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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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Continuous method for applying antireflection coating to solar cells increases efficiency of devices by preventing energy from being reflected away, but adds little to manufacturing cost. Method consists of spraying solution on cells or glass collector plates, drying sprayed layer, and curing it. Solution is formulated to spread evenly over surfaces.
A new concept in Stirling engine technology is embodied in the base engine now being developed at Stirling Thermal Motors, Inc. This is a versatile energy conversion unit suitable for many different applications and heat sources. The base engine, rated 40 kW at 2800 RPM, is a four-cylinder, double-acting variable displacement Stirling engine with pressurized crankcase and rotating shaft seal. Remote-heating technology is incorporated with a stacked-heat-exchanger configuration and a liquid metal heat pipe connected to a distinctly separate combustor or other heat source. High efficiency over a wide range of operating conditions, long life, low manufacturing cost and low material cost are specifically emphasized. The base engine, its design philosophy and approach, its projected performance, and some of its more attractive applications are described.
The design of reference Stirling engine system as well as the engine auxiliaries and controls is described. Manufacturing costs in production quantity are also presented. Engine system performance predictions are discussed and vehicle integration is developed, along with projected fuel economy levels.
The lithium-molybdenum disulfide system offers attractive characteristics including high rate capability, successful operation up to 75 C, a very low self-discharge rate, a good cycle life and safety characteristics which compare favorably to those of other lithium cells. Moreover, the materials and manufacturing costs for the system is effectively controlled, so the cells should ultimately be competitive with currently marketed rechargeable cells.
The current status of the automotive-Stirling-engine development program being undertaken by DOE and NASA Lewis is reviewed. The program goals and the reference-engine design are explained, and the modifications introduced to improve performance and lower manufacturing costs are discussed and illustrated, including part-power optimization; increased operating temperature (from 720 to 820 C); 45.4-kg weight reduction; elimination of Co and reduction of Cr used; and improved seals, ceramic components, and high-temperature alloys. The test program, some difficulties encountered, and results after 2042 h are summarized.
The principal effort under this program was directed at the fuel cell stack technology required to accomplish the initial feasibility demonstrations of increased cell stack operating pressures and temperatures, increased cell active area, incorporation of the ribbed substrate cell configuration at the bove conditions, and the introduction of higher performance electrocatalysts. The program results were successful with the primary accomplishments being: (1) fabrication of 10 sq ft ribbed substrate, cell components including higher performing electrocatalysts; (2) assembly of a 10 sq ft, 30-cell short stack; and (3) initial test of this stack at 120 psia and 405 F. These accomplishments demonstrate the feasibility of fabricating and handling large area cells using materials and processes that are oriented to low cost manufacture. An additional accomplishment under the program was the testing of two 3.7 sq ft short stacks at 12 psia/405 F to 5400 and 4500 hours respectively. These tests demonstrate the durability of the components and the cell stack configuration to a nominal 5000 hours at the higher pressure and temperature condition planned for the next electric utility power plant.
Circulation-control variable-pitch propeller has large lift value at moderate blowing coefficients. Based on circulation-control airfoil concept, has no moving parts other than needed for propeller rotation. Substituted for conventional variable-pitch propeller airfoil, lowers manufacturing costs, reduces maintenance, and improves reliability.
Two new processes have been developed that are based on laser-heated gases. Both permit unusually precise levels of process control and, thereby, materials having superior properties. The power process yields Si, Si3N4 and SiC powders that are uniform in size, nonagglomerated, small diameter, spherically shaped and high purity. Manufacturing cost analyses show that submicron powders can be made with an energy cost of approximately 2 kWhr/kg and a dollar cost of 2-3.30 $/kg, exclusive of the costs of feed materials. The laser-induced chemical vapor deposition process (LICVD) causes reactant gases to be heated by absorbing IR light from a laser beam that passes parallel to the substrate surface. Laser heating permits independent control of gas and substrate temperatures while operating in a conventional, thermally activated chemical vapor deposition mode. Spin density, hydrogen content, electrical conductivity and mobility gap properties show the LICVD process capable of producing very high quality films.
Four resin systems show improved properties after postcuring. Comparison of flexural properties made of pultrusions reinforced by Kevlar (or equivalent) aromatic polyamide and having constant fiber volume and varied matrices, pretreatments, and postcures. Objective of study to improve flexural properties of pultrusion reinforced with Kevlar (or equivalent). Advantages of using pultrusion process, over conventional hand-layup methods included higher production rates, low facility and labor requirements, and reduced manufacturing costs of advanced composites.
