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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Thermal Testing and Analysis Techniques for Wires and Wire Bundles

Determining wire and wire bundle amperage capacity (i.e., “ampacity”) currently relies on the use of standards to derate wire ampacity when in a bundle configuration. The feasibility of developing physics-based and regression thermal models of single wires and wire bundles to determine ampacity using a customized test apparatus was investigated during a pathfinder study. A test facility was developed and various wire and wire bundle articles were tested under a variety of temperature and pressure conditions using an efficient test matrix formulated using Design of Experiments (DOE) techniques. Physics-based models were developed and correlated to the test results. Regression models were formulated and compared to test results and standards.

Thermal↗
NASA NTRSDate not supplied

Thermal Testing and Analysis Techniques for Wires and Wire Bundles

Determining wire and wire bundle amperage capacity (i.e., “ampacity”) currently relies on the use of standards to derate wire ampacity when in a bundle configuration. The feasibility of developing physics-based and regression thermal models of single wires and wire bundles to determine ampacity using a customized test apparatus was investigated during a pathfinder study. A wire bundle test apparatus was developed for measuring the temperatures of single wires and wire bundles and collected wire conductor temperature data under high vacuum and atmospheric conditions and varying environmental temperatures and currents for the two most common wire types used on spacecraft.

Thermal↗
NASA NTRS1992

NASA Lewis Stirling SPRE testing and analysis with reduced number of cooler tubes

Free-piston Stirling power converters are candidates for high capacity space power applications. The Space Power Research Engine (SPRE), a free-piston Stirling engine coupled with a linear alternator, is being tested at the NASA Lewis Research Center in support of the Civil Space Technology Initiative. The SPRE is used as a test bed for evaluating converter modifications which have the potential to improve the converter performance and for validating computer code predictions. Reducing the number of cooler tubes on the SPRE has been identified as a modification with the potential to significantly improve power and efficiency. Experimental tests designed to investigate the effects of reducing the number of cooler tubes on converter power, efficiency and dynamics are described. Presented are test results from the converter operating with a reduced number of cooler tubes and comparisons between this data and both baseline test data and computer code predictions.

Wong, Wayne A.↗
DOE OSTI2022

Pilot Testing of a Highly Efficient Pre-combustion Sorbent-based Carbon Capture System

