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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Encapsulation Residual Stress and Ferrite Loss in Inductive Coil Assemblies

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

Foote, Andrew↗
NASA NTRS1981

Design aspects of a solar array drive for spot, with a high platform stability objective

A solar array drive mechanism (MEGS) for the SPOT platform, which is a prototype of a multimission platform, is described. High-resolution cameras and other optical instruments are carried by the platform, requiring excellent platform stability in order to obtain high-quality pictures. Therefore, a severe requirement for the MEGS is the low level of disturbing torques it may generate considering the 0.6 times 10 to the minus 3 power deg/sec stability required. The mechanical design aspects aiming at reducing the mean friction torque, and therefore its fluctuations, are described as well as the method of compensation of the motor imperfections. It was concluded, however, that this is not sufficient to reach the stability requirement.

Cabillic, J.↗
DOE OSTI2024

CharIN Megawatt Charging System: 4 th Event Summary Report

Medium- and heavy-duty electric vehicles require higher charging power levels than are supported by present light-duty EV charging standards. The Charging Interface Initiative (CharIN) Megawatt Charging System (MCS) Task Force is undertaking efforts to develop a new high-power charging standard for medium- and heavy-duty vehicle electrification. The fourth MCS evaluation event at NREL focused on thermal and mechanical performance evaluations of high-power MCS electric vehicle charging connectors and inlets from several different manufacturers, at current levels up to 3000A. Additionally, the event evaluated the performance of a reference inlet design, which will provide a baseline level of thermal performance for use in future evaluation and certification efforts of MCS connectors.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1973

An electric motor with magnetic bearings: A concept

Because same magnetic flux is used to control rotor as to drive it, size, weight, and power required are minimized. Constant total current keeps motor torque invarient, and absence of mechanical bearings eliminates wear and reduces frictional power loss.

Studer, P. A.↗
NASA NTRS1994

A very low shock alternative to conventional, pyrotechnically operated release devices

NiTiNOL is best known for its ability to remember a preset shape, even after being 'plastically' deformed. This is accomplished by heating the material to an elevated temperature up to 120 degrees C. However, NiTiNOL has other material and mechanical properties that provide a novel method of structural release. This combination of properties allows NiTiNOL to be used as a mechanical fuse between structural components. When electrical power is applied to the NiTiNOL fuse(s), the material is annealed reducing the mechanical strength to a small fraction of the as-wrought material. The preload then fractures the weakened NiTiNOL fuse(s) and releases the structure. This paper describes the mechanical characteristics of the NiTiNOL allow used in this invention, structural separation design concepts using the NiTiNOL material, and initial test data. Elimination of the safety hazard, high shock levels, and non-reusability inherent with pyrotechnic separation devices allows NiTiNOL actuated release devices to become a viable alternative for aerospace components and systems.

Robinson, Steven P.↗
NASA NTRS2010

Miniature Piezoelectric Shaker for Distribution of Unconsolidated Samples to Instrument Cells

The planned Mars Science Laboratory mission requires inlet funnels for channeling unconsolidated powdered samples from the sampling and sieving mechanisms into instrument test cells, which are required to reduce cross-contamination of the samples and to minimize residue left in the funnels after each sample transport. To these ends, a solid-state shaking mechanism has been created that requires low power and is lightweight, but is sturdy enough to survive launch vibration. The funnel mechanism is driven by asymmetrically mounted, piezoelectric flexure actuators that are out of the load path so that they do not support the funnel mass. Each actuator is a titanium, flextensional piezoelectric device driven by a piezoelectric stack. The stack has Invar endcaps with a half-spherical recess. The Invar is used to counteract the change in stress as the actuators are cooled to Mars ambient temperatures. A ball screw is threaded through the actuator frame into the recess to apply pre-stress, and to trap the piezoelectric stack and endcaps in flexure. During the vibration cycle of the flextensional actuator frame, the compression in the piezoelectric stack may decrease to the point that it is unstressed; however, because the ball joint cannot pull, tension in the piezoelectric stack cannot be produced. The actuators are offset at 120 . In this flight design, redundancy is required, so three actuators are used though only one is needed to assist in the movement. The funnel is supported at three contact points offset to the hexapod support contacts. The actuator surface that does not contact the ring is free to expand. Two other configurations can be used to mechanically tune the vibration. The free end can be designed to drive a fixed mass, or can be used to drive a free mass to excite impacts (see figure). Tests on this funnel mechanism show a high density of resonance modes between 1 and 20 kHz. A subset of these between 9 and 12 kHz was used to drive the CheMin actuators at 7 V peak to peak. These actuators could be driven by a single resonance, or swept through a frequency range to decrease the possibility that a portion of the funnel surface was not coincident with a nodal line (line of no displacement). The frequency of actuation can be electrically controlled and monitored and can also be mechanically tuned by the addition of tuning mass on the free end of the actuator. The devices are solid-state and can be designed with no macroscopically moving parts. This design has been tested in a vacuum at both Mars and Earth ambient temperatures ranging from 30 to 25 C

