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At least 505 records · Page 28

Rating of a Pitch Bearing for a 1.5-Megawatt Wind Turbine

Slew ring or "pitch" bearings are used in wind turbines to connect the blade root to the hub. They support the resulting simultaneous radial, axial, and overturning moment loads while allowing relative rotation of the blade with respect to the hub. NREL has recently begun a research program related to pitch bearing reliability, recognizing its growing importance for wind turbines. The purpose of this first paper is to describe the rating analysis for a reference pitch bearing representative of that used a 1.5-megawatt (MW) wind turbine. The analysis will serve as a baseline for future finite-element analyses and strain and deflection measurements of an installed pitch bearing. If successful, this work will enable the design and specification of more reliable pitch bearings, a key concern in the long-term operation of land-based wind turbines and new development of offshore wind turbines.

17 WIND ENERGY↗

Lunar gravity via the Apollo 15 and 16 subsatellites

Dense Doppler tracking coverage of the Apollo 15 and 16 subsatellites over ten and eighteen day periods when periapsis altitudes were 15-50 km has provided detailed gravity mapping of the lunar frontside. Many new gravity features are revealed, including one that does not correlate with any visible topographic structure. All unfilled craters sampled are negative anomalies. The mascons consistently produce gravity heights that load the surface with about 800 kg/sq cm excess mass. The Orientale region is represented with a solution grid of 177 point masses that clearly show the ringed structure. The eastern limb is also displayed with a solution grid of point masses. The gravity variations over the central portion of the frontface are shown as line-of-sight acceleration contours in milligals.

Sjogren, W. L.↗

Bending strength model for internal spur gear teeth

Internal spur gear teeth are normally stronger than pinion teeth of the same pitch and face width since external teeth are smaller at the base. However, ring gears which are narrower have an unequal addendum or are made of a material with a lower strength than that of the meshing pinion may be loaded more critically in bending. In this study, a model for the bending strength of an internal gear tooth as a function of the applied load pressure angle is presented which is based on the inscribed Lewis constant strength parabolic beam. The bending model includes a stress concentration factor and an axial compression term which are extensions of the model for an external gear tooth. The geometry of the Lewis factor determination is presented, the iteration to determine the factor is described, and the bending strength J factor is compared to that of an external gear tooth. This strength model will assist optimal design efforts for unequal addendum gears and gears of mixed materials.

Savage, Michael↗

Advanced Manufacturing of the SLS Block 1B Payload Adapter: Engineering Development Unit

The Payload Adapter (PLA) for the Space Launch System Block 1B configuration (SLS B1B) is a structural frustum that interfaces with the Exploration Upper Stage (EUS) and the Universal Stage Adapter (USA) or the cargo fairing at the aft end and interfaces with the primary or co-manifested payload at the forward end. The primary structure is composed of a single piece aluminum forward ring, a segmented aluminum aft ring, eight carbon composite sandwich panels, and composite bonded longitudinal joints. The PLA is designed and fabricated in-house at MSFC. Development and flight article builds are joint efforts between the Materials & Processes Laboratory (EM), the Spacecraft & Vehicle Systems Department (EV), the Space Systems Department (ES), and the Test Laboratory (ET). The large-scale manufacturing efforts associated with this task include the fabrication of pathfinder panels; the fabrication and assembly of a full-scale Manufacturing Demonstration Article (MDA); the fabrication, assembly, and test of an Engineering Demonstration Unit (EDU); the fabrication, assembly, and test of a qualification Article; and the fabrication, assembly, and proof test of subsequent flight articles. The PLA team recently completed assembly of the EDU. The final assembly included the instillation of the co-manifested secondary payload, NEST, and the instillation and tensioning of the Payload Separation System (PSS). This poster will detail the assembly process which includes: (1) composite panel to ring assembly, (2) adhesive bonding for the longitudinal joints, and (3) instillation of the NEST and PSS. The PLA EDU is prepared to undergo modal and static load testing.