TDA developed and demonstrated a highly efficient pre-combustion carbon capture system. The overall objective of this work was to develop a new sorbent-based pre-combustion carbon capture technology for Integrated Gasification Combined Cycle (IGCC) power plants. In this project our goal was to demonstrate the techno-economic viability of the new technology by 1) demonstrating it in large-scale slipstream tests, and 2) carrying out a high fidelity engineering and cost analysis. TDA’s process used an advanced physical adsorbent that selectively removes CO 2 from coal-derived synthesis gas above the dew point of the gas at temperatures as high as 300°C. The sorbent consists of a mesoporous carbon whose surface was grafted with functional groups that remove CO 2 via a well-known acid-base interaction. As documented in bench-scale experiments and field tests with actual coal gas, the sorbent achieved a very high capacity for CO 2 at temperatures as high as 300°C. The sorbent bound CO 2 more strongly than common physical adsorbents, providing the chemical potential needed for the high temperature operation. However, because CO 2 does not form a true covalent bond with the surface sites (as is the case with chemical absorbents), the sorbent regeneration could be carried out with only a very small energy input. The heat input to regenerate our sorbent was only 4.9 kcal per mol of CO 2 , which is much lower than that for chemical absorbents (e.g., 29.9 kcal/mol CO 2 for sodium carbonate) and was similar to the requirements of physical solvents (e.g., 4 kcal/mol CO 2 for Selexol TM ). Because the sorbent operates above the dew point of the synthesis gas (unlike the Selexol TM process), a higher power cycle efficiency can be achieved. With previous DOE/NETL funding (Contract No. DE-FE-0000469), we demonstrated the techno-economic viability of the technology in bench-scale tests and slipstream demonstrations at the National Carbon Capture Center (NCCC), Wilsonville, Alabama and Wabash River IGCC plant in Terra Haute, Indiana. We demonstrated a stable working CO 2 capacity for over 11,650 cycles with simulated synthesis gas. We also evaluated its performance with actual synthesis gas in two test campaigns at the Wabash River IGCC Plant, Terre Haute, IN and the National Carbon Capture Center (NCCC), Wilsonville, AL. The slipstream tests clearly showed that the actual coal gas constituents and potential contaminants (e.g. trace metals, halides, tars) had no effect on the sorbent’s ability to remove CO 2 (the same sorbent beds were used in both field tests with no sign of deactivation for 2,000 cycles with over 26,750 SCF of gas treated). As expected, due to the high temperature CO 2 removal capability and low energy needed to regenerate the sorbent, the power cycle efficiency with our process was greater than 34% on a higher heating value (HHV) basis; in comparison, the same IGCC plant equipped with the Selexol TM solvent for carbon capture can only achieve 31.4% HHV efficiency. The capital cost for an IGCC system with TDA’s process is estimated as $2,417/kW e , which is 12% lower than that of the IGCC/ Selexol TM process. The levelized cost for electricity including the transport, storage and monitoring (TS&M) cost for CO 2 was calculated as $\$ $92.9/MWh (lowest reported to our knowledge), which is much better than the $105.2/MWh estimated for the IGCC/ Selexol TM process. In this project (DE-FE0013105), TDA Research, in collaboration with our partners Gas Technology Institute (GTI), Illinois Clean Coal Institute (ICCI), University of California, Irvine (UCI), University of Alberta (UOA), Siemens, NCCC and Sinopec advanced the technical maturity of the technology; scaling it up by a factor of 100. We optimized the reactor design using computational fluid dynamics (CFD); using adsorption modeling we improved the pressure swing adsorption (PSA) cycle sequence. We carried out two field test campaigns with a fully-equipped 0.1 MW e prototype unit (for a total of 844 hours) using actual synthesis gas to prove the viability of the new technology. A successful 30 day (707 hrs) evaluation was completed at NCCC under air blown gasification conditions. We demonstrated 97.3% carbon capture at 1,500 SLPM, 93% carbon capture at 1,800 SLPM, and 90% carbon capture at 2,100 SLPM in the NCCC tests. We also demonstrated the system for 137 hours at a Sinopec petrochemical plant under oxygen blown gasification, demonstrating 86% carbon capture at 2,660 SLPM. In collaboration with University of California, Irvine (UCI), we completed a techno-economic analysis (TEA) for TDA’s warm gas cleanup technology integrated to IGCC power plant. The net plant efficiencies (on a coal HHV basis) for the warm gas cleanup cases were estimated to be 34.0% for E-GasTM gasifier, 34.4% for GE gasifier, 33.4 for the Shell gasifier and 34.2 for the TRIG TM gasifier (Cases 2, 4, 6 and 8 in this study) with a catalytic combustor for CO 2 purification, which are significantly higher than those for the Cold Gas Case, or an increase of as much as 12% in the heat rate for Case 2, 6% for Case 4, 9% for Case 6, and 9% for Case 8. The 1st year cost of electricity with the transport, storage and monitoring (TS&M) costs for the CO 2 included was $\$ $129.2/MWh for the E-GasTM gasifier Warm Gas Cleanup Case, $\$ $131.9/MWh for the GE gasifier Warm Gas Cleanup Case, $\$ $146.8/MWh for the Shell Gasifier Warm Gas Cleanup Case, and $\$ $129.9/MWh for the TRIG TM gasifier Warm Gas Cleanup Case. For comparison, the costs for the baseline Cold Gas CO 2 removal with Selexol for the different gasifiers were: $\$ $146.6/MWh for the E-Gas TM gasifier, $\$ $142.2/MWh for the GE gasifier, $\$ $159.0/MWh for the Shell gasifier and $\$ $144.3/MWh for the TRIG TM gasifier. In summary, the costs for our system were 7 to 12% lower than the corresponding Cold Gas Cleanup cases. The results of this techno-economic analysis suggested that TDA’s high temperature PSA-based Warm Gas Clean-up Technology can make a substantial improvement in the IGCC plant thermal performance for achieving near zero CO 2 emissions for E-Gas TM , GE, Shell and TRIG TM gasifier based IGCC power plants. The capital expenses were estimated to be lower than that of Selexol’s™. Taken together, the higher net plant efficiency and lower capital and operating costs resulted in substantial reduction in the cost of carbon capture for the IGCC plant equipped with TDA’s high temperature PSA-based carbon capture system. Finally, in collaboration with Gas Technology Institute (GTI) we completed the environmental health and safety assessment for TDA’s warm gas carbon capture technology.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1974

