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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 NTRS1993

STS-56, RSRM-031, 360L031 KSC processing configuration and data report

KSC Processing Configuration and Data Report is being provided as a historical document and as an enhancement to future RSRM manufacturing and processing operations. The following sections provide information on segment receipt, aft booster build-up, booster assembly, and closeout for STS-56, RSRM flight set 36OL031. Section 2.0 contains a summary of RSRM-031 processing. Section 3.0 discusses any significant problems or special issues that require special attention. Sections 4.0 through 6.0 contain narrative descriptions of all key events, including any related processing problems. Appendix A provides engineering specifications and changes. A list and matrix of all problem reports (PR's) pertinent to this flight set is provided in Appendix B. The matrix was provided by the Thiokol LSS Quality Engineering office. Copies of the PR's generated during the processing of RSRM-031 will be provided upon request. Appendix C contains the motor set status matrix, which provides milestone dates for the RSRM-031 flow. Section 7.0 provides recommendations, if any, for the improvement of flight hardware processing. Section 8.0 contains data sheets that provide flight hardware parts and consumables information installed during the booster build-up and stacking operations by location, lot/serial number, expiration and cure dates/times, and installation dates.

Source record↗
DOE OSTI2024

Transient Chemo‐Mechanical Model of Lithium Plating Impacted by External Pressure

Abstract Lithium anodes show great promise in commercial applications, but are hindered by lithium plating and dendrite growth which cause safety concerns during long‐term cell operation. Stack pressure is experimentally observed to improve cell lifetime; however, the relationship between stress and lithium deposition has remained difficult to elucidate. In this work, a transient, 3D, finite‐element model of the evolution of a lithium anode due to stripping and plating is developed. The evolution of a microscale protrusion on the anode surface is tracked over one charge‐discharge cycle with respect to stack pressure and lithium yield strength. Lithium plastic deformation, nonconformal anode‐separator contact, and separator porosity effects are accounted for. Over the course of several hours of stripping/plating, the anode surface evolves to a similar morphology under pressure regardless of the initial conditions due to lithium plastic deformation and hardening. The rate of this evolution highly depends on the applied pressure and assumed lithium yield strength.

25 ENERGY STORAGE↗
DOE OSTI2023

Highly-Conductive and Durable SOFC Cathode-Side Contact Based on Reactively-Sintered Mn-Co Spinel

A cathode-side contact layer with well-matched coefficient of thermal expansion is needed to prevent cracking of solid oxide fuel cell stacks from thermal cycling during stack operations. An Mn 1.25 Co 1.75 O 4 (MCO) spinel layer synthesized via reactive sintering with a metal-containing precursor was proposed as a highly conductive and durable contact material. Compared to the interconnect/contact/cathode assemblies with the (La 0.80 Sr 0.20 ) 0.95 MnO 3-x and La(Mn 0.45 Co 0.35 Cu 0.2 )O 3 contacts, the assembly with the MCO contact exhibited the lowest area-specific resistance at 800 °C (8.2 mΩ·cm 2 ) during 2000-h cyclic exposure and was crack-free based on the cross-sectional examination, indicative of the superiority of the spinel contact over the perovskite counterparts.

Electrochemistry↗
DOE OSTI2024

Transport Analysis & Optimization in a MW-Scale CO2 Electrolyzer (Final Report)

As Twelve continues to scale up their CO2 electrolyzers, both in the size of a single cell and in the number of cells used in a stack, thermal management becomes a growing concern, since excess heat can affect reaction yield and accelerate degradation. In this project, we aim to computationally explore how the anode flow fields used in Twelve’s CO2 electrolyzers function as heat exchangers. In particular, using a homogenized model of a CO2 electrolyzer, we first estimate the amount of heat generated in a cell. Then, we develop a computational fluid dynamics (CFD) model of the so-called “flow field”, i.e. a flow manifold, based on Twelve’s CAD drawings, to evaluate how these flow fields perform as a heat exchanger for the generated heat. We explore both a single cell and a 3-cell stack operating in parallel, where heat generated in one cell can now be transferred to another cell. We evaluate how performance is affected when environmental heat losses are taken into account. Finally, we leverage topology optimization to explore the types of design features a computational optimization algorithm would suggest to supplement our intuition. Overall, our work aims to provide design recommendations for CO2 electrolyzer flow fields and provides a foundation for future studies of flow field optimization.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1989

Advanced space power PEM fuel cell systems

A model showing mass and heat transfer in proton exchange membrane (PEM) single cells is presented. For space applications, stack operation requiring combined water and thermal management is needed. Advanced hardware designs able to combine these two techniques are available. Test results are shown for membrane materials which can operate with sufficiently fast diffusive water transport to sustain current densities of 300 ma per square centimeter. Higher power density levels are predicted to require active water removal.