Monique Wallace↗

The Effects of Peel Ply on the Damage Tolerance Characteristics of the Space Launch System (SLS) Payload Adapter Fitting (PAF)

A payload adaptor fitting (PAF) has been manufactured at NASA’s Marshall Space Flight Center (MSFC) in support of the Space Launch System (SLS) program. This structure is essentially a large cone made up of eight curved “lobes” that are joined together to form the cone. The lobes were manufactured via automated fiber placement (AFP). The PAF will carry predominantly compressive loads thus compression strength will be the focus of this study. The lobes are sandwich structure made with aluminum honeycomb core and carbon/epoxy face sheets. The lobes will be inserted into metallic rings at the top and bottom of the cone to form the full cone. Both front and back exterior surfaces of each lobe have a plain weave fabric placed at ±45⁰ to the vertical direction to help prevent fiber “breakout” during drilling. The face sheet of each lobe is thickest at the top and plies are dropped as the cone reaches the main acreage in the bottom section of the cone. The entire structure used resin impregnated peel ply that, once removed, supplies a good bonding surface for secondary bonding steps. The peel ply can be removed either directly after cure, or just before any bonding operation. Since foreign object impact can occur to the structure at any time during its life, damage tolerance of the PAF structure both with and without peel ply needed to be addressed because a previous study, albeit with limited data, showed some significant differences in damage tolerance whether the peel ply was present or not [1]. A literature search showed no results for comparing impact damage on composite laminates with and without peel ply. Load versus deflection of impact curves, visual damage, dent depth, damage as ascertained by thermography and cross-sectional microscopy were evaluated as part of the damage resistance of the structure. Compression After Impact (CAI) was performed to assess damage tolerance. The impact tests were conducted on representative specimens both with and without the peel ply present.

Sandwich Structure↗

Designing the Next Generation of Human Spacecraft

Lunar Space Station Common Module: A new concept for a module for a lunar space station attempts to reduce the module's mass by abandoning the traditional rack structure currently used on the ISS for the mounting of internal hardware and replacing it with a core structure. By using this design, the pressure shell will not have to carry the loads resulting from the internal mass. I worked with another intern to create the initial design for the module, with him focusing on the core and myself focusing on the pressure shell. To start, I was given the shell overall dimensions and material and tasked with sizing the wall thickness and placing stiffeners such that the shell could withstand the required loads. At the same time, I had to keep the mass to a minimum to keep the overall module within the allowable launch mass. Once I had done initial sizing based on pressure loads, I combined the pressure shell with the inner core to perform optimization of the design. Currently, the design involves circumferential stiffeners along the entire length of the pressure shell with longitudinal stiffeners on either end. In addition, extra wall thickness was added around each of the hatches. At this stage, the design shows a comparable mass to a more traditional design, but we are hopeful that, through optimization, we will be able to reduce the mass even further. There is currently a patent pending for the module design, for which I am listed as a co-inventor. ALON Material Testing: I was given samples of aluminum oxynitride (ALON) that had been impacted by a previous intern on which to perform residual strength tests as part of a plan to approve them for space use. Before testing, I measured the pucks and their damages using a ruler and optical micrometer in order to verify that the puck dimensions were within the tolerances set by the test guidelines and that the damages had not grown when the pucks were thinned. The test was a ring-ring test, which used two concentric rings to place the ring in axisymmetric bending, with the puck set up so that the damaged side was always in tension. Though I was unable to do the setup of the test or run the load machine due to a period of changing test procedures, I was able to observe the testing and perform the data collection. The pucks behaved as expected, breaking at the damage, as did the strengths calculated from the data, being lower than for the unimpacted pucks and having less scatter between the puck values. The attached image is of myself during the ALON strength testing. Over the course of my internship, I was able to learn much more about real-life structural analysis and about the behavior of materials, and it confirmed my previous interest in structural analysis. At the same time, due to the opportunities offered to interns, I was able to learn a lot about mission control, and, in doing so, I developed a second interest in working in mission control. In addition, being able to meet the people here and learn about the type of work NASA does made me want to come back to work for NASA full time.

