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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Lessons Learned from the Space Shuttle Engine Hydrogen Flow Control Valve Poppet Breakage

The Main Propulsion System (MPS) uses three Flow Control Valves (FCV) to modulate the flow of pressurant hydrogen gas from the Space Shuttle Main Engines (SSME) to the hydrogen External Tank (ET). This maintains pressure in the ullage volume as the liquid level drops, preserving ET structural integrity and assuring the engines receive a sufficient amount of head pressure. On Space Transportation System (STS)-126 (2009), with only a handful of International Space Station (ISS) assembly flights from the end of the Shuttle program, a portion of a single FCV?s poppet head broke off at about a minute and a half after liftoff. The risk of the poppet head failure is that the increased flow area through the FCV could result in excessive gaseous hydrogen flow back to the external tank, which could result in overboard venting of hydrogen ullage pressure. If the hydrogen venting were to occur in first stage (i.e., lower atmosphere), a flammability hazard exists that could lead to catastrophic loss of crew and vehicle. Other failure risks included particle impact damage to MPS downstream hardware. Although the FCV design had been plagued by contamination-related sluggish valve response problems prior to a redesign at STS-80 (1996), contamination was ruled out as the cause of the STS-126 failure. Employing a combination of enhanced hardware inspection and a better understanding of the consequences of a poppet failure, safe flight rationale for subsequent flights (STS-119 and later) was achieved. This paper deals with the technical lessons learned during the investigation and mitigation of this problem at a time when assembly flights were each in the critical path to Space Station success.

Martinez, Hugo E.↗
NASA NTRS2012

Repair Concepts as Design Constraints of a Stiffened Composite PRSEUS Panel

A design and analysis of a repair concept applicable to a stiffened thin-skin composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure is presented. The concept is a bolted repair using metal components, so that it can easily be applied in the operational environment. The damage scenario considered is a midbay-to-midbay saw-cut with a severed stiffener, flange and skin. In a previous study several repair configurations were explored and their feasibility confirmed but refinement was needed. The present study revisits the problem under recently revised design requirements and broadens the suite of loading conditions considered. The repair assembly design is based on the critical tension loading condition and subsequently its robustness is verified for a pressure loading case. High fidelity modeling techniques such as mesh-independent definition of compliant fasteners, elastic-plastic material properties for metal parts and geometrically nonlinear solutions are utilized in the finite element analysis. The best repair design is introduced, its analysis results are presented and factors influencing the design are assessed and discussed.

Przekop, Adam↗
NASA NTRS2020

Kilopower Project: The KRUSTY Fission Power Experiment and Potential Missions

The Kilopower Project was initiated by NASA’s Space Technology Mission Directorate/Game Changing Development Program in fiscal year 2015 to demonstrate subsystem-level technology readiness of small space fission power in a relevant environment (Technology Readiness Level 5) for space science and human exploration power needs. The Kilopower Project centerpiece is the Kilowatt Reactor Using Stirling TechnologY (KRUSTY) test, which consists of the development and testing of a ground technology demonstrator of a 1-kW(electric)–class fission power system (FPS). The technologies to be developed and validated by KRUSTY are extensible to space FPSs from 1 to 10 kW(electric), which can enable modular surface FPSs for human exploration as well as higher-power future potential deep space science missions. The KRUSTY demonstration is cofunded by NASA and the U.S. Department of Energy National Nuclear Security Administration. The KRUSTY demonstration in the National Critical Experiment Research Center’s Device Assembly Facility was completed in the first quarter of 2018.

Space nuclear reactor↗
NASA NTRS2024

Exploration Extravehicular Mobility Unit (xEMU) Lunar Boot Chamber B Thermal Vacuum Testing Results

