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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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
NASA NTRS1973

Trajectory analysis for solar electric propulsion stage /SEPS/ planetary missions

This paper summarizes a portion of the planetary mission analysis results of past and present studies conducted by Rockwell International for NASA-MSFC (Contract NAS8-27360) dealing with the feasibility of a Solar Electric Propulsion Stage (SEPS). The SEPS is envisioned as an upper stage of a transportation system capable of delivering either separable payload spacecraft or attached science packages to various planetary targets. The purpose of the paper is to demonstrate that, from a payload performance capability standpoint, a common SEP Stage can deliver various payloads to a host of planetary targets including inner and outer planets, asteroids, and comets.

Dazzo, E. J.↗
NASA NTRS1975

ERTS-C (Landsat 3) cryogenic heat pipe experiment definition

A flight experiment designed to demonstrate current cryogenic heat pipe technology was defined and evaluated. The experiment package developed is specifically configured for flight aboard an ERTS type spacecraft. Two types of heat pipes were included as part of the experiment package: a transporter heat pipe and a thermal diode heat pipe. Each was tested in various operating modes. Performance data obtained from the experiment are applicable to the design of cryogenic systems for detector cooling, including applications where periodic high cooler temperatures are experienced as a result of cyclic energy inputs.

Brennan, P. J.↗
NASA NTRS1975

Numerical methods for the calculation of three-dimensional nozzle exhaust flow fields

Numerical codes developed for the calculation of three-dimensional nozzle exhaust flow fields associated with hypersonic airbreathing aircraft are described. Both codes employ reference plane grid networks with respect to three coordinate systems. Program CHAR3D is a characteristic code utilizing a new wave preserving network within the reference planes, while program BIGMAC is a finite difference code utilizing conservation variables and a one-sided difference algorithm. Secondary waves are numerically captured by both codes, while the underexpansion shock and plume boundary are treated discretely. The exhaust gas properties consist of hydrogen-air combustion product mixtures in local chemical equilibrium. Nozzle contours are treated by a newly developed geometry package based on dual cubic splines. Results are presented for simple configurations demonstrating two- and three-dimensional multiple wave interactions.

Dash, S. M.↗
NASA NTRS1975

Energy conservation and the transportation sector

The present status of the energy implications of the transportation systems in the United States was illustrated, with primary emphasis on the technologies and methods for achieving a substantial reduction in the associated energy price (approximately 25% of the nation's energy is consumed directly in the operation of these systems). These technologies may be classified as follows: (1) improvement of system efficiency (system operations or technological), (2) substitution for scarce energy resources (electrification, alternate fuels, use of man power, recycling), (3) curtailment of end use (managed population growth rate, education of citizenry, alternatives to personal transportation, improved urban planning, reduced travel incentives). Examples and illustrations were given. Thirty-four actions were chosen on the basis of a preliminary filtering process with the objective of: (1) demonstrating a methodological approach to arrive at logical and consistent conservation action packages, (2) recommending a viable and supportable specific set of actions.

Source record↗
NASA NTRS1980

High efficiency compound semiconductor concentrator photovoltaics

Special emphasis was given to the high yield pilot production of packaged AlGaAs/GaAs concentrator solar cells, using organometallic VPE for materials growth, the demonstration of a concentrator module using 12 of these cells which achieved 16.4 percent conversion efficiency at 50 C coolant inlet temperature, and the demonstration of a spectral splitting converter module that achieved in excess of 20 percent efficiency. This converter employed ten silicon and ten AlGaAs cells with a dichroic filter functioning as the beam splitter. A monolithic array of AlGaAs/GaAs solar cells is described.