Vanderborgh, N. E.↗
NASA NTRS2018

Challenges and Opportunities in Gen3 Embedded Cooling with High-Quality Microgap Flow

Gen3, Embedded Cooling, promises to revolutionize thermal management of advanced microelectronic systems by eliminating the sequential conductive and interfacial thermal resistances which dominate the present 'remote cooling' paradigm. Single-phase interchip microfluidic flow with high thermal conductivity chips and substrates has been used successfully to cool single transistors dissipating more than 40kW/sq cm, but efficient heat removal from transistor arrays, larger chips, and chip stacks operating at these prodigious heat fluxes would require the use of high vapor fraction (quality), two-phase cooling in intra- and inter-chip microgap channels. The motivation, as well as the challenges and opportunities associated with evaporative embedded cooling in realistic form factors, is the focus of this paper. The paper will begin with a brief review of the history of thermal packaging, reflecting the 70-year 'inward migration' of cooling technology from the computer-room, to the rack, and then to the single chip and multichip module with 'remote' or attached air- and liquid-cooled coldplates. Discussion of the limitations of this approach and recent results from single-phase embedded cooling will follow. This will set the stage for discussion of the development challenges associated with application of this Gen3 thermal management paradigm to commercial semiconductor hardware, including dealing with the effects of channel length, orientation, and manifold-driven centrifugal acceleration on the governing behavior.

microchannel↗
NASA NTRSDate not supplied

NASA’s Space Launch System: High C3 Launch Capability for Science Missions

As NASA’s initial Space Launch System (SLS) Block 1 vehicle enters integration and stacking operations at Kennedy Space Center (KSC) this year in preparation for a 2021 launch, work is in progress on future more powerful variants of the vehicle. Available in the mid 2020s and 2030s, Block 1B and Block 2 will feature increased performance and unparalleled volume for payloads, providing an enabling launch option for science mission planners. The baseline SLS architecture consists of two five-segment solid rocket boosters and four RS-25 LH2/LOX engines. The evolved Block 1B and Block 2 vehicles use a four-engine LH2/LOX upper stage and can be outfitted with an 8.4 m-diameter pay-load fairing. Additional upper stages can be packaged in the 8.4 m fairing to enable high C3 (in the range of 300 km2/sec2) missions to Mercury, the Jovian system, the ice giants, the Kuiper Belt and beyond.

Stephen D Creech↗
NASA NTRS2010

Modeling and Simulation of the ARES UPPER STAGE Transportation, Lifting, Stacking and Mating Operations Within the Vehicle Assembly Building at KSC

This viewgraph presentation describes the modeling and simulation of the Ares Upper Stage Transportation, lifting, stacking, and mating operations within the Vehicle Assembly Building (VAB) at Kennedy Space Center (KSC). An aerial view of KSC Launch Shuttle Complex, two views of the Delmia process control layout, and an upper stage move subroutine and breakdown are shown. An overhead image of the VAB and the turning basin along with the Pegasus barge at the turning basin are also shown. This viewgraph presentation also shows the actual design and the removal of the mid-section spring tensioners, the removal of the AFT rear and forward tensioners tie downs, and removing the AFT hold down post and mount. US leaving the Pegasus Barge, the upper stage arriving at transfer aisle, upper stage receiving/inspection in transfer aisle, and an overhead view of upper stage receiving/inspection in transfer aisle are depicted. Five views of the actual connection of the cabling to the upper stage aft lifting hardware are shown. The upper stage transporter forward connector, two views of the rotation horizontal to vertical, the disconnection of the rear bolt ring cabling, the lowering of the upper stage to the inspection stand, disconnection of the rear bolt ring from the upper stage, the lifting of the upper stage and inspection of AFT fange, and the transfer of upper stage in an integrated stack are shown. Six views of the mating of the upper stage to the first stage are depicted. The preparation, inspection, and removal of the forward dome are shown. The upper stage mated on the integrated stack and crawler is also shown. This presentation concludes with A Rapid Upper Limb Assessment (RULA) utilizing male and female models for assessing risk factors to the upper extremities of human beings in an actual physical environment.

Kromis, Phillip A.↗
NASA NTRS1992

Effects of the cooling system parameters on heat transfer and performance of the PAFC stack during transient operation

An experimental investigation for the effects of transient operation of a phosphoric acid fuel-cell stack on heat transfer and temperature distribution in the electrodes has been conducted. The proposed work utilized the experimental setup with modifications, which was designed and constructed under NASA Contract No. NCC-3-17(5). The experimental results obtained from this investigation and the mathematical model obtained under NASA Contract No. NCC3-17(4) after modifications, were utilized to develop mathematical models for transient heat transfer coefficient and temperature distribution in the electrode and to evaluate the performance of the cooling - system under unsteady state conditions. The empirical formulas developed were then implemented to modifying the developed computer code. Two incompressible coolants were used to study experimentally the effect of the thermophysical properties of the cool-ants on the transient heat transfer coefficient and the thermal contact resistance during start-up and shut-down processes. Coolant mass flow rates were verified from 16 to 88.2 Kg/hr during the transient process when the electrical power supply was gradually increased or decreased in the range (O to 3000 W/sq m). The effect of the thermal contact resistance with a range of stack pressure from O to 3500 KPa was studied.