Simmons, Emily↗

Nonaxisymmetric Disturbances in a Jet and Their Effect on Structural Loading

A model of sound generated in a high subsonic (Mach 0.9) circular jet is solved numerically in cylindrical coordinates for nonaxisymmetric disturbances. The jet is excited by transient mass injection by a finite duration pulse via a rotating ring source. The flow field, near field and far field pressure disturbances corresponding to these sources are described. In particular, the resulting pressure field, which would serve to excite nearby panels, is illustrated together with preliminary results on the excitation of thin slices of nearby panels. We consider both the short time behavior of the jet and the long time behavior, after the initial excitation pulse has exited the computational domain. The long time behavior of the jet is dominated by vorticity and pressure disturbances generated at the nozzle lip and growing as they convect downstream in the jet. These disturbances generate sound as they propagate. We find that rotating nonaxisymmetric disturbances persist for long times. Furthermore, depending on location, both in phase and out of phase behavior can be found upon reflection across the jet axis.

Bayliss, A.↗

Mirror Illumination and Spillover Measurements of the Atacama Cosmology Telescope

The Atacama Cosmology Telescope (ACT) is a 6 m telescope designed to map the Cosmic Microwave Background (CMB) simultaneously at 145 GHz, 220GHz and 280GHz, The receiver in ACT, the Millimeter Bolometer Array Camera, features 1000 TES bolometers in each band, The detector performance depends critically on the total optical loading, requiring the spmover contributions from the optics to be minimal. This inspired the use of a cold Lyot stop to limit the illumination of the primary and the use of guard rings surrounding the primary and secondary reflectors. Here, we present a direct measurement of the illumination aperture for both reflectors and of the attenuation level outside the main optical path. We used a 145 GHz, 1 m W source and a chopper wheel to produce a time-varying signal with a broad heam proflle, We sampled the response of the camera for different locations of the source, placed in front and beside the primary and secondary mirrors. The aperture of the primary was measured to be 5,72 plus or minus 0,17m in diameter (95 plus or minus 3% of its geometrical size), while the aperture of the secondary yielded 2 plus or minus 0.12m in diameter. Both apertures are consistent with the optical design. Comparing to previous measurements of the beam solid angle from planet observations, we estimate an optical efficiency of 72.3 plus or minus 4,8%. We found that the attenuation outside the primary aperture was -16 plus or minus 2dB, which is below the theoretical expectations, and -22 plus or minus 1 dB outside the secondary aperture, which is consistent with simulations. These results motivated the extension of the baffles surrounding the secondary mirror, with the following reduction in detector optical loading from 2,24 pW to 188pW.

Gallardo, Patricio↗

Model predictive control of mixing controlled compression ignition operation for low reactivity fuels

Using gasoline or other low reactivity fuels with a pilot injection or port fuel injection in a compression ignition engine has shown great potential in reducing NOx emissions while keeping high thermal efficiency compared to diesel. However, excessive combustion noise is caused by a high maximum pressure rise rate in the cylinder due to the higher fractions of premixed charge of the low-reactivity fuel. This noise can result in structural damage to engine components and as such, combustion noise limits the range of the operating parameters and makes the control of such engines challenging. In this study, a simulation environment was built up in MATLAB/Simulink leveraging a physics-based zero-dimension combustion model to capture the in-cylinder pressure time traces as well as metrics relevant to thermal efficiency and combustion noise. Here, in order to also facilitate the control of emissions, machine learning models were investigated to capture NOx emissions. A kernel-based extreme learning machine (K-ELM) performed best and had a coefficient of correlation (R-squared) of 0.998. The combustion and NOx emission models are valid for not only conventional gasoline fuel but also oxygenated alternative fuel blends at three different pilot injection strategies. In order to track key combustion metrics while keeping noise and emissions within constraints, a model predictive control (MPC) was applied for a compression ignition engine operating with a range of potential fuels and fuel injection strategies. The MPC is validated under different scenarios, including a load step change, fuel type change, and injection strategy change, with proportional–integral (PI) control as the baseline. The simulation results show that MPC reduces about 26% of ringing intensity in the transient process and 17% at the steady state for E30. Generally, MPC can optimize the overall performance through modifying the main injection timing, pilot fuel mass, and exhaust gas recirculation (EGR) fraction.