Space payload dynamic testing

More cost effective methods for insuring payload reliability are required to efficiently utilize the projected payload capacity of future space systems such as the Space Shuttle. Studies are needed to better define the vibration environment of space vehicles to develop improved and more routine methods of testing and to develop better dynamic protection systems. Such improvements in environment definition, testing, and isolation will lead to less stringent design specification, improved payload reliability, fewer and more realistic qualification and flight acceptance tests. This paper presents current payload test philosophies, effectiveness of testing, and research needed to achieve more cost effective payload reliability for future applications.

Pinson, L. D.↗
DOE OSTI2024

Assessment of Amine-Based CO2BOLs for Direct Air Capture

Direct air capture (DAC) technologies extract CO 2 from the atmosphere for CO 2 storage, or utilization. Capturing CO 2 from the air is the most expensive application of carbon capture because CO 2 in the atmosphere is very dilute. There are limited number of CO 2 capture technologies for DAC application. This project aims at developing an energy efficient technology for DAC, leveraging two PNNL’s chemistries (solid and liquid CO 2 capture). Three CO 2 capture sorbents consisting of amine based CO 2 BOLs immobilized in mesoporous silica were designed, synthesized, and tested. These sorbents had ~ 19-23 wt.% amine loadings which is lower than typical amine-based silica sorbents. The surface area and pore volumes of these solid supported CO 2 BOLs are lower compared to those of the pristine silica support. The CO 2 capture performance of these materials was significantly lower than the typical silica supported amines due to low amine loading and higher molecular weight with low amine density. These results show that immobilize CO 2 BOLs in silica are not viable materials for removing CO 2 from ambient air. This project also designed, synthesized at tested liquid solvents for DAC application. Solvent properties that is vapor pressure, CO 2 uptake capacity, kinetics, and viscosity for three novel solvents were evaluated. The CO 2 uptake capacity for one of the most promising amine-based solvent BEPBEGDA was the highest at 13.2 wt% corresponding to 97 mol%. The vapor pressure of the BEPBEGDA solvents were very low at 80 °C compared to other solvents making them suitable for DAC application. The effect of humidity on the CO 2 capture performance of these solvents was evaluated which shows that presence of moisture doesn’t have a negative effect on the CO 2 uptake performance but makes it slightly better. The performances of these solvents were slightly below that of the 0.1M NaOH solution tested under similar conditions. Despite of the slightly lower CO 2 uptake, it is expected that these liquid solvents will have lower regeneration temperature and minimum evaporative losses due their low vapor pressure. Future work will focus on optimization of the liquid solvents for DAC application to improve both CO 2 capture efficiency and capacity without viscosity and vapor pressure increase. Testing of these solvents under DAC conditions using a gas liquid contactor that mimic industrial applications is needed. Solvent cost projection, techno-economic analysis and life cycle analysis are required to evaluate economic viability of this technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1994

Carbon-Carbon Heat Pipe Testing and Evaluation

This report discusses development and proof-of-concept testing of a new lightweight carbon-carbon (C-C) space radiator heat pipe developed under the NASA Civil Space Technology Initiative (CSTI) High Capacity Power Program. The heat pipe was filled with potassium working fluid and tested for 11 hours including startup from ambient temperature with the working fluid initially in the frozen state to near 700 K condenser temperature. Steady-state heat pipe input power during testing was facility limited to about 300 watts, representing about 50 percent of the design input power. Post test inspection showed the heat pipe to be in excellent condition after eight thermal cycles from ambient to steady-state operating temperature. Potential applications, ranging from small spacecraft heat rejection to aircraft and terrestrial uses, are discussed.