Borden, P.↗
NASA NTRS1987

An efficient quadrilateral element for plate bending analysis

A simple, shear flexible, quadrilateral plate element is developed based on the Hellinger/Reissner mixed variational principle with independently assumed displacement and stress fields. The crucial point of the selection of appropriate stress parameters is emphasized in the formulation. For this purpose, a set of guidelines is formulated based on the follwoing considerations: (1) suppression of all kinematic deformation modes, (2) the element has a favorable value for the constraint index in the thin plate limit, and (3) element properties are frame-invariant. For computer implementation the components of the element stiffness matrix are evaluated analytically using the symbolic manipulation package MACSYMA. The effectiveness and practical usefulness of the proposed element are demonstrated by the numerical results of a variety of problems involving thin and moderately thick plates under different loading and support conditions.

Saleeb, A. F.↗
NASA NTRS1987

Multispectral remote sensing as stratigraphic and structural tool, Wind River Basin and Big Horn Basin areas, Wyoming

The use of Landsat TM, Airborne Imaging Spectrometer, and airborne Thermal IR Multispectral Scanner data in the geological evaluation of two sites in central Wyoming is described and illustrated with diagrams, maps, photographs, sample images, and tables of numerical data. The value of the remotely sensed information on the areal variation of attitude, sequence, thickness, and lithology of exposed strata is demonstrated; details of the data analysis are given; and the specialized software packages employed are briefly characterized.

Lang, Harold R.↗
NASA NTRS1990

Deep space optical communications - A program update

Technological developments leading toward the use of optical communications on deep-space missions are reviewed. Developments in the characterization of atmospheric visibility and the development of advanced composite materials for use in optical communications systems are discussed. System demonstrations involving the Galileo Optical Experiment and a very lightweight optical communications package intended for the Cassini mission to Saturn are addressed. Proposed flight experiments and a deep-space optical communication long-range plan are discussed.

Lesh, James R.↗
NASA NTRS1998

GSFC Cutting Edge Avionics Technologies for Spacecraft

With the launch of NASA's first fiber optic bus on SAMPEX in 1992, GSFC has ushered in an era of new technology development and insertion into flight programs. Predating such programs the Lewis and Clark missions and the New Millenium Program, GSFC has spearheaded the drive to use cutting edge technologies on spacecraft for three reasons: to enable next generation Space and Earth Science, to shorten spacecraft development schedules, and to reduce the cost of NASA missions. The technologies developed have addressed three focus areas: standard interface components, high performance processing, and high-density packaging techniques enabling lower cost systems. To realize the benefits of standard interface components GSFC has developed and utilized radiation hardened/tolerant devices such as PCI target ASICs, Parallel Fiber Optic Data Bus terminals, MIL-STD-1773 and AS1773 transceivers, and Essential Services Node. High performance processing has been the focus of the Mongoose I and Mongoose V rad-hard 32-bit processor programs as well as the SMEX-Lite Computation Hub. High-density packaging techniques have resulted in 3-D stack DRAM packages and Chip-On-Board processes. Lower cost systems have been demonstrated by judiciously using all of our technology developments to enable "plug and play" scalable architectures. The paper will present a survey of development and insertion experiences for the above technologies, as well as future plans to enable more "better, faster, cheaper" spacecraft. Details of ongoing GSFC programs such as Ultra-Low Power electronics, Rad-Hard FPGAs, PCI master ASICs, and Next Generation Mongoose processors.

Luers, Philip J.↗
NASA NTRS1994

Interactive Visualization of Computational Fluid Dynamics using Mosaic

The Web provides new Methods for accessing Information world-wide, but the current text-and-pictures approach neither utilizes all the Web's possibilities not provides for its limitations. While the inclusion of pictures and animations in a paper communicates more effectively than text alone, It Is essentially an extension of the concept of "publication." Also, as use of the Web increases putting images and animations online will quickly load even the "Information Superhighway." We need to find forms of communication that take advantage of the special nature of the Web. This paper presents one approach: the use of the Internet and the Mosaic interface for data sharing and collaborative analysis. We will describe (and In the presentation, demonstrate) our approach: using FAST (Flow Analysis Software Toolkit), a scientific visualization package, as a data viewer and interactive tool called from MOSAIC. Our intent is to stimulate the development of other tools that utilize the unique nature of electronic communication.