NASA’s Exploration Extravehicular Mobility Unit (xEMU) is the government reference next-generation spacesuit design and is engineered to protect astronauts from extreme lunar environmental temperatures. To evaluate the xEMU hardware thermal requirements, the xEMU Testing Team invented, designed, and executed a dual-suit, uncrewed thermal vacuum (TVAC) test at Johnson Space Center’s (JSC) Chamber B. This paper details the test methodology, hardware setup, and results from the xEMU lunar boots. Eleven unique thermal profiles were tested including both cold and hot environmental cases over the course of five continuous days of testing. This paper will address only the cold environment testing results. The radiative thermal environment was controlled through exposure to liquid-nitrogen shrouds on the chamber walls and through a heater cage surrounding the boots. Notably, the xEMU boots also contacted the liquid-nitrogen chilled floor inside of Chamber B, which provided a conduction pathway to simulate the thermal effects of the lunar surface. Test hardware was developed to extend the water tubing from the Liquid Cooling Ventilation Garment (LCVG) into the boots to set the internal thermal boundary nominally provided by the astronaut’s foot. Thirty-three temperature sensors were used to collect data in critical locations in the xEMU boot assembly as well as for calorimetry to determine heat flux to and from the boots. This paper will document the testing results and provide a high-level interpretation of the testing results. To conclude, this paper will address possible forward work and knowledge gaps present in lunar boot thermal performance and testing.

xEMU↗
NASA NTRS2024

Exploration Extravehicular Mobility Unit (xEMU) Hard Upper Torso (HUT) Chamber B Thermal Vacuum Testing Results

NASA’s Exploration Extravehicular Mobility Unit (xEMU) is the government reference next-generation spacesuit design and is engineered to protect astronauts from extreme lunar environmental temperatures. To evaluate the xEMU hardware thermal requirements, the xEMU Testing Team invented, designed, and executed a dual-suit, uncrewed thermal vacuum (TVAC) test at Johnson Space Center’s (JSC) Chamber B. This paper details the test methodology, hardware setup, and results from the xEMU hard upper torso (HUT). Two HUTs, one composite HUT and one aluminum HUT, were tested simultaneously in Chamber B, with different thermal environments. For the aluminum HUT on the Short xEMU (SxEMU) test article, five thermal profiles were tested during five simulated EVAs. For the composite HUT on the second xEMU, eleven unique thermal profiles were tested including both cold and hot environmental cases over the course of five continuous days of testing. The radiative thermal environment was controlled through exposure to liquid-nitrogen shrouds on the chamber walls and through two separate heater cages surrounding each respective test article. Seventy-two temperature sensors were used to collect data in critical locations in the xEMU HUT assembly. This paper will document the testing results and compare the test data against the xEMU HUT and system-level thermal models for model validation.

xEMU↗
DOE OSTI2023

Computation of the Strain Induced Critical Current Reduction in the 16 T Nb 3 Sn Test Facility Dipole

A test facility dipole is being developed at LBNL, targeting a 16 T field in a 144 mm wide aperture. The magnet uses a block design, with two double-pancake coils. In order to minimize motion under the large Lorentz forces, the coils are preloaded against a thick aluminum shell and iron yoke using bladder and key technology. It is then crucial to verify that the performance of the magnet is not degraded due to strain induced on the Nb 3 Sn conductor during assembly, cool-down and powering. The critical current of extracted strands was measured in a varying background magnetic field and as a function of the applied longitudinal strain. Finite element analysis was used to extract the strain state inside the superconducting strands during magnet assembly and operation. This strain was then compared to the measurements to evaluate potential reversible and irreversible effects on the magnet performances. Here the results suggest that the magnet can reach 16 T with sufficient margin, with no irreversible degradation in the high field region.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Electronic structure calculations of twisted multi-layer graphene superlattices

Quantum confinement endows two-dimensional (2D) layered materials with exceptional physics and novel properties compared to their bulk counterparts. Although certain two- and few-layer configurations of graphene have been realized and studied, a systematic investigation of the properties of arbitrarily layered graphene assemblies is still lacking. We introduce theoretical concepts and methods for the processing of materials information, and as a case study, apply them to investigate the electronic structure of multi-layer graphene-based assemblies in a high-throughput fashion. We provide a critical discussion of patterns and trends in tight binding band structures and we identify specific layered assemblies using low-dispersion electronic bands as indicators of potentially interesting physics like strongly correlated behavior. A combination of data-driven models for visualization and prediction is used to intelligently explore the materials space. This work more generally aims to increase confidence in the combined use of physics-based and data-driven modeling for the systematic refinement of knowledge about 2D layered materials, with implications for the development of novel quantum devices.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Encapsulation Residual Stress and Ferrite Loss in Inductive Coil Assemblies

