductors under mechanical loading such as stretch, bend, and twist need to be studied through experiments as well as simulations. This paper focuses on the damage evolution of the thin-film conductors under cyclic bending. Four types of double-sided copper conductors: straight trace without coverlay, straight trace with coverlay, notched trace without coverlay, and notched trace with coverlay on multi-layer substrates were studied in this work. The adaptive curvature flexure test method, which is suitable for thin-film bending, was employed in this work. Adaptive curvature flexure test is one where the flexible substrate with its conductor is positioned between two parallel plates, and the parallel plates are moved relative to each other such that the gap distance between the parallel plates changes in one of the configurations of the adaptive curvature flexure test. Different strain levels can be achieved easily in such an adaptive curvature flexure test by controlling the gap distance between the parallel plates. By subjecting flexible substrates with thin conductors to such bend tests, the fatigue life of the specimen was determined for different magnitudes of strain ranges. The results were then compared among the four types of conductors. Specimens were designed such that the conductors were placed on both sides of the substrate so that the one of the conductors would undergo tensile straining, while the other one would undergo compressive straining. It was shown that the fatigue life was highly dependent on the magnitude of strain range, and that the conductor on the compressive side failed sooner than that on the tensile side. The failed specimens were examined in a microscope at different number of cycles. Also, the resistance of the conductors, which is directly related to the reliability of thin-film conductors, was monitored in-situ during bending. The resistance change with the strain range change as well as the resistance progression with the number of cycles in tensile as well as compressive mode were determined, and such information is then used to create failure prediction models for thin-film conductors on flexible substrates.

damage evolution, flexible conductor, multi-layer ↗
DOE OSTI2020

Sensitivity Effects of High Temperature Overhead Conductors to Line Rating Variables

For traditional overhead transmission lines, the maximum allowable conductor operating temperature on ASCR, AAC, or AAAC lines for determining the static line ratings can be quite low, typically well under 100 C. At these low temperatures, the primary driver for determining static line ratings are assumptions made about the wind speed and direction and the ambient temperature. Assumptions for solar loading and emitted thermal radiation, driven by line emissivity and absorptivity, are secondary factors, and only provide small changes to the static ratings. However, when considering newer high temperature conductors such as ACSS, ACCR, ZTACIR, and ACCC® the maximum allowable conductor temperatures can be significantly higher, up to 250° C. This higher temperature shifts the importance of the emissivity assumptions of the overhead transmission line, due to the nature of the T4 dependence of the radiative heat loss compared to the T1 dependence of the convective heat loss, as well as shifting the dependency on local wind conditions. Typical assumptions in the United States for the emissivity/absorptivity of overhead transmission lines in determining the static ratings are to use a value of 0.5 for both parameters or set a value in the range of 0.7 to 0.9. Recent experimental tests at EPRI have shown that higher emissivity aging assumptions may not be valid in some regions of the US, and that actual values may be much lower (0.25-0.45) than older studies have predicted (0.8-0.9). Here, the assumptions of different US Regional Transmission Operators (RTOs) and different utilities within RTOs are examined for the static ratings for traditional lower operating temperatures up to 100° C as well as with the higher maximum temperature conductors associated with newer conductor designs at 250° C. The sensitivity of the static ratings is examined at both lower and higher temperature conductors with respect to overhead line emissivity and absorptivity, wind speed, wind direction, and solar loading, and ambient temperature. It is shown that the effects of the conductor absorptivity, solar flux and ambient temperature on the static rating are increased when the transmission line has a lower maximum conductor temperature. The effects of the conductor emissivity, wind direction and wind speed have increased effects on the static rating when the transmission line has a higher maximum conductor temperature. In addition, example weather data is used to calculate the conductor temperature with different line emissivity and absorptivity assumptions. This shows the effect of assumptions made for emissivity only has a minor impact for low temperature lines, but for high temperature transmission lines can cause a 150-200° C temperature swing.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Aluminum Ultra-conductors for Energy-Efficient Aerospace Busbar Applications (Abstract)

