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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 361 records · Page 20

Ensuring Safety of Government Personnel During Suborbital Spaceflight

The NASA Suborbital Crew (SubC) project is focused on enabling flights by NASA civil servants, such as scientists and engineers conducting research, on suborbital vehicles. A broader goal is ensuring that commercial human spaceflight is both viable and safe. Within the Commercial Crew Program (CCP), the SubC project is exploring game-changing methods to perform safety assessments to enable NASA personnel to fly on suborbital missions. Commercial suborbital space flight capabilities are anticipated to be more accessible, affordable, and available than missions to the International Space Station and could provide additional opportunities for testing and qualification of space flight hardware, human-tended microgravity research, and further cutting-edge research enabled by the space environment. Although NASA currently permits human tended suborbital payloads for non-civil servants under auspices of NASA’s Flight Opportunities Program, the SubC effort will enable civil servant scientists, researchers, and even engineers to accompany their experiments and tests into the space microgravity environment. Figure 1 illustrates how the SubC program complements other microgravity experimental platforms. The targeted scope for SubC includes end-to-end suborbital capabilities reaching ~80km with several minutes of sustained microgravity (Table 1). The NASA SubC project office is working with the Federal Aviation Administration’s Office of Commercial Space Transportation (FAA-AST) and the commercial suborbital space transportation industry to develop an efficient and holistic approach to a safety review and eventual government participation in suborbital flight. The current FAA certification process for suborbital launches is congressionally mandated to only consider public safety. NASA is responsible for understanding the risks to its employees should they fly on a commercially available suborbital flight. The SubC project is employing a Safety Case approach, applied to commercial suborbital providers, which is not a traditional certification process as was used for the SpaceX Dragon and Boeing Starliner vehicles. Rather, it is an assessment using elements of NASA’s Risk-Informed Safety Case and the Armstrong Flight Research Center’s Airworthiness Assessment process.

Elizabeth C Blome↗

A mechanistic, multiscale model for predicting Pd penetration in TRISO fuels using BISON

TRistructural ISOtropic (TRISO) particles use silicon carbide (SiC) as the primary structural member and barrier against metallic fission product (FP) release. palladiums (PDs), produced by fission in the fuel kernel, can diffuse to and chemically interact with the SiC layer, degrading its structural integrity and ability to contain radioactive FPs. Existing temperature-dependent correlations for predicting Pd penetration rely on experimental data with significant scatter due to varying conditions, potentially complicating ongoing fuel qualification and licensing efforts for advanced reactors that would subject TRISO fuels to operating conditions outside of those examined in the experiments. A mechanistic model of Pd production, transport, and reaction is developed in this work to better understand and predict PD attack of SiC in TRISO particles. molecular dynamicss (MDs) simulations are utilized to calculate the Pd diffusivity in SiC grain bulk and grain boundaries. A mesoscale phase-field diffusion model, informed by the MD diffusivities, is used to develop a reduced order model (ROM) for the effect of SiC microstructure on the Pd penetration rate. The engineering scale BISON model calculates Pd production and transport, utilizing the ROM to predict penetration rates consistent with experimental data. This novel mechanistic ROM captures the effect of temperature, microstructure, and irradiation history on Pd penetration. In conclusion, these new capabilities are expected to support ongoing qualification and licensing efforts associated with near-term TRISO-fueled reactor applications.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Specifying Calibration of Environmental Sensors

The emergence of the Internet of Things is resulting in an increased ability of devices and systems to share data and is generating increasing interest in integrating sensors into a variety of devices deployed in the built environment. The value of such data is a function of how the data can be used. Data-producing devices and systems that enable valuable use-cases in turn can be seen as more valuable. Lighting systems are particularly interesting platforms for integrated sensors. Both indoor and outdoor lighting devices are becoming more connected, and their location is often ideally suited for hosting environmental sensors that can characterize the properties of indoor or outdoor spaces in ways that support a wide variety of use cases, from improving air quality to supporting fault diagnostics and prediction. The value of environmental-sensor-driven use-cases and the lighting systems that house them is dependent to some degree on sensor accuracy. Environmental sensors utilize a wide variety of sensing techniques or technologies and have varying accuracy. More-accurate, laboratory-grade products or reference standards are often used to characterize, refine, calibrate, adjust, and monitor devices that are deployed, or are intended to be deployed, in physical spaces of interest. Sensors or reference standards need to be calibrated periodically to ensure that their use yields accurate measurements. Calibration needs, however, vary in sophistication, based on user and use-case requirements. This paper provides guidance for evaluating the performance of environmental sensors so as to ensure that they meet user or use-case needs. It describes best practices that have been developed for a) calibrating sensors to ensure some known level of accuracy, and b) determining whether calibration-laboratory accreditation meets user or use-case needs. Excerpts from laboratory scopes of accreditation are shared to reveal the diversity of terminology and format among them. In an effort to aid those who currently have sensors calibrated or who have new or changing needs for sensor calibration, rationale is provided for why a specification might be used to request calibration services that meet specific needs. Commercially available calibration-service providers that are accredited for environmental-sensor calibration are compared and contrasted, and a specification template that might be used for requesting this calibration is presented. The specification template should be tailored to meet each user’s needs. To illustrate, an example set of environmental-sensor test conditions (reflecting the planned usage of the device to be calibrated) is used to develop a customized calibration specification, and commercially available service providers are assessed in terms of their qualifications for calibration to that particular implementation of the specification template.