42 ENGINEERING↗

Confinement of Iodine Molecules into Triple-Helical Chains within Robust Metal–Organic Frameworks

During nuclear waste disposal process, radioactive iodine as a fission product can be released. The widespread implementation of sustainable nuclear energy thus requires the development of efficient iodine stores that have simultaneously high capacity, stability and more importantly, storage density (and hence minimized system volume). Here, we report high I 2 adsorption in a series of robust porous metal–organic materials, MFM-300(M) (M = Al, Sc, Fe, In). MFM-300(Sc) exhibits fully reversible I 2 uptake of 1.54 g g –1 , and its structure remains completely unperturbed upon inclusion/removal of I 2 . Direct observation and quantification of the adsorption, binding domains and dynamics of guest I 2 molecules within these hosts have been achieved using XPS, TGA-MS, high resolution synchrotron X-ray diffraction, pair distribution function analysis, Raman, terahertz and neutron spectroscopy, coupled with density functional theory modeling. These complementary techniques reveal a comprehensive understanding of the host–I 2 and I 2 –I 2 binding interactions at a molecular level. The initial binding site of I 2 in MFM-300(Sc), I 2 I , is located near the bridging hydroxyl group of the [ScO 4 (OH) 2 ] moiety [I 2 I ···H–O = 2.263(9) Å] with an occupancy of 0.268. I 2 II is located interstitially between two phenyl rings of neighboring ligand molecules [I 2 II ···phenyl ring = 3.378(9) and 4.228(5) Å]. I 2 II is 4.565(2) Å from the hydroxyl group with an occupancy of 0.208. Significantly, at high I 2 loading an unprecedented self-aggregation of I 2 molecules into triple-helical chains within the confined nanovoids has been observed at crystallographic resolution, leading to a highly efficient packing of I 2 molecules with an exceptional I 2 storage density of 3.08 g cm –3 in MFM-300(Sc).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Advanced High Torque Density Magnetically Geared Generator

The objective of this research project was to investigate the fundamental torque density limitations of multistage flux focusing magnetic gears and magnetically geared direct-drive generators for wind turbines. Magnetic gears create non-contact speed amplification by modulating the air-gap magnetic field harmonics created by magnetic rotors. By integrating a stator into the magnetic gear structure a very high torque density direct-drive generator can be created. Magnetic geared systems offer unique capabilities that are currently not available using existing mechanically geared systems, such as overload protection. Magnetic gears also offer the potential for higher reliability, higher efficiency and quieter operation than is currently achievable using a mechanically geared generator. By increasing reliability and design life magnetic gears could decrease the overall life-cycle costs when compared with equivalent mechanical or direct-drive drivetrains. This research project investigated and experimentally testing two sub-scale magnetic gearboxes (0.12 m diameter) and two large diameter magnetic gearboxes (0.56m and 0.63m diameter). The goal of the project was to demonstrate a torque density >300Nm/L for a multistage magnetic gearbox with integrated stator. A nested multistage magnetic gear structure was first proposed and studied. However, it was shown that the nested design greatly increased mechanical complexity and therefore a two-stage series typology was utilized. A multi-stage magnetic gear with a 59:1 gear ratio was successfully experimentally tested. A peak torque of 4.25 kN·m was measured and this resulted in an overall active region torque density of 141 N·m/L (when including support rings). The torque density was significantly reduced from what was computed using 2-D electromagnetic analysis. This reduction was due to the 3-D edge effects, increased power losses and the inclusion of additional mechanical support rings as well as other mechanical assembly design changes. At large diameters contiguous lamination parts could not be fabricated and so a segmented laminated rotor design had to be used. This reduced the mechanical strength of the design when compared to small diameter magnetic gears and resulted in the need for the addition of mechanical support rings to prevent deflection. The final experimentally tested design also had a high torque ripple and the power loss within the magnetic gear did not change significantly with load. This therefore resulted in the efficiency being high only at peak loads. Despite not experimentally achieving the 2-D calculated high torque density the analysis has shown that the problems encountered with the scaling can be overcome with careful design changes. For example, understanding the unique mechanical deflection requirements during the electromagnetic design of the large diameter magnetic gears is key to achieving both a high torque density based on the electromagnetic analysis and a high torque density based on the mechanical support needs. Furthermore, ensuring that end plates are made of non-conductive material and minimizing other conductive support elements within the magnetic structure is a key requirement for reducing eddy current losses. In summary, if the mechanical design can be made more robust and eddy current loss mitigation strategies are used in the mechanical design phase then the magnetic gear is capable of being scaled up whilst operating at a very high torque density. This will then enable it to be potentially performance and cost competitive with alternative direct-drive and mechanically geared wind turbine drivetrains.