Ridha, Rabi M. J.↗
NASA NTRS2014

Development and Experimental Evaluation of Passive Fuel Cell Thermal Control

To provide uniform cooling for a fuel cell stack, a cooling plate concept was evaluated. This concept utilized thin cooling plates to extract heat from the interior of a fuel cell stack and move this heat to a cooling manifold where it can be transferred to an external cooling fluid. The advantages of this cooling approach include a reduced number of ancillary components and the ability to directly utilize an external cooling fluid loop for cooling the fuel cell stack. A number of different types of cooling plates and manifolds were developed. The cooling plates consisted of two main types; a plate based on thermopyrolytic graphite (TPG) and a planar (or flat plate) heat pipe. The plates, along with solid metal control samples, were tested for both thermal and electrical conductivity. To transfer heat from the cooling plates to the cooling fluid, a number of manifold designs utilizing various materials were devised, constructed, and tested. A key aspect of the manifold was that it had to be electrically nonconductive so it would not short out the fuel cell stack during operation. Different manifold and cooling plate configurations were tested in a vacuum chamber to minimize convective heat losses. Cooling plates were placed in the grooves within the manifolds and heated with surface-mounted electric pad heaters. The plate temperature and its thermal distribution were recorded for all tested combinations of manifold cooling flow rates and heater power loads. This testing simulated the performance of the cooling plates and manifold within an operational fuel cell stack. Different types of control valves and control schemes were tested and evaluated based on their ability to maintain a constant temperature of the cooling plates. The control valves regulated the cooling fluid flow through the manifold, thereby controlling the heat flow to the cooling fluid. Through this work, a cooling plate and manifold system was developed that could maintain the cooling plates within a minimal temperature band with negligible thermal gradients over power profiles that would be experienced within an operating fuel cell stack.

Fuel Cells↗
NASA NTRS1988

Effects of operating parameters on PAFC stack performance

This work was performed to assess actual relationships of phosphoric acid fuel cell voltage responses obtained from subscale cells with air-cooled and full size cells in stacks as a function of operating parameters. Key relationships were verified and found to be in agreement with the Nerst equation. An empirical equation was developed to predict cell voltages as a function of the measureable parameters.

Le, M. T.↗
DOE OSTI2021

Preventing Voltage Divergence in Series-Stacked Bidirectional Battery Energy Storage DC-DC Converter under Asymmetrical Operating Conditions

DC stacked topologies have gained popularity for interfacing individual photovoltaic panels to a high-voltage DC bus. A similar approach can be used to interface individual battery packs to the same DC bus, which allows active balancing of battery substrings and the use of lower voltage switches. Any imbalance in battery current, however, can cause the converter output voltages to diverge. This paper describes the source of voltage divergence and demonstrates a solution that allows seamless stacking of multiple battery packs to be interfaced to a high voltage DC bus. To prevent the voltage divergence phenomenon and allow asymmetrical battery charging for efficient battery state of charge management, the PI-based decentralized voltage control enabling both capacitor voltage sharing and asymmetrical capacitor voltage control is proposed. The effectiveness of the decentralized voltage control strategy is demonstrated through controller hardware-in-the-loop test results.

Kim, Namwon↗
NASA NTRS1984

Develop and test fuel cell powered on-site integrated total energy systems. Phase 3: Full-scale power plant development

Two 25-cell, 13 inch x 23 inch (4kW) stacks were started up to evaluate the reliability of component and stack technology developed through the end of 1983. Both stacks started up well and are running satisfactorily on hydrogen-air after 1900 hours and 800 hours, respectively. A synthetic-reformat mixing station is nearing completion, and both stacks will be operated on reformate fuel. A stack-protection control system was placed in operation for Stack No. 2, and a similar set-up is in preparation for Stack No. 1. This system serves to change operating conditions or shut the stack down to avoid deleterious effects from nonstack-related upsets. The capability will greatly improve changes of obtaining meaningful long-term test data.

Kaufman, A.↗
NASA NTRS1989

Static regenerative fuel cell system for use in space

The cell stack can be operated as a fuel cell stack or as an electrolysis cell stack. The stack consists of a series of alternate fuel cell subassemblies with intervening electrolysis cell subassemblies, and interspersed cooling plates. The water produced and consumed in the two modes of operation migrates between adjacent cell subassemblies. The component plates are annular with a central hydrogen plenum and integral internal oxygen manifolds. No fluid pumps are needed to operate the stack in either mode.

Levy, Alexander H.↗