Sherrit, Stewart↗
DOE OSTI2022

Integrated Computational Materials and Mechanical Modeling for Additive Manufacturing of Alloys with Graded Structure Used in Fossil Fuel Power Plants

Wire-arc additive manufacturing (WAAM) has demonstrated its unique capability of producing large-size alloy components with a significantly reduced fabrication time and enhanced geometry design freedom. In this project, the team has developed an ICME (Integrated Computational Materials Engineering) modeling framework, which supports the WAAM of the AUSC (Advanced Ultra-Supercritical) power plant components. The manufacturing design has been applied to Inconel 740H, steel P91, as well as the dissimilar alloy components between steel P91 and Inconel 740H. The ICME model framework is developed by considering two types of modeling. First, mechanistic modeling has been applied to control the printing quality and understand the sequence of the dissimilar printing of the wall structure. The following models have been included in the developed ICME framework: finite element thermal model, grain structure model, residual stress simulation, crystal plasticity model, CALPHAD-based precipitation kinetic model, phase stability prediction, thermal expansion predictive model, and heuristic creep model. Secondary, a physics-based machine learning model has also been developed based on the ICME model structure. The machine learning model development is based on the ICME model prediction with calibration of the experiments. In addition, the WAAM has been utilized as a high-throughput experimental tool rapidly generating a gradient of alloy composition to facilitate experimental database generation for process-structure-property relationships. Such a database directly supported the ICME-enhanced machine learning, which further assisted in intermediate composition block design between P91 and 740H. A high-throughput screening study of the oxidation resistance has been performed based on such high-throughput experimentation. Based on the computational design, several dissimilar alloy manufacturing with post-heat treatment have been performed with a comprehensive evaluation of mechanical performance, including hardness mapping, yield strength, creep resistance. In this project, the single component of P91 and 740H processed by WAAM after heat treatment designed by ICME has demonstrated higher performance in yield strength and creep resistance than the wrought materials. The P91 sample prepared by WAAM with ICME-designed heat treatment performs better than P92 in creep resistance. The designed graded alloy printing with intermediate block shows a promising performance that exceeds the traditional welding. Moreover, the current research indicates the high need for location-specific design analysis with uncertainty quantification, an important topic that deserves more dedicated research. The achievement of this project demonstrated the promising future of WAAM in structural alloy manufacturing for energy power plant development. Successful printing requires synergetic efforts made by manufacturing, mechanical, and materials sciences.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Automating Component-Level Stress Measurements for Inverter Reliability Estimation

In the near future, grid operators are expected to regularly use advanced distributed energy resource (DER) functions, defined in IEEE 1547-2018, to perform a range of grid-support operations. Many of these functions adjust the active and reactive power of the device through commanded or autonomous operating modes which induce new stresses on the power electronics components. In this work, an experimental and theoretical framework is introduced which couples laboratory-measured component stress with advanced inverter functionality and derives a reduction in useful lifetime based on an applicable reliability model. Multiple DER devices were instrumented to calculate the additional component stress under multiple reactive power setpoints to estimate associated DER lifetime reductions. A clear increase in switch loss was demonstrated as a function of irradiance level and power factor. This is replicated in the system-level efficiency measurements, although magnitudes were different—suggesting other loss mechanisms exist. Using an approximate Arrhenius thermal model for the switches, the experimental data indicate a lifetime reduction of 1.5% when operating the inverter at 0.85 PF—compared to unity PF—assuming the DER failure mechanism thermally driven within the H-bridge. If other failure mechanisms are discovered for a set of power electronics devices, this testing and calculation framework can easily be tailored to those failure mechanisms.