17 WIND ENERGY↗

High strain rate properties of angle-ply composite laminates, part 3

Angle-ply graphite/epoxy and graphite/S-glass/epoxy laminates were characterized in uniaxial tension at strain rates ranging from quasi-static to over 500 s(sup -1). Laminate ring specimens of +/-15(sub 2s), +/-22.5(sub 2s), +/-30(sub 2s), +/-45(sub 2s), +/-60(sub 2s), +/-67.5(sub 2s), and +/-75(sub 2s) degree layups were loaded under internal pressure. Results were presented in the form of stress-strain curves to failure. Properties determined included moduli, Poisson's ratios, strength, and ultimate strain. In all seven laminates for the two materials tested the modulus and strength increase with strain rate. The effect of strain rate varies with layup, being lowest for the fiber dominated +/-15(sub 2s) degree laminates and highest for the matrix dominated +/-75(sub 2s) degree laminates. The highest increments over the static values are 10 to 25 percent for the +/-15(sub 2s) degree layup and 200 to 275 percent for the +/-75(sub 2s) degree layup. Ultimate strains do not show any significant trends with strain rate. In almost all cases the ultimate strain values are within +/-20 percent of the mean value and in half of the cases the deviation from the mean are less than 10 percent.

Daniel, I. M.↗

An in-depth probabilistic study of external tank attach ring

This report deals with conducting a probabilistic study of the external tank attach ring (ETA) used as an interface between the external tank attach struts and the solid rocket booster. The ideas were to use probabilistic distributions for material, geometric, and load properties; to calculate probabilistic margins of safety; and then to compare results against the deterministic factors of safety that were used in the actual design process. The report describes how this was done and discusses some of the road blocks and data problems that were encountered during the study and provides some conclusions. A further refinement of this study is being considered for future work which would make more direct use of finite element analysis data coupled with Monte Carlo simulation. The basic conclusion herein indicates that the probabilistic margins of safety for the cases analyzed (by use of existing data) appear to support deterministic results and actually indicate higher reliabilities.

Pizzano, Frank↗

The efficiency of photovoltaic cells exposed to pulsed laser light

Future space missions may use laser power beaming systems with a free electron laser (FEL) to transmit light to a photovoltaic array receiver. To investigate the efficiency of solar cells with pulsed laser light, several types of GaAs, Si, CuInSe2, and GaSb cells were tested with the simulated pulse format of the induction and radio frequency (RF) FEL. The induction pulse format was simulated with an 800-watt average power copper vapor laser and the RF format with a frequency-doubled mode-locked Nd:YAG laser. Averaged current vs bias voltage measurements for each cell were taken at various optical power levels and the efficiency measured at the maximum power point. Experimental results show that the conversion efficiency for the cells tested is highly dependent on cell minority carrier lifetime, the width and frequency of the pulses, load impedance, and the average incident power. Three main effects were found to decrease the efficiency of solar cells exposed to simulated FEL illumination: cell series resistance, LC 'ringing', and output inductance. Improvements in efficiency were achieved by modifying the frequency response of the cell to match the spectral energy content of the laser pulse with external passive components.

Lowe, R. A.↗

Foil Face Seal Testing

In the seal literature you can find many attempts by various researchers to adapt film riding seals to the gas turbine engine. None have been successful, potential distortion of the sealing faces is the primary reason. There is a film riding device that does accommodate distortion and is in service in aircraft applications, namely the foil bearing. More specifically a foil thrust bearing. These are not intended to be seals, and they do not accommodate large axial movement between shaft & static structure. By combining the 2 a unique type of face seal has been created. It functions like a normal face seal. The foil thrust bearing replaces the normal primary sealing surface. The compliance of the foil bearing allows the foils to track distortion of the mating seal ring. The foil seal has several perceived advantages over existing hydrodynamic designs, enumerated in the chart. Materials and design methodology needed for this application already exist. Also the load capacity requirements for the foil bearing are low since it only needs to support itself and overcome friction forces at the antirotation keys.