Juhasz, Albert J.↗
NASA NTRS1986

Voltage-temperature charge verification testing of 34 ampere-hour nickel-cadmium cells

This testing was designed to evaluate various voltage-temperature (V-T) charge curves for use in low-Earth-orbit (LEO) applications of nickel-cadmium battery cells. The trends established relating V-T level to utilizable capacity were unexpected. The trends toward lower capacity at higher V-T levels was predominant in this testing. This effect was a function of the V-T level, the temperature, and the cell history. This effect was attributed to changes occurring in the positive plate. The results imply that for some applications, the use of even lower V-T levels may be warranted. The need to limit overcharge, especially in the early phases of missions, is underlined by this test program.

Timmerman, P. J.↗
DOE OSTI2021

Experimental validation of an organic rankine-vapor compression cooling cycle using low GWP refrigerant R1234ze(E)

There is a significant global opportunity to capture and utilize low grade waste heat to reduce fossil fuel consumption, greenhouse gas emissions, and improve energy efficiency across a wide range of industries. In this work, an advanced type of thermally activated cooling system, an organic Rankine-vapor compression cycle (ORVC) with novel heat integration strategies, was designed and tested at a relevant scale for industrial waste heat recovery (300 kW th cooling capacity). The ORVC linked an organic Rankine power cycle and a vapor compression cooling cycle using a turbine and compressor that shared a single shaft. The ORVC test facility absorbed waste heat from a liquid stream at 91 °C to simulate engine coolant in diesel generator sets, rejected heat to a glycol stream at 30 °C, and generated chilled water at 7 °C. A cooling capacity of 264 kW ± 3.5 kW was experimentally validated with a COP of 0.56 ± 0.01 during steady-state operation at the design temperatures. The thermal efficiency, accounting for pump work, of the Rankine cycle was 7.7% ± 0.22% and the COP of the vapor compression cycle was 5.25 ± 0.09. The centrifugal turbo-compressor operated at 31.5 kRPM ± 0.3 kRPM, with a turbine and compressor isentropic efficiencies of 76.7% ± 0.90% and 84.8% ± 0.54%, respectively, with near-perfect power transmission between these components. The pressure drop in the piping and heat exchangers were significantly larger than expected which had a detrimental impact on the performance of the ORVC. In addition, the condenser on the cooling cycle could not deliver the subcooling as specified from the design point modeling. Furthermore, the results from the sensitivity analysis showed that the higher condenser glycol outlet temperature had the largest impact on performance, which is consistent with other analytical models in the literature. When the ORVC simulations were updated with experimental values for isentropic efficiencies of the turbomachinery, the thermal COP was 0.66 which represents an estimate of the predicted performance if test facility limitations are overcome.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS1978

Design and test of the 172K fluidic rudder

Progress in the development of concepts for control of aircraft without moving parts or a separate source of power is described. The design and wind tunnel tests of a full scale fluidic rudder for a Cessna 172K aircraft, intended for subsequent flight tests were documented. The 172K fluidic rudder was designed to provide a control force equivalent to 3.3 degrees of deflection of the conventional rudder. In spite of an extremely thin airfoil, cascaded fluidic amplifiers were built to fit, with the capacity for generating the required level of control force. Wind tunnel tests demonstrated that the principles of lift control using ram air power are sound and reliable under all flight conditions. The tests also demonstrated that the performance of the 172K fluidic rudder is not acceptable for flight tests until the design of the scoop is modified to prevent interference with the lift control phenomenon.