42 ENGINEERING↗

Computational Design of Alloys for Energy Technologies

Advanced materials that maintain their mechanical performance under elevated temperatures, corrosive environments, and a range of static and evolving stresses are needed to improve the efficiency and reduce the environmental impact of a wide spectrum of energy technologies. For instance, cost-efficient alloys that can withstand high temperatures (e.g., 700 °C) have a critical role in improving the efficiency and economics of power generation to support decarbonization of the energy sector; such is true of both the nuclear and fossil energy sectors. Considering both the threats of the energy crisis, namely soaring costs of greenhouse gas emission-producing energy and climate change, it is essential to increase the pace of material discovery and enable rapid paths for material qualification to advance clean energy technologies. Conventionally, alloy development has followed a slow Edisonian process that uses repeated cycles of making, characterizing, and modifying to arrive at optimum composition and processing conditions to achieve the desired component performance. This optimization is followed by the necessary stepwise materials qualification. Furthermore, the increasing adoption of sound data management and physics-informed machine learning represents the next step in the acceleration of materials design and development. In the integrated computational materials engineering (ICME) approach, computational modeling and simulation data from different length and time scales can be combined with complex microstructural details from multimodal experimental characterization and selective property testing to close the design loop for rapid alloy development.

Computational Design Of Materials↗

Material Needs and Measurement Challenges for Advanced Semiconductor Packaging: Understanding the Soft Side of Science

This Perspective builds upon insights from the National Institute of Standards and Technology (NIST)-organized workshop, “Materials and Metrology Needs for Advanced Semiconductor Packaging Strategies,” held at the 35th annual Electronics Packaging Symposium in Binghamton, NY, on September 5, 2024. It outlines critical challenges and opportunities related to polymer-based “soft” materials in advanced semiconductor packaging, with emphasis on polymer science, measurement science (metrology), and the strategic development of Research-Grade Test Materials (RGTMs). These efforts, led by the NIST CHIPS team, aim to advance the fundamental understanding of structure-property-processing relationships, promote standardized guidelines and innovative methods for material characterization, and accelerate the development, qualification, and adoption of next-generation packaging materials. The Perspective also distills key insights from the panel discussion with industry experts, emphasizing the need for close collaboration among materials scientists, process engineers, and metrology experts to enable a holistic strategy, further highlighting the importance of cross-sector partnerships among industry, academia, and government to address pressing challenges in packaging materials and processes.

97 MATHEMATICS AND COMPUTING↗

The Space Shuttle's testing gauntlet

The Space Shuttle verification program is detailed, with verification network flowcharts. Performance qualification tests, life endurance tests, structural verification tests, and vibration/dynamic tests of components, subsystems, and major systems at various test levels are dealt with. Ground tests, static firings of the Shuttle main engine, external-tank separation tests, ground vibration tests of vehicle mated to external tank, and main propulsion tests and test scheduling are described. Functions of the Shuttle avionics integration laboratory and electronic systems test laboratory are discussed. Test preparations and procedures for orbital flight testing, launch pad tests, and Shuttle approach- and landing-tests are described.

Mcintosh, G. P.↗

LDEF Materials Results for Spacecraft Applications

These proceedings describe the application of LDEF data to spacecraft and payload design, and emphasize where space environmental effects on materials research and development is needed as defined by LDEF data. The LDEF six years of exposure of materials has proven to be by far the most comprehensive source of information ever obtained on the long-term performance of materials in the space environment. The conference provided a forum for materials scientists and engineers to review and critically assess the LDEF results from the standpoint of their relevance, significance, and impact on spacecraft design practice. The impact of the LDEF findings on materials selection and qualification, and the needs and plans for further study, were addressed from several perspectives. Many timely and needed changes and modifications in external spacecraft materials selection have occurred as a result of LDEF investigations.