In this project, we will develop aluminum ultra-conductors with graphene additives demonstrating enhanced electrical conductivity at 90 °C compared to electric grade aluminum alloy AA1100 (43% IACS at 90 °C). While ultra-conductivity has been developed in copper and copper alloys, it is yet to be reported extensively in aluminum-based materials. This project will scale initial work done at PNNL on aluminum ultra-conductors using shear-assisted processing and extrusion (ShAPETM), a novel solid phase processing technique. Ultra-conductors are an emerging class of composites, comprised of a metal substrate with small quantities of nanocrystalline additives such as graphene or carbon nanotubes that demonstrate enhanced conductivity at relevant operating temperatures. Aluminum ultra-conductors can improve efficiency and power density while reducing the demand for copper in a wide range of applications, such as power transmission cables and electric motors. Busbars are an important component in aerospace systems that require lightweight and high-current power distribution including both future electric vertical take-off and landing (eVTOL) aircrafts and current aircraft electrical systems. We will accelerate aluminum ultra-conductor composite formulation development using combinatorial synthesis and testing methods aided by process/microstructure modeling, developed previously at PNNL. Eaton will test the properties of the ShAPE aluminum ultra-conductor feedstock (used to make the busbars) in relevant operating conditions (20 – 90 °C), predict the improvement in busbar performance when manufactured with ultra-conductors over commercial conductors (such as AA1100), and perform technoeconomic analysis to evaluate the potential for commercialization of ShAPE aluminum ultra-conductors. The project is expected to have a budget of $\$375$K, with $\$300$K in federal funding and $\$75$K in-kind cost-share contribution from Eaton over a period of performance of 24 months. Of the $\$300$K of federal funds, $\$140$K is allocated for CRADA activities that generate intellectual property (IP), and the remaining $\$160$K is reserved for modeling, material testing, characterization, travel, and reporting-related activities.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Advanced Conductor Testing – 1431 kcmil Prysmian ACSS with E3X

Advanced conductors represent a significant evolution in transmission line technology. These conductors utilize innovative materials, such as composite cores, ultra-high-strength steel, and heat-dissipating coatings, to offer improved performance compared to traditional Aluminum Conductor Steel Reinforced (ACSR) designs. However, the deployment of these technologies has so far been limited. As each conductor comes with nuances in test setup and specifications, a standard test is not readily available to apply to all advanced conductors. Idaho National Laboratory’s (INL) Advanced Conductor Testing project, sponsored by the Department of Energy (DOE) Office of Cybersecurity, Energy Security, and Emergency Response (CESER) and Office of Electricity (OE), focuses on developing and implementing testing protocols and plans for advanced conductor technologies to assess and demonstrate physical performance under varying operational conditions, including extreme environmental stressors such as wildfires. This report contains the fire testing results of a 1431 kcmil Prysmian ACSS with E3X conductor.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Intern Poster - Characterizing Wildland Fire Conditions for Lab-Scale Testing of Advanced Conductors

As the demand for energy increases each year, electric utilities face the challenge of delivering more power than before. Current transmission/distribution networks have proved reliable in the past but are physically unable to meet higher energy demands. Traditional overhead conductor cables (such as Aluminum Conductor Steel Reinforced (ACSR)) are limited in their ability to hold more voltage due to increased temperatures and resulting sag. When the cable sags, it comes closer to the ground, violating clearance standards and presenting an environmental risk. Newly developed advanced conductors, aluminum conductors with carbon fiber composite cores (instead of steel) mitigate this risk. Advanced conductors are engineered to perform in higher operating temperatures without sagging, thus possessing higher capacity potential. Regardless, utilities are hesitant to adopt this new technology due to scarcity of use data. The largest looming risk for utilities is wildland fires. There is little to no data on how advanced conductors perform in the event of a wildland fire. To address these concerns, this project aims to test the mechanical performance of advanced conductors in these conditions, providing utilities use data for their reference. The initial steps of the project will be to design and construct a fire table apparatus to reproduce wildland fire conditions, calculate proper parameters for this testing, and analyze the impact mathematically. After completing these actions, the next steps will be to test the advanced conductors in the laboratory fire chamber.

24 POWER TRANSMISSION AND DISTRIBUTION↗