As inductive wireless charging reaches higher power levels, thermal management and mechanical durability become more critical. To address these concerns, past works have demonstrated the benefit of encapsulating coil assemblies in thermally conductive materials. However, due to the sensitivity of the MnZn ferrites commonly used in coil assemblies to mechanical stress, care must be taken to avoid creating large stresses in the ferrite that cause higher hysteresis loss. The stress formation in the encapsulant curing process is overviewed and modeled and an experiment is performed to demonstrate the effect in a small-scale coil assembly. Finally, the effect is shown in the reduced coil-coil efficiency of a first generation high power inductive power transfer prototype using a stiff epoxy compared to better performance in a second prototype using a softer thermally-conductive silicone encapsulant.

Foote, Andrew↗
NASA NTRS2010

Development of an Advanced Recycle Filter Tank Assembly for the ISS Urine Processor Assembly

Recovering water from urine is a process that is critical to supporting larger crews for extended missions aboard the International Space Station. Urine is collected, preserved, and stored for processing into water and a concentrated brine solution that is highly toxic and must be contained to avoid exposure to the crew. The brine solution is collected in an accumulator tank, called a Recycle Filter Tank Assembly (RFTA) that must be replaced monthly and disposed in order to continue urine processing operations. In order to reduce resupply requirements, a new accumulator tank is being developed that can be emptied on orbit into existing ISS waste tanks. The new tank, called the Advanced Recycle Filter Tank Assembly (ARFTA) is a metal bellows tank that is designed to collect concentrated brine solution and empty by applying pressure to the bellows. This paper discusses the requirements and design of the ARFTA as well as integration into the urine processor assembly.

Link, Dwight E., Jr.↗
NASA NTRS2005

Advanced Ceramic Matrix Composites (CMCs) for High Temperature Applications

Advanced ceramic matrix composites (CMCs) are enabling materials for a number of demanding applications in aerospace, energy, and nuclear industries. In the aerospace systems, these materials are being considered for applications in hot sections of jet engines such as the combustor liner, vanes, nozzle components, nose cones, leading edges of reentry vehicles, and space propulsion components. Applications in the energy and environmental industries include radiant heater tubes, heat exchangers, heat recuperators, gas and diesel particulate filters, and components for land based turbines for power generation. These materials are also being considered for use in the first wall and blanket components of fusion reactors. In the last few years, a number of CMC components have been developed and successfully tested for various aerospace and ground based applications. However, a number of challenges still remain slowing the wide scale implementation of these materials. They include robust fabrication and manufacturing, assembly and integration, coatings, property modeling and life prediction, design codes and databases, repair and refurbishment, and cost. Fabrication of net and complex shape components with high density and tailorable matrix properties is quite expensive, and even then various desirable properties are not achievable. In this presentation, a number of examples of successful CMC component development and testing will be provided. In addition, critical need for robust manufacturing, joining and assembly technologies in successful implementation of these systems will be discussed.

Singh, M.↗
DOE OSTI2022

Rossi-α Measurements on a System Consisting of Weapons Grade Plutonium Moderated by Polyethylene

A critical experiment was performed on the Planet assembly to provide nuclear data in a thermal neutron spectrum, in particular to provide experimental data to help validate thermal scattering laws for polyethylene. The fuel consisted of layers of weapons grade plutonium plates that were moderated and reflected by various thicknesses of high density polyethylene. Rossi-α measurements were performed on a slightly modified configuration from the configuration used for the critical measurements. The Rossi-α measurement techniques are discussed and results are presented.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2022

Facile alignment estimation in carbon nanotube films using image processing

Whether a macroscopic assembly of carbon nanotubes can exhibit the one-dimensional properties expected from individual nanotubes critically depends on how well the nanotubes are aligned inside the assembly. Therefore, a simple and accurate method for assessing the degree of alignment is desired for the rapid characterization of carbon nanotube films and fibers. Here, we present an end-to-end solution for determining the global and local spatial orientation of carbon nanotubes in films within a short amount of time using a fast, precise, and economical approach based on an image processing method applied to scanning electron microscopy images. Further, we first use Laplacian edge enhancement filtering for improving the appearance of edge regions, which is followed by image partitioning into multiple blocks to capture the nanoscale orientation characteristics and total variation-based image decomposition of these image blocks. We then perform a 2D-fast Fourier transform on the image decomposed textural components of these edge-enhanced image blocks to determine the orientation distribution, which is utilized to estimate the 2D nematic order parameter. To show the effectiveness of our method, we corroborated our results against results obtained with other state-of-the-art image processing and experimental techniques.