Whitaker, Ann F.↗

NASA Aerospace Flight Battery Program: Generic Safety, Handling and Qualification Guidelines for Lithium-Ion (Li-Ion) Batteries; Availability of Source Materials for Lithium-Ion (Li-Ion) Batteries; Maintaining Technical Communications Related to Aerospace Batteries (NASA Aerospace Battery Workshop)

This NASA Aerospace Flight Battery Systems Working Group was chartered within the NASA Engineering and Safety Center (NESC). The Battery Working Group was tasked to complete tasks and to propose proactive work to address battery related, agency-wide issues on an annual basis. In its first year of operation, this proactive program addressed various aspects of the validation and verification of aerospace battery systems for NASA missions. Studies were performed, issues were discussed and in many cases, test programs were executed to generate recommendations and guidelines to reduce risk associated with various aspects of implementing battery technology in the aerospace industry. This report contains the Appendices to the findings from the first year of the program's operations.

Manzo, Michelle A.↗

Feature Based Qualification of 17-4PH Stainless Steel to Evaluate Location-Specific Variability in Wire Arc Additive Manufacturing

Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.

36 MATERIALS SCIENCE↗

Engineering Scale Testing of Transformational Non-Aqueous Solvent-Based CO 2 Capture Process at Technology Center Mongstad

Progress is reported for the period from August 8, 2018 to June 30, 2023. This final report involves work performed under ten tasks spanning two budget periods. The tasks are Task 1 Project Management, Task 2 TCM EH&S Risk Evaluation and Permitting, Task 3 Solvent Qualification, Task 4 Preliminary Design of NAS Optimized System, Task 5 TCM Amine Plant Equipment Procurement, Modification and Commissioning, Task 6 Solvent Production, Task 7 NAS Modified Amine Plant Test Plan Development, Testing, and Data Analysis, Task 8 Decommissioning and Waste Handling, Task 9 Final Techno-Economic Assessment and EH&S Risk Assessment, and Task 10 Cost Benefit Analysis and Technology Maturation Planning.

01 COAL, LIGNITE, AND PEAT↗

Integrated Advanced Microwave Sounding Unit-A (AMSU-A. Engineering Report: Electromagnetic Interface (EMI)/Electromagnetic Radiation (EMR) and Electromagnetic Compatibility (EMC), for the METSAT/METOP AMSU-A1

This document contains the procedure and the test results of the Advanced Microwave Sounding Unit-A (AMSU-A) Electromagnetic Interference (EMI), Electromagnetic Susceptibility, and Electromagnetic Compatibility (EMC) qualification test for the Meteorological Satellite (METSAT) and the Meteorological Operation Platform (METOP) projects. The test was conducted in accordance with the approved EMI/EMC Test Plan/Procedure, Specification number AE-26151/5D. This document describes the EMI/EMC test performed by Aerojet and it is presented in the following manner: Section-1 contains introductory material and a brief summary of the test results. Section 2 contains more detailed descriptions of the test plan, test procedure, and test results for each type of EMI/EMC test conducted. Section 3 contains supplementary information that includes test data sheets, plots, and calculations collected during the qualification testing.

Valdez, A.↗

The design and development of a mounting and jettison assembly for the shuttle orbiter advanced gimbal system

This paper describes the requirements, design development, and qualification of the mounting and jettison assembly (MJA) which serves as the base structure for the advanced gimbal system (AGS) developed for NASA, Marshall Space Flight Center, for use during shuttle missions. An engineering model of the MJA has been built and subjected to the following testing: stiffness and modal characterization, sine and random vibration, and a jettison function and energy release. A qualitative summary of the results and the problems encountered during testing, together with the design solutions, is presented.