Belsterling, C. A.↗
DOE OSTI2026

Cascading economic losses from port disruptions under capacity constrained multimodal freight networks

This study quantifies how throughput disruptions at major seaports cascade through capacity-constrained multimodal freight networks and interregional production systems. We couple an agent-based model (ABM) multimodal freight simulation that resolves rerouting, terminal queueing, and inventory drawdown under binding modal and facility capacities with a multiregional output loss input-output (MRIIM) model that propagates realized delivery shortfalls across regions and sectors. The framework is demonstrated for the Port of Los Angeles using Freight Analysis Framework flows and Bureau of Economic Analysis input-output accounts and is evaluated over a 52-week horizon under deterministic sector targeted shocks and stochastic disruption realizations with uncertain severity and duration. Results indicate nonlinear amplification: realized national losses concentrate in manufacturing and transportation/warehousing even when exogenous port shocks are dispersed, suggesting that congestion spillback and limited short-run substitution can dominate the initial shock allocation. We further evaluate a tabular reinforcement-learning (Q-learning) intervention layer that selects among a small set of implementable system level levers (truck-to-rail and truck-to-barge shift settings) without overriding shipper routing, finding that such interventions reduce total losses for moderate disruptions but yield diminishing returns once substitute modes approach capacity. By linking operational freight behavior to system wide impacts under uncertainty, the proposed ABM-MRIIM pipeline provides a reusable workflow for port disruption stress testing, identification of structurally critical sectors/corridors, and evaluation of resilience interventions under realistic capacity limits.

42 ENGINEERING↗
NASA NTRS2000

Acceptance Testing of a Satellite SCADA Photovoltaic-Diesel Hybrid System

Satellite Supervisory Control and Data Acquisition (SCADA) of a Photovoltaic (PV)/diesel hybrid system was tested using NASA's Advanced Communication Technology Satellite (ACTS) and Ultra Small Aperture Terminal (USAT) ground stations. The setup consisted of a custom-designed PV/diesel hybrid system, located at the Florida Solar Energy Center (FSEC), which was controlled and monitored at a "remote" hub via Ka-band satellite link connecting two 1/4 Watt USATs in a SCADA arrangement. The robustness of the communications link was tested for remote monitoring of the health and performance of a PV/diesel hybrid system, and for investigating load control and battery charging strategies to maximize battery capacity and lifetime, and minimize loss of critical load probability. Baseline hardware performance test results demonstrated that continuous two-second data transfers can be accomplished under clear sky conditions with an error rate of less than 1%. The delay introduced by the satellite (1/4 sec) was transparent to synchronization of satellite modem as well as to the PV/diesel-hybrid computer. End-to-end communications link recovery times were less than 36 seconds for loss of power and less than one second for loss of link. The system recovered by resuming operation without any manual intervention, which is important since the 4 dB margin is not sufficient to prevent loss of the satellite link during moderate to heavy rain. Hybrid operations during loss of communications link continued seamlessly but real-time monitoring was interrupted. For this sub-tropical region, the estimated amount of time that the signal fade will exceed the 4 dB margin is about 10%. These results suggest that data rates of 4800 bps and a link margin of 4 dB with a 1/4 Watt transmitter are sufficient for end-to-end operation in this SCADA application.

Kalu, A.↗
NASA NTRS1972

Rolling-element fatigue life of silicon nitride balls: Preliminary test results

Hot pressed silicon nitride was evaluated as a rolling element bearing material. The five-ball fatigue tester was used to test 12.7 mm (0.500 in.) diameter balls at a maximum Hertz stress of 800,000 psi at a race temperature of 130 F. The fatigue spalls in the silicon nitride resembled those in typical bearing steels. The ten-percent fatigue life of the silicon nitride balls was approximately one-eighth to one-fifth that of typical bearing steels (52100 and M-50). The load capacity of the silicon nitride was approximately one-third that of typical bearing steels. The load capacity of the silicon nitride was significantly higher than previously tested ceramic materials for rolling element bearings.

Parker, R. J.↗
NASA NTRS1984

Factors Affecting Nickel-oxide Electrode Capacity in Nickel-hydrogen Cells

The nickel-oxide electrode common to the nickel hydrogen and nickel cadmium cell is by design the limiting or capacity determining electrode on both charge and discharge. The useable discharge capacity from this electrode, and since it is the limiting electrode, the useable discharge capacity of the cell as well, can and is optimized by rate of charge, charge temperature and additives to electrode and electrolyte. Recent tests with nickel hydrogen cells and tests performed almost 25 years ago with nickel cadmium cells indicate an improvement of capacity as a result of using increased electrolyte concentration.