Clucas, Jean↗
NASA NTRS1997

Experimental and Computational Studies of the Flow Over a Sting Mounted Planetary Probe Configuration

This paper summarizes the results of a series of experimental studies in the LENS shock tunnel and computations with DSMC and Navier Stokes codes which have been made to examine the aerothermal and flowfield characteristics of the flow over a sting-supported planetary probe configuration in hypervelocity air and nitrogen flows. The experimental program was conducted in the LENS hypervelocity shock tunnel at total enthalpies of 5and 10 MJkg for a range of reservoir pressure conditions from 70 to 500 bars. Heat transfer and pressure measurements were made on the front and rear face of the probe and along the supporting sting. High-speed and single shot schlieren photography were also employed to examine the flow over the model and the time to establish the flow in the base recirculation region. Predictions of the flowfield characteristics and the distributions of heat transfer and pressure were made with DSMC codes for rarefied flow conditions and with the Navier-Stokes solvers for the higher pressure conditions where the flows were assumed to be laminar. Analysis of the time history records from the heat transfer and pressure instrumentation on the face of the probe and in the base region indicated that the base flow was fully established in under 4 milliseconds from flow initiation or between 35 and 50 flow lengths based on base height. The measurements made in three different tunnel entries with two models of identical geometries but with different instrumentation packages, one prepared by NASA Langley and the second prepared by CUBRC, demonstrated good agreement between heat transfer measurements made with two different types of thin film and coaxial gage instrumentation. The measurements of heat transfer and pressure to the front face of the probe were in good agreement with theoretical predictions from both the DSMC and Navier Stokes codes. For the measurements made in low density flows, computations with the DSMC code were found to compare well with the pressure and heat transfer measurements on the sting, although the computed heat transfer rates in the recirculation region did not exhibit the same characteristics as the measurements. For the 10MJkg and 500 bar reservoir match point condition, the measurements and heat transfer along the sting from the first group of studies were in agreement with the Navier Stokes solutions for laminar conditions. A similar set of measurements made in later tests where the model was moved to a slightly different position in the test section indicated that the boundary layer in the reattachment compression region was close to transition or transitional where small changes in the test environment can result in larger than laminar heating rates. The maximum heating coefficients on the sting observed in the present studies was a small fraction of similar measurements obtained at nominally the same conditions in the HEG shock tunnel, where it is possible for transition to occur in the base flow, and in the low enthalpy studies conducted in the NASA Langley high Reynolds number Mach 10 tunnel where the base flow was shown to be turbulent. While the hybrid Navier- StokedDMSC calculations by Gochberg et al. (Reference 1) suggested that employing the Navier- Stokes calculations for the entire flowfield could be seriously in error in the base region for the 10 MJkg, 500 bar test case, similar calculations performed by Cornell, presented here, do not.

Holden, Michael S.↗
NASA NTRS1987

Incorporation of a circulating protein into megakaryocyte and platelet granules

To determine whether or not proteins circulating in plasma can be incorporated into megakaryocytes and platelets, horseradish peroxidase (HRP) was injected intravenously into guinea pigs and these cells were examined for its uptake by electron microscopy and cytochemistry. Enriched samples of megakaryocytes enabled ultrastructural analysis of large numbers of these rare cells. In megakaryocytes, 50% of alpha granules contained HRP between 75 min and 7 hr after injection. At 24 hr, 25% of the megakaryocyte granules were peroxidase-positive, less were positive by 48 hr, and there were none at 4 days. Thus, the findings demonstrate that a circulating protein can be endocytosed by megakaryocytes and rapidly packaged into alpha granules. Platelet granules also contain HRP by 7 hr after injection, and they can secrete it in response to thrombin. Unfortunately, our present studies do not allow us to distinguish between direct endocytosis by the platelet and/or shedding of new platelets from recently labeled megakaryocytes. It is concluded that while some alpha granule proteins are synthesized by megakaryocytes, others may be acquired from plasma by endocytosis. In addition to providing evidence that some of the proteins of alpha granules may be of exogenous origin, this study has allowed the definition of a pathway whereby plasma proteins may be temporarily sequestered in megakaryocytes before reentering the circulation in platelets.