2D-FFT↗
DOE OSTI2022

Thermal Neutron Scattering Law for Beryllium Hydride and Critical Mass Calculations

The thermal neutron scattering law (TSL) for crystalline beryllium hydride (BeH 2 ) is developed from first-principles ab initio lattice dynamics calculations and the impact of neutron thermalization in this material on critical mass is estimated. BeH 2 has a body-centered orthorhombic crystal structure with 12 molecules per unit cell and a theoretical density of 0.755 g/cm 3 . The vibrational (phonon) densities of states for H and Be bound in BeH 2 are determined using VASP density functional theory and PHONON lattice dynamics calculations. The TSLs for H bound in BeH 2 , H(BeH 2 ), and Be bound in BeH 2 , Be(BeH 2 ), are then evaluated in the incoherent approximation from the calculated H and Be partial phonon density of states using FLASSH. Finally, critical mass as a function of 235 U loading density for bare and reflected BeH 2 moderated spheres is predicted from MC21 Monte Carlo neutron transport calculations using ENDF/B-VIII.0 cross sections and the H(BeH 2 ) and Be(BeH 2 ) TSL evaluations. Comparisons are made to water (H 2 O), polyethylene (CH 2 ), and beryllium oxide (BeO) as moderators. These critical mass predictions are a refinement upon the prior work by Rao and Srinivasan that neglected thermal neutron scattering effects. The minimum critical mass of a BeH 2 moderated assembly is estimated to be 0.207 kg 235 U for a 0.20 m thick BeO reflected sphere and 0.178 kg 235 U for a 0.40 m thick BeO reflected sphere.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2020

Systems and methods for monitoring a power-generation module assembly after a power-generation module shutdown event

Embodiments are directed to providing a user interface (UI) that streamlines and simplifies the process of monitoring critical power-generation module (PGM) parameters after a PGM assembly is shutdown. The UI displays, in real-time, indicators corresponding to one or more post-shutdown PGM parameters. The UI provides indications of whether the post-shutdown PGM parameters meet post-shutdown criteria of the PGM assembly. When a post-shutdown PGM parameter does not meet the post-shutdown criteria, a user alert is provided to the user. A protocol may additionally be provided to the user. In some embodiments, the protocol may enable the user to return the PGM assembly to a condition that satisfies the post-shutdown criteria. The protocol may be a safety protocol and/or an asset protection protocol.

Buenaventura, Don↗
DOE OSTI2022

Systems and methods for monitoring a power-generation module assembly after a power-generation module shutdown event

Embodiments are directed to providing a user interface (UI) that streamlines and simplifies the process of monitoring critical power-generation module (PGM) parameters after a PGM assembly is shutdown. The UI displays, in real-time, indicators corresponding to one or more post-shutdown PGM parameters. The UI provides indications of whether the post-shutdown PGM parameters meet post-shutdown criteria of the PGM assembly. When a post-shutdown PGM parameter does not meet the post-shutdown criteria, a user alert is provided to the user. A protocol may additionally be provided to the user. In some embodiments, the protocol may enable the user to return the PGM assembly to a condition that satisfies the post-shutdown criteria. The protocol may be a safety protocol and/or an asset protection protocol.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Interfacial dynamics mediate surface binding events on supramolecular nanostructures

The dynamic behavior of biological materials is central to their functionality, suggesting that interfacial dynamics could also mediate the activity of chemical events at the surfaces of synthetic materials. Here, we investigate the influence of surface flexibility and hydration on heavy metal remediation by nanostructures self-assembled from small molecules that are decorated with surface-bound chelators in water. We find that incorporating short oligo(ethylene glycol) spacers between the surface and interior domain of self-assembled nanostructures can drastically increase the conformational mobility of surface-bound lead-chelating moieties and promote interaction with surrounding water. In turn, we find the binding affinities of chelators tethered to the most flexible surfaces are more than ten times greater than the least flexible surfaces. Accordingly, nanostructures composed of amphiphiles that give rise to the most dynamic surfaces are capable of remediating thousands of liters of 50 ppb Pb 2+ -contaminated water with single grams of material. These findings establish interfacial dynamics as a critical design parameter for functional self-assembled nanostructures.