Flicker, Jack (ORCID:0000000212232154)↗
DOE OSTI2022

Thermal-Mechanical Analysis of an Additive Manufacturing Ceramic Heat Exchanger for High-Temperature Recuperator in a sCO2 Power System

Supercritical CO2 (sCO2) Brayton power cycle can be configured in a closed-loop power system and has a potentially high cycle efficiency. Compactness and high efficiency of a sCO2 power block make the sCO2 Brayton cycle a versatile power cycle in broad applications. While many heat sources are of sufficient intensity to produce high temperature working fluids to achieve high cycle efficiency, the thermal-mechanical stability of traditional materials (e.g., steels and nickel-based superalloys) used in construction of heat exchangers and turbine components limits the operating conditions and thus thermodynamic efficiency of the system. This effort seeks to establish the viability of ceramic heat exchanger technologies for the most extreme operating conditions envisioned for power generation and other high temperature processes. Heat exchangers constructed from ultra-high temperature ceramics, a class of extreme environment materials featuring melting points (Tmp.) above 3000 degrees C, is particularly appealing for sCO2 Brayton cycles given their ultra-low creep rates and very high retained strength at low homologous temperatures (i.e., T < 0.5 Tmp., or at least 1500 degrees C). To translate these materials properties to ultra-high temperature heat exchangers, innovations are required in ceramic manufacturing techniques to realize the complex architectures featured in compact heat exchangers with high power density. With appropriate processing, ZrB2-SiC based compositions can be sintered to near full density and shaped into complex topologies via ceramic additive manufacturing methods. This paper analyzes heat exchanger designs and explores thermal-mechanical implications of the operating environment. Thermal flow, heat transfer, and conjugate mechanical analyses provide insights into benefits and risks associated with the design approach.

additive manufacturing↗
DOE OSTI2024

Application of a Prize Mechanism to Address Data Utilization Challenges at Utilities

The electric industry sector is facing an “explosion” of data from a variety of sources. Electric sector stakeholders need to define how to capitalize on large datasets, both those they create and those from other sources (like data on weather, buildings, electric vehicles, etc.), to improve reliability and resilience and meet the changing system dynamics from renewable integration. For the electricity sector to fully utilize these vast new datasets, it must undergo a transformation in how it manages data quality, storage, and processing. The U.S. Department of Energy (DOE) Office of Electricity (OE) is committed to accelerating research, development, and demonstration of new technologies and tools within the electricity sector to advance reliability, resilience, and affordable operation of the power system. Through the prize mechanism, OE identified two widespread data-related challenges for utilities—load modeling and data analysis automation—and offered an opportunity for utilities and teams of software engineers to identify additional challenges faced by utilities. After completing one round of the American-Made Digitizing Utilities Prize, OE, the National Renewable Energy Laboratory (NREL) as the prize administrator, and Pacific Northwest National Laboratory (PNNL) as the domain experts have compiled the results and lessons learned to feed into the second round of the prize.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