Megakaryocytes/metabolism/ultrastructure↗
NASA NTRS1994

Space Flyable Hg(sup +) Frequency Standards

We discuss a design for a space based atomic frequency standard (AFS) based on Hg(sup +) ions confined in a linear ion trap. This newly developed AFS should be well suited for space borne applications because it can supply the ultra-high stability of a H-maser but its total mass is comparable to that of a NAVSTAR/GPS cesium clock, i.e., about 11kg. This paper will compare the proposed Hg(sup +) AFS to the present day GPS cesium standards to arrive at the 11 kg mass estimate. The proposed space borne Hg(sup +) standard is based upon the recently developed extended linear ion trap architecture which has reduced the size of existing trapped Hg(sup +) standards to a physics package which is comparable in size to a cesium beam tube. The demonstrated frequency stability to below 10(sup -15) of existing Hg(sup +) standards should be maintained or even improved upon in this new architecture. This clock would deliver far more frequency stability per kilogram than any current day space qualified standard.

clocks cesium atomic frequency standard Hg ions li↗
NASA NTRS2007

Coherent Lidar Activities at NASA Langley Research Center

NASA Langley Research Center has been developing and using coherent lidar systems for many years. The current projects at LaRC are the Global Wind Observing Sounder (GWOS) mission preparation, the Laser Risk Reduction Program (LRRP), the Instrument Incubator Program (IIP) compact, rugged Doppler wind lidar project, the Autonomous precision Landing and Hazard detection and Avoidance Technology (ALHAT) project for lunar landing, and the Skywalker project to find and use thermals to extend UAV flight time. These five projects encompass coherent lidar technology development; characterization, validation, and calibration facilities; compact, rugged packaging; computer simulation; trade studies; data acquisition, processing, and display development; system demonstration; and space mission design. This paper will further discuss these activities at LaRC.

Kavaya, Michael J.↗
NASA NTRSDate not supplied

An Optimization Approach to Support Science Decision Making for Lunar Surface Exploration