Korzeniowski, E. S.↗

Plans and Concepts for a New Generation of RTGs for Planetary Science Missions

Of the six types of radioisotope thermoelectric generators NASA has flown in space, only the Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) is currently available for spaceflight, and it relies on technology first used for RTGs in the 1970s. The MMRTG is a rugged power system capable of delivering 110W at launch. NASA is considering future missions with higher power demands however, and sponsored a study to identify concepts and plans to address those needs. The Director of NASA’s Planetary Sciences Division was briefed on a potential enhancement to the MMRTG in late-2012, just a couple of days after the landing of the Mars Science Laboratory rover, Curiosity, on Mars. NASA subsequently funded system-level engineering and technology maturation tasks for a proposed enhanced MMRTG, or eMMRTG, in fiscal year 2013. There was no plan to build a complete generator, rather the engineering of one, and the transfer of technology from laboratories at the Jet Propulsion Laboratory to industry were begun. NASA has now formed a Project to take the eMMRTG from technology to a qualification unit. This would form the first of a new generation of RTGs in 50 years. NASA has also formed a Project for a Next-Generation RTG concept based upon a study led by this author and a large team. NASA’s Radioisotope Power Systems (RPS) Program set the objective for the study to explore what possible options NASA has for Next-Generation-RTGs. The scope and breadth of the study included many possible destinations within the solar system, and traded a variety of RTG conceptual designs, and risk rated a variety of thermoelectric materials and couple configurations. Requirements were defined for the RTG concepts, a variety of thermoelectric materials were evaluated to find the most mature candidates, and performance was estimated for each RTG concept that could use the most mature of these new thermoelectric materials. The study relied upon mission concepts outlined in the latest Planetary Science Decadal Survey (2011), other more recent mission studies completed throughout the agency, and recent analyses of potential missions to ocean worlds to identify requirements that were not applied to previous RTGs but might prove valuable to these NG-RTGs. RTG concepts with maximal potential utility were identified as being modular and ranging in power output from 50 to 500W. A variety of RTG design concepts with several distinguishing characteristics were formulated. The plans and concepts for a new generation of RTGs (the eMMRTG and NG-RTG) will be discussed.

Woerner, David F.↗

Integration of sensors through additive manufacturing leading to increased efficiencies of gas turbines for power generation and propulsion

To realize the full capability of additively manufactured components in complex energy systems, it is imperative to minimize early component failures during development phases and during operation. Traditional field feedback timelines and offline inspection protocols significantly reduce the design-manufacturing iteration times. To address this specific question, the project developed and demonstrated a method for the integration of sensors into complex components through additive manufacturing. The team used gas turbine engines as a platform, which meets the need of both power generation and propulsion and offer opportunities for cost reductions and efficiency increases. The innovation of this intelligent integration of sensors into complex components uniquely customized to address questions of integrity and durability for additively manufactured components. With real-time sensing data from additively manufactured components, turbine manufacturers will realize higher efficiencies, reduced component failures, and a 30-50% acceleration in product deployment of high efficiency gas turbine components due to a faster reduction in component risk assessment under actual operating conditions. This is a transformative shift towards a data-driven design and qualification of additively manufactured gas turbine components. To directly integrate sensors into additively manufactured components with all the complexities of actual hardware, powder bed fusion (direct metal laser sintering) and laser metal deposition technologies was developed. Validation took take place in two university laboratories both of which contain actual engine hardware and closely simulate a gas turbine prior to demonstrating the technology in a turbine development test. Indeed, two major technologies from this research cold impact turbine systems in the near future: (1) higher efficiency materials and designs enabled by additive manufacturing with 50% faster design to manufacturing cycle time, to enable faster time-to-market targets; and (2) integration of sensors into additively manufactured components enabling broad health and condition based prognostics for faster component and engine risk reduction.

33 ADVANCED PROPULSION SYSTEMS↗

Characterization of 8-cm engineering model thruster

Development of 8 cm ion thruster technology which was conducted in support of the Ion Auxiliary Propulsion System (IAPS) flight contract (Contract NAS3-21055) is discussed. The work included characterization of thruster performance, stability, and control; a study of the effects of cathode aging; environmental qualification testing; and cyclic lifetesting of especially critical thruster components.

Williamson, W. S.↗

Non-intrusive Shock Measurements Using Laser Doppler Vibrometers

Stud mount accelerometers are widely used by the aerospace industry to measure shock environments during hardware qualification. The commonly used contact-based sensors, however, interfere with the shock waves and distort the acquired signature, which is a concern not actively discussed in the community. To alleviate these interference issues, engineers at the Jet Propulsion Laboratory are investigating the use of non-intrusive sensors, specifically Laser Doppler Vibrometers, as alternatives to the stud mounted accelerometers. This paper will describe shock simulation tests completed at the Jet Propulsion Laboratory, compare the measurements from stud mounted accelerometers and Laser Doppler Vibrometers, and discuss the advantages and disadvantages of introducing Laser Doppler Vibrometers as alternative sensors for measuring shock environments.

shock testing↗