Specially constructed cushion retards fires in aircraft seats through action of catalytic matrix that cracks flammable gaseous decomposition products to less flammable species. Improved cushion contributes substantially to fire safety without adding significantly to weight or to manufacturing cost. In this fire-blocking covering for an aircraft seat cushion, flammable pyrolysis products cracked to less flammable species by catalytic layer covering foam core of cushion. Aluminum foil holds in pyrolysis vapors to promote catalysis and prevent spread of fire by ignition of released vapors.
The Ceramic Automotive Stirling Engine Program evaluated the application of advanced ceramic materials to an automotive Stirling engine. The objective of the program was to evaluate the technical feasibility of utilizing advanced ceramics to increase peak engine operating temperature, and to evaluate the performance benefits of such an increase. Manufacturing cost estimates were also developed for various ceramic engine components and compared with conventional metallic engine component costs.
Development of predictive techniques, with regard to cell behavior, under various operating conditions is needed to improve cell performance, increase energy density, reduce manufacturing cost, and to broaden utilization of various fuels. Such technology would be especially beneficial for the solid oxide fuel cells (SOFC) at it early demonstration stage. The development of computer models to calculate the temperature, CD, reactant distributions in the tubular and monolithic SOFCs. Results indicate that problems of nonuniform heat generation and fuel gas depletion in the tubular cell module, and of size limitions in the monolithic (MOD 0) design may be encountered during FC operation.
The conceptual design and analysis of a solar thermal free-piston Stirling hydraulic engine system designed to deliver 25 kWe when coupled to a 11 meter test bed concentrator is documented. A manufacturing cost assessment for 10,000 units per year was made. The design meets all program objectives including a 60,000 hr design life, dynamic balancing, fully automated control, more than 33.3 percent overall system efficiency, properly conditioned power, maximum utilization of annualized insolation, and projected production costs. The system incorporates a simple, rugged, reliable pool boiler reflux heat pipe to transfer heat from the solar receiver to the Stirling engine. The free-piston engine produces high pressure hydraulic flow which powers a commercial hydraulic motor that, in turn, drives a commercial rotary induction generator. The Stirling hydraulic engine uses hermetic bellows seals to separate helium working gas from hydraulic fluid which provides hydrodynamic lubrication to all moving parts. Maximum utilization of highly refined, field proven commercial components for electric power generation minimizes development cost and risk.
A process for the fabrication of a formed platelet regeneratively cooled combustion chamber liner is described, and the benefits offered by the combustor liner are discussed. The advantages of using formed platelet combustor liners include a substantially increased cycle life and decreased coolant pressure drop in conjunction with low manufacturing costs. In the initial experiments, zirconium copper combustor liner sections with a hot gas wall thickness as small as 0.008 inch and channel aspect ratios of 15 have been achieved. It is also shown that HIP provides an excellent bonding technique for joining chamber liner panels.
Full custom VLSI is presented as a viable technology for addressing the need for the computing capabilities required for the real-time health monitoring of spacecraft systems. This technology presents solutions that cannot be realized with stored program computers or semicustom VLSI; also, it is not dependent on current IC processes. It is argued that, while design time is longer, full custom VLSI produces the fastest and densest VLSI solution and that high density normally also yields low manufacturing costs.
An account is given of the fabrication techniques, microstructural characteristics, and mechanical behavior of a lightweight, high service temperature SiC-reinforced alpha-2 Ti-14Al-21Nb intermetallic-matrix composite. Fabrication techniques under investigation to improve the low-temperature ductility and environmental resistance of this material system, while reducing manufacturing costs to competitive levels, encompass powder-cloth processing, foil-fiber-foil processing, and thermal-spray processing. Attention is given to composite microstructure problems associated with fiber distribution and fiber-matrix interfaces, as well as with mismatches of thermal-expansion coefficient; major improvements are noted to be required in tensile properties, thermal cycling effects, mechanical damage, creep, and environmental effects.
Electron-tunneling magnetometer is conceptual solid-state device operating at room temperature, yet offers sensitivity comparable to state-of-art magnetometers such as flux gates, search coils, and optically pumped magnetometers, with greatly reduced volume, power consumption, electronics requirements, and manufacturing cost. Micromachined from silicon wafer, and uses tunneling displacement transducer to detect magnetic forces on cantilever-supported current loop.
A large amount of engineering effort is consumed in conducting experiments to obtain information needed for making design decisions. Efficiency in generating such information is the key to meeting market windows, keeping development and manufacturing costs low, and having high-quality products. The principal focus of this project is to develop and implement applications of Taguchi's quality engineering techniques. In particular, we show how these techniques are applied to reduce the number of experiments for trajectory simulation of the LifeSat space vehicle. Orthogonal arrays are used to study many parameters simultaneously with a minimum of time and resources. Taguchi's signal to noise ratio is being employed to measure quality. A compromise Decision Support Problem and Robust Design are applied to demonstrate how quality is designed into a product in the early stages of designing.