Introduction: Scientific exploration is one of the three pillars of NASA’s Moon2Mars architecture, with crew surface extra vehicular activities (EVA) serving a critical enabling function. Development of surface EVA operational planning and execution, specifically integrating science and flight control teams (FCT), is currently being explored through analog scenarios. This integration, exercised, for example, through the Joint EVA and Hu-man Surface Mobility Test Team (JETT), allows for science input on EVA activities in near real-time through a Science Evaluation Room (SER), or Arte-mis science backroom, which integrates with the broader FCT through the Science Officer. The SER works within the FCT to support dynamic EVA planning in response to changes in operational constraints as well as science opportunities and re-prioritization, increasing the mission science return and accelerating the accomplishment of the Moon2Mars science objectives. The SER works within the FCT to provide recommendations to traverse execution in near real-time. One challenge is the requirement to deliver SER inputs to the FCT on operationally relevant timelines. Failure to do so may result in suboptimal execution of science exploration EVAs or even loss of key science objectives. To close this gap, we present a network optimization tool to allow the SER to provide rapid input to the FCT in response to changes in operational constraints or science opportunities. Inputs are predicated on approved science objectives, and clear rationale must be provided to the FCT for any requested change. Accordingly, this tool incorporates the Science Traceability Matrix (STM), SER prioritization scheme, and station characterization and action planning with operational constraints such as duration, traverse speed, and distance to maximize science objectives based on SER priorities, consistent with FCT operational requirements. Method: As a proof of concept, we used an existing linear programing software package used to simulate optimal routes through cellular metabolism. We built a Demonstrative Model with three STM objectives and four stations on a region of the Moon. The objectives were given an arbitrary prioritization and mapped to the stations through four possible crew actions. (Figs. 1 and 2). This station to STM mapping is consistent with the method used by the JETT5 Science Team to develop analog surface EVA science planning. We used a grid system with the landing site at the origin and the four stations placed across the positive x,y quadrant. Actions were assigned to each station and the accomplishment of those actions resulted in a numerical “reward” based on the ability of that action to achieve science objectives. The aggregate reward from each individual STM objective contributes to a global score (Science Yield), weighted by its priority. Operational constraints included a requirement to start and end at the landing site, 5 minutes each for initial station characterization and “clean up,” and variable total EVA time, traverse rate (fixed to 0.5 meters per second in our example), and time to perform each action (10, 5, 7, and 15 min for actions 1, 2, 3, and 4, respectively). Additional constraints and variables will be added in the future (e.g., sample mass, number of stations, traverse route constraints, illumination). Optimization. We converted the connections (arcs) between these stations (nodes) into a mixed integer linear programming optimization problem (arcs = constraints, nodes = variables) with the objective to maximize Science Yield. For any action, the Science Yield is equal to the relevance of that action to an STM objective [3, 2, and 1 point(s) for High, Med., and Low relevance, respectively], multiplied by the STM Objective Priority [3, 2, and 1 point(s) for High, Med., and Low priority, respectively]. This resulted in a model that computes the optimal station and action combination to maximize the Science Yield. These weightings can be adjusted by the SER as desired. Results: We explored three test cases for the Demonstrative Model. First, we set the maximum EVA duration to 120 minutes and computed the optimal route (Fig. 3A). The model suggested per-forming Actions 1 and 2 at Station P01, followed by Actions 1 and 2 at Station P02, and finally Actions 1 and 3 at Station P04 before returning to the Landing Site. Second, we adjusted the STM Objective Priori-ty order and computed the new optimal route (Fig. 3B). Under this situation, the model suggested per-forming all Actions at Station P02 followed by all Actions at Station P03. The previous test cases were relevant to SER planning activities. Next, we explored providing mid-EVA replanning input to the FCT. Scenario: While executing the Route in Fig. 3A the crew finishes at Station P01 and FCT decides that the EVA needs to finish in 45 minutes back at the Landing Site. FCT asks SER to recommend changes to the plan to accommodate this operation-al change. Using the model and incorporating these new constraints (start at Station P01, max. time of 45 min), the model suggested performing Actions 2 and 4 at Station P03 (Fig. 4), requiring 41 minutes to complete and return to the Landing Site. Interestingly, Station 3 was not part of the original route. Using the model, we determined the EVA would need 66 minutes, instead of 45, in order for the original Station P04 to yield a larger Science Yield than Station P03. The parametrization and simulation was per-formed in less than a minute, demonstrating the operational relevance of the approach. Future Efforts: The results from the Demonstrative Model suggest this tool can accelerate SER decision making on operationally relevant timelines. Use in analog activities, such as JETT5 or follow-ons, which have over a dozen stations for a crew to explore and over a dozen actions per station, will provide needed validation of the utility of this tool for planning EVAs, replanning mid-EVA, or planning follow-on EVAs based on previous results. Further integration with FCT execution monitoring tools may provide additional efficiency gains, al-lowing rapid and iterative exploration of operation-al and science decision space by the FCT and SER.

Science Operations↗
DOE OSTI2015

Understanding the consequences of hypothetical post-closure transient criticality in a geological disposal facility - 14439