42 ENGINEERING↗
NASA NTRS2017

NASA's Space Launch System Takes Shape

Major hardware and software for NASA's Space Launch System (SLS) began rolling off assembly lines in 2016, setting the stage for critical testing in 2017 and the launch of a major new capability for deep space human exploration. SLS continues to pursue a 2018 first launch of Exploration Mission 1 (EM-1). At NASA's Michoud Assembly Facility near New Orleans, LA, Boeing completed welding of structural test and flight liquid hydrogen tanks, and engine sections. Test stands for core stage structural tests at NASA's Marshall Space Flight Center, Huntsville, AL. neared completion. The B2 test stand at NASA's Stennis Space Center, MS, completed major structural renovation to support core stage green run testing in 2018. Orbital ATK successfully test fired its second qualification solid rocket motor in the Utah desert and began casting the motor segments for EM-1. Aerojet Rocketdyne completed its series of test firings to adapt the heritage RS-25 engine to SLS performance requirements. Production is under way on the first five new engine controllers. NASA also signed a contract with Aerojet Rocketdyne for propulsion of the RL10 engines for the Exploration Upper Stage. United Launch Alliance delivered the structural test article for the Interim Cryogenic Propulsion Stage to MSFC for tests and construction was under way on the flight stage. Flight software testing at MSFC, including power quality and command and data handling, was completed. Substantial progress is planned for 2017. Liquid oxygen tank production will be completed at Michoud. Structural testing at Marshall will get under way. RS-25 hotfire testing will verify the new engine controllers. Core stage horizontal integration will begin. The core stage pathfinder mockup will arrive at the B2 test stand for fit checks and tests. EUS will complete preliminary design review. This paper will discuss the technical and programmatic successes and challenges of 2016 and look ahead to plans for 2017.

Askins, Bruce↗
NASA NTRSDate not supplied

Designing a Software Architecture for the Precision Assembly of Space Structures

As NASA’s space exploration and science missions expand in complexity, longevity, anddistance beyond earth’s orbit, Orbital Servicing, Assembly and Manufacturing (OSAM)technologies and concepts have become a critical area of ongoing research and innovation.Artemis’ Moon-to-Mars goals of building sustainable elements on and around the Moon andMars that allow our robots and astronauts to explore and conduct more scientific researchwill demand in situ resource utilization, construction, and maintenance to succeed. In-spaceAssembly (ISA), as a sub-component of OSAM, focuses on the on-orbit building or fabricationof mission infrastructure and payloads. One such ISA application is highlighted by the recentNASA In-Space Assembled Telescope (iSAT) study, which stated that the next generation ofspace observatories will exceed the fairing size of existing or even planned launch vehicles andISA has emerged as a viable approach for observatory assembly. Research efforts at NASALangley Research Center have led to the design of a novel TriTruss structural concept for themodular construction of large complex persistent platforms. The TriTruss design and otherdeveloping OSAM technologies enable larger and persistent space missions that would notbe possible with single-launch-sized structures. For example, 20 meter or larger telescopesor orbital platform applications. However, the increased complexity will require autonomousoperations for the construction and maintenance of long-term infrastructure to achieve missionsuccess. NASA’s Precision Assembly of Space Structures (PASS) project is focused on thestructural and autonomy capabilities required to construct an iSAT in deep space. PASSresearch efforts will develop and validate critical technologies needed for effective efficienton-orbit assembly that can be confidently adopted for future systems. PASS will utilize theTriTruss modules to demonstrate the autonomous modular assembly of a 20m-class iSAT mirrorbackbone structure including simulated mirrors and wiring harness. In this paper, we addressthe software and hardware design considerations, technologies, and challenges of designing arobust robotics framework for assembling modular space structures in support of In SpaceAssembly missions in general as well as for PASS specifically.

Benjamin N Kelley↗