Munson, John↗

Ball Bearings Equipped for In Situ Lubrication on Demand

In situ systems that provide fresh lubricants to ball/race contacts on demand have been developed to prolong the operational lives of ball bearings. These systems were originally intended to be incorporated into ball bearings in mechanisms that are required to operate in outer space for years, in conditions in which lubricants tend to deteriorate and/or evaporate. These systems may also be useful for similarly prolonging bearing lifetimes on Earth. Reservoirs have been among the means used previously to resupply lubricants. Lubricant- resupply reservoirs are bulky and add complexity to bearing assemblies. In addition, such a reservoir cannot be turned on or off as needed: it supplies lubricant continuously, often leading to an excess of lubricant in the bearing. A lubricator of the present type includes a porous ring cartridge attached to the inner or the outer ring of a ball bearing (see Figure 1). Oil is stored in the porous cartridge and is released by heating the cartridge: Because the thermal expansion of the oil exceeds that of the cartridge, heating causes the ejection of some oil. A metal film can be deposited on a face of the cartridge to serve as an electrical-resistance heater. The heater can be activated in response to a measured increase in torque that signals depletion of oil from the bearing/race contacts. Because the oil has low surface tension and readily wets the bearing-ring material, it spreads over the bearing ring and eventually reaches the ball/race contacts. The Marangoni effect (a surface-tension gradient associated with a temperature gradient) is utilized to enhance the desired transfer of lubricant to the ball/race contacts during heating. For a test, a ball bearing designed for use at low speed was assembled without lubricant and equipped with a porous-ring lubricator, the resistance heater of which consumed a power of less than 1 W when triggered on by a torque-measuring device. In the test, a load of 20 lb (.89 N) was applied and the bearing was turned at a rate of 200 RPM. The lubricator control was turned on at the beginning of the test, turned off for about 800 seconds, then turned on again. As shown in Figure 2, the controlled lubricator stabilized the torque in a low range, starting immediately after initial turn-on and immediately after resumption of the lubricator control.

Marchetti, Mario↗

Bifunctional Nanoparticle-SILP Catalysts (NPs@SILP) for the Selective Deoxygenation of Biomass Substrates

We immobilized ruthenium nanoparticles onto an acidic supported ionic liquid phase (RuNPs@SILP) in the development of bifunctional catalysts for the selective deoxygenation of biomass substrates. RuNPs@SILPs possessed high catalytic activities, selectivities and recyclabilities in the hydrogenolytic deoxygenation and ring opening of C 8 - and C 9 -substrates derived from furfural or 5-hydroxymethylfurfural and acetone. When we tailor the acidity of the SILP through the ionic liquid loading provided a molecular parameter by which the catalytic activity and selectivity of the RuNPs@SILPs were controlled to provide a flexible catalyst system toward the formation of different classes of value-added products: cyclic ethers, primary alcohols or aliphatic ethers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Experiment to demonstrate separation of Cherenkov and scintillation signals

The ability to separately identify the Cherenkov and scintillation light components produced in scintillating mediums holds the potential for a major breakthrough in neutrino detection technology, allowing development of a large, low-threshold, directional detector with a broad physics program. Furthermore, the CHESS (CHErenkov/Scintillation Separation) experiment employs an innovative detector design with an array of small, fast photomultiplier tubes and state-of-the-art electronics to demonstrate the reconstruction of a Cherenkov ring in a scintillating medium based on photon hit time and detected photoelectron density. Our paper describes the physical properties and calibration of CHESS along with first results. The ability to reconstruct Cherenkov rings are demonstrated in a water target, and a time precision of 338 ± 12 ps FWHM is achieved. Finally, Monte Carlo–based predictions for the ring imaging sensitivity with a liquid scintillator target predict an efficiency for identifying Cherenkov hits of 94 ± 1 % and 81 ± 1 % in pure linear alkyl benzene (LAB) and LAB loaded with 2 g/L of a fluor, PPO, respectively, with a scintillation contamination of 12 ± 1 % and 26 ± 1 % .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