Radioactive Waste Management (RWM) is responsible for implementing geological disposal of the UK's higher-activity radioactive wastes. These wastes include significant quantities of fissile nuclides and, therefore, demonstration of criticality safety for the wastes under disposal conditions forms an important component of RWM's disposal system safety case. At the time of disposal all waste packages will be safely sub-critical. Containment provided by the engineered barrier system of a geological disposal facility (GDF) will ensure that criticality is not possible for some time after disposal. However, as waste packages degrade, fissile and other materials may be mobilised, which could affect the potential for criticality. Although the likelihood of a critical configuration developing is demonstrably low, it cannot be assumed to be zero over long post-closure timescales. The UK environment agencies' Guidance on Requirements for Authorisation for a GDF includes a specific requirement to consider the consequences of hypothetical 'what-if' post-closure criticality. RWM has undertaken a programme of research to model and understand the consequences of hypothetical post-closure criticality events. Initially focused on the scenario of fissile material relocation and accumulation following intermediate level waste (ILW) disposal, two bespoke computer models were developed. The quasi-steady-state (QSS) model considered critical systems maintained by accumulation of fissile materials where the temperature feedback remains negative throughout the transient. The rapid transient model (RTM) considered systems with positive temperature feedback. The QSS model development included a successful comparison with the Oklo natural reactors. With a requirement to consider post-closure criticality for a wider range of potential waste types under different illustrative disposal concepts, the initial transient criticality models had some limitations. For the QSS model this was the assumption of fixed geometry, while the complex functional inputs required in the RTM were not readily available for different materials. For the QSS model this paper describes the model development to allow changing volume; this has enabled its application to 'what-if' scenarios of flooding within a spent fuel waste package and the slumping of a stack of ILW packages. For rapid transient criticality this paper explains how the development of a simpler 'bounding approach' model to complement the RTM has enabled transient criticality analysis for a wider range of host materials. The role of this research in demonstrating post-closure criticality safety of a GDF in the UK is presented in a companion paper which also draws on the results of a parallel research project to demonstrate that the likelihood of post-closure criticality is low. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1995

SEL's Software Process-Improvement Program

The goals and operations of the Software Engineering Laboratory (SEL) is reviewed. For nearly 20 years the SEL has worked to understand, assess, and improve software and the development process within the production environment of the Flight Dynamics Division (FDD) of NASA's Goddard Space Flight Center. The SEL was established in 1976 with the goals of reducing: (1) the defect rate of delivered software, (2) the cost of software to support flight projects, and (3) the average time to produce mission-support software. After studying over 125 projects of FDD, the results have guided the standards, management practices, technologies, and the training within the division. The results of the studies have been a 75 percent reduction in defects, a 50 percent reduction in cost, and a 25 percent reduction in development time. Over time the goals of SEL have been clarified. The goals are now stated as: (1) Understand baseline processes and product characteristics, (2) Assess improvements that have been incorporated into the development projects, (3) Package and infuse improvements into the standard SEL process. The SEL improvement goal is to demonstrate continual improvement of the software process by carrying out analysis, measurement and feedback to projects with in the FDD environment. The SEL supports the understanding of the process by study of several processes including, the effort distribution, and error detection rates. The SEL assesses and refines the processes. Once the assessment and refinement of a process is completed, the SEL packages the process by capturing the process in standards, tools and training.

Basili, Victor↗
DOE OSTI2023

IACMI Project 4.7: Pultruded Textile Carbon Fiber for Spar Caps (Final Report)