Ritterman, P. F.↗
NASA NTRS1973

Development of a magnetically suspended momentum wheel

An engineering model of a magnetically suspended momentum wheel was designed, fabricated, and tested under laboratory conditions. The basic unit consisted of two magnet bearings, a sculptured aluminum rotor, brushless dc spin motor, and electronics. The magnet bearings, utilizing rare-earth cobltrat-samarium magnets were active radially and passive axially. The results of the program showed that momentum wheels with magnetic bearings are feasible and operable, and that magnetic bearings of this type are capable of being used for applications where high capacity, high stiffness, and low power consumption are required. The tests performed developed criteria for improved performance for future designs.

Hamilton, S. B.↗
DOE OSTI2025

Insight into the deformation features and capacity loss mechanisms of lithium-ion pouch cells under spherical indentation conditions

Mechanical deformation under extreme conditions is one of the important reasons for the failure of lithium-ion batteries in automotive application. However, the deformation features and component failure of lithium-ion cells to external loading has never been a design consideration. Here, in this study, we conduct spherical indentation tests on a dozen of lithium-ion cells with different capacities under different control mode conditions to investigate their deformation features and capacity loss mechanisms. The experimental results show that, under mechanical deformation conditions, internal faults of cells occur in stages, and energy accumulation and sudden release are two key processes of cell's mechanical failure. The cells' state of charge is the main factor affecting their thermal runaway behaviors. In addition, a finite element model is developed to simulate the deformation features and the failure mechanism of key components of lithium-ion pouch cells; the 3D x-ray computed tomography is employed to demonstrate its internal configuration. With this model, the force-strain response, the deformation features as well as the size of the failure area of lithium-ion cells under spherical indentation conditions are accurately predicted. In 3D x-ray computed tomography images, unique mud cracks in cooper current collector are observed, and the influence mechanisms of the isolated fragments on the cell capacities are revealed. These results may provide useful information for the mechanical structure design of the components of lithium-ion pouch cells.

25 ENERGY STORAGE↗
NASA NTRS1992

Primary zinc-air batteries for space power

Prismatic HR and LC cells and batteries were built and tested, and they performed well with respect to the program goals of high capacity and high rate capability at specific energies. The HR batteries suffered reduced utilizations owing to dryout at the 2 and 3 A rates for the 50 C tests owing to the requirement for forced convection. The LC batteries suffered reduced utilizations under all conditions owing to the chimney effect at 1 G, although this effect would not occur at 0 G. An empirical model was developed which accurately predicted utilizations and average voltages for single cells, although thermal effects encountered during battery testing caused significant deviations, both positive and negative, from the model. Based on the encouraging results of the test program, we believe that the zinc-air primary battery of a flat, stackable configuration can serve as a high performance and safe power source for a range of space applications.

Bragg, Bobby J.↗
NASA NTRS2007

The Effect of Variable End of Charge Battery Management on Small-Cell Batteries

ABSL Space Products is the world leading supplier of Lithium-ion batteries for space applications and has pioneered the use of small capacity COTS cells within large arrays. This small-cell approach has provided many benefits to space application designers through increased flexibility and reliability over more traditional battery designs. The ABSL 18650HC cell has been used in most ABSL space battery applications to date and has a recommended End Of Charge Voltage (EOCV) of 4.2V per cell. For all space applications using the ABSL 18650HC so far, this EOCV has been used at all stages of battery life from ground checkout to in orbit operations. ABSL and NASA have identified that, by using a lower EOCV for the same equivalent Depth Of Discharge (DOD), battery capacity fade could be reduced. The intention of this paper is to compare battery performance for systems with fixed and variable EOCV. In particular, the effect of employing the blanket value of 4.2V per cell versus utilizing a lower EOCV at Beginning Of Life (BOL) before gradually increasing it (as the effects of capacity fade drive the End Of Discharge Voltage closer to the acceptable system level minimum) is analyzed. Data is compared from ABSL in-house and NASA GRC tests that have been run under fixed and variable EOCV conditions. Differences in capacity fade are discussed and projections are made as to potential life extension capability by utilizing a variable EOCV strategy.

Neubauer, Jeremy↗