The primary objective of this project was to demonstrate the potential to significantly reduce the cost of wind turbine blades with carbon fiber reinforced polymer (CFRP) structure. Applicability of textile carbon fibers (TCF) were evaluated for use in pultruded spar cap (SC) elements as a path to cost reduction for utility scale wind turbine blades. In earlier work for the Department of Energy (DOE) Wind Energy Technologies Office (WETO), a collaboration of Sandia National Laboratory (SNL), Oak Ridge National Laboratory (ORNL), and Montana State University has demonstrated potential for pultruded TCF to compete with infused fiberglass and commercially available carbon fiber pultruded sections for spar cap construction. In the design cases evaluated, the TCF sections fared well when compared on cost per unit composite stiffness and cost per unit composite compressive strength for those designs [1]. Both stiffness and compressive strength tend to be key factors in the design of blade composite Spar Cap which carry the bulk of the blade structural loads in bending. Spar Cap design tends to distribute largely symmetric tensile and compressive stresses to opposite sides of the spar structure, but since carbon fiber composite compressive strength is typically 20-50% lower than tensile strength, the compressive loading reaches failure levels well before the tensile loading. Stiffness is critical in containing the large tip deflection in high wind loading situations. However, materials and process development were very limited in the earlier study and the work in this project was expanded to make the comparative information more representative of what will be required in order to make further inroads towards implementation. Similar to that study, this project team confirmed that the primary materials of interest for pultruded spar cap elements should be thermoset (TS) resins reinforced by carbon fibers, utilizing as high a percentage of TCF as practical to benchmark cost and performance against commercial carbon fibers. To make the closest comparison possible and eliminate specific test article size, resin selection, and equipment/operational nuance effects, the team planned to pultrude sections with 100% commercially available carbon fiber (Panex 35 carbon fiber from Zoltek) as well as samples utilizing high fractions of TCF. The resin system chosen was based on formulations recommended by large wind industry supplier Hexion and consisted of Hexion resin RSL-4597, curing agent CCA-138, and internal mold release additive 117, along with common kaolin filler ASP400P from BASF. As commonly deployed in spar cap configurations, the team had a mold built to pultrude a rectangular spar cap element of 100mm width and 3mm thickness. The extremely limited number of samples produced for the earlier study were produced with a “generic” epoxy utilized for a variety of applications by the pultruder contracted to produce test articles for demonstration purposes. More importantly, those samples were produced at a fiber fraction only slightly over 50%. Based on feedback from our industrial advisory team for that project and strongly recommended by this project team, the consensus is that it is highly desirable to obtain fiber fractions of 65-68% for significant penetration in wind blade spar cap. Although this requirement has yet to be exhaustively confirmed in readily available information, this was established as a project goal and informally decided we needed to exceed 60% fiber fraction to gain serious industry consideration. Previous TCF pultrusion trials have been challenged by the lack of robust TCF packages, resulting in non-uniform tension across and between tows, as well as excess labor and waste for removal of interleaved paper. The non-uniform tension and associated intermingling of tows in textile acrylic fiber tows and associated difficulties created from broken filaments in carbon fiber conversion inhibit the ordered packing necessary to enhance fiber fraction elevation. (These “cross-overs” are not considered undesirable for textile applications and there is some sense that they might be advantageous for those applications). In addition to work that is ongoing at the acrylic fiber manufacturers to improve their formats, The Institute of Advanced Composites Manufacturing Innovation (IACMI) Project 6.12 (report PA16-0349-6.12-01) [2] has developed and demonstrated a more robust packaging and creeling approach that at least partially addresses these issues, thus improving control of the TCF feed into the pultrusion unit. It was hoped that these and other improvements currently being implemented would allow us to achieve fiber fractions at least approaching these fiber fraction targets. During this project, sections utilizing 100% commercially available carbon fiber reinforcement were produced as a baseline, as well as sections reinforced with about 94% TCF and the balance being commercially available fiber for comparison. The most important finding was that similar to results reported in the earlier WETO-funded project and results from tests of TCF reported at IACMI meetings, this work demonstrated that sections pultruded with TCF in an epoxy resin frequently utilized in actual spar cap production had stiffness and compressive strengths largely comparable to similar sections pultruded with a commercially available carbon fiber also frequently utilized in the wind industry. Although the amount of that data is limited, some of the tensile strength results were actually closer than would have been expected based on fiber strength results provided by the TCF and commercial fiber producers. The actual test data are reported and discussed in detail in Section 5. The pultruded sections dominated by TCF reinforcement were approximately 8-10% lower in fiber fraction than for the sections produced using commercial fiber alone, making direct comparison difficult. The COVID-19 project has provided significant insight into the current state-of-the-art with various TCF product forms. The data obtained in this project will guide the planned improvements at the precursor level, especially in attaining uniform tensioning and payout to facilitate enhanced fiber fractions and overall processability of the TCF composites. The project team is providing guidance to stakeholders concerning the attributes, needs, and potential demand for TCF in wind blade spar caps. Results achieved in this project are consistent with findings in the related work cited [1] and support this guidance and the high potential for this product type. TCF precursor-producing partners continue to express interest in enhancing their product forms and the team looks forward to working with these improved materials as they become available.

42 ENGINEERING↗