GeoRePORT Protocol Volume VI: Resource Size Assessment Tool

GeoRePORT is based on the concept that a geothermal system can be described both in terms of the quality of the geothermal resource as it relates to the potential to extract heat ("Resource Grade") and the progress of research and development over the lifetime of the project ("Project Progress"). Resource grade and project progress are reported for three assessment categories: geologic, technical, and socio-economic. Each category has specific criteria and guidelines for assessing both resource grade and project progress, as outlined in each of the following assessment tools (and associated colors): (1) Geological Assessment Tool (representative colors: reds, oranges, browns); (2) Technical Assessment Tool (representative colors: blues, purples); (3) Socio-Economic Assessment Tool (representative colors: greens, yellows). Additionally, users may need to estimate the project size (often reported in MWe or MWth). The resource size assessment tool (RSAT) is an essential addition to GeoRePORT due to the economic and legal context of geothermal development. In order to utilize a geothermal resource, a competitive Power Purchase Agreement (PPA), or similar, often must be obtained, for which the resource's power capacity must be demonstrated. To determine that a geothermal heat or power project is worthy of development, investors or other funding mechanisms often require information on the anticipated heat and/or power potential of the reservoir. They might also be interested in the certainty of that estimate. However, proving the existence and size of a geothermal resource is comparatively expensive and risky relative to other renewable technologies; it can cost developers 5 to 10 million USD to demonstrate a financially viable geothermal resource (Young et al. 2017). GeoRePORT aims to address this barrier to development by providing a consistent and clear assessment of resource quality and certainty. The RSAT will enable GeoRePORT users to not only qualitatively report on a given a resource, but also to compare standard methodologies for quantitatively estimating a resource size in terms of potential heat and/or power output.

15 GEOTHERMAL ENERGY↗
NASA NTRS2011

Selected Lessons Learned in Space Shuttle Orbiter Propulsion and Power Subsystems

Over its 30 years of space flight history, plus the nearly 10 years of design, development test and evaluation, the Space Shuttle Orbiter is full of lessons learned in all of its numerous and complex subsystems. In the current paper, only selected lessons learned in the areas of the Orbiter propulsion and power subsystems will be described. The particular Orbiter subsystems include: Auxiliary Power Unit (APU), Hydraulics and Water Spray Boiler (WSB), Mechanical Flight Controls, Main Propulsion System (MPS), Fuel Cells and Power Reactant and Storage Devices (PRSD), Orbital Maneuvering System (OMS), Reaction Control System (RCS), Electrical Power Distribution (EPDC), electrical wiring and pyrotechnics. Given the complexity and extensive history of each of these subsystems, and the limited scope of this paper, it is impossible to include most of the lessons learned; instead the attempt will be to present a selected few or key lessons, in the judgment of the authors. Each subsystem is presented separate, beginning with an overview of the hardware and their function, a short description of a few historical problems and their lessons, followed by a more comprehensive table listing of the major subsystem problems and lessons. These tables serve as a quick reference for lessons learned in each subsystem. In addition, this paper will establish common lessons across subsystems as well as concentrate on those lessons which are deemed to have the highest applicability to future space flight programs.

Hernandez, Francisco J.↗
NASA NTRS1990

Space station common module network topology and hardware development

Conceptual space station common module power management and distribution (SSM/PMAD) network layouts and detailed network evaluations were developed. Individual pieces of hardware to be developed for the SSM/PMAD test bed were identified. A technology assessment was developed to identify pieces of equipment requiring development effort. Equipment lists were developed from the previously selected network schematics. Additionally, functional requirements for the network equipment as well as other requirements which affected the suitability of specific items for use on the Space Station Program were identified. Assembly requirements were derived based on the SSM/PMAD developed requirements and on the selected SSM/PMAD network concepts. Basic requirements and simplified design block diagrams are included. DC remote power controllers were successfully integrated into the DC Marshall Space Flight Center breadboard. Two DC remote power controller (RPC) boards experienced mechanical failure of UES 706 stud-mounted diodes during mechanical installation of the boards into the system. These broken diodes caused input to output shorting of the RPC's. The UES 706 diodes were replaced on these RPC's which eliminated the problem. The DC RPC's as existing in the present breadboard configuration do not provide ground fault protection because the RPC was designed to only switch the hot side current. If ground fault protection were to be implemented, it would be necessary to design the system so the RPC switched both the hot and the return sides of power.

Anderson, P.↗
NASA NTRS2015

Feasibility of Self Powered Actuation for Flow, Separation and Vibration Control

A gas turbine engine is anywhere from 40-50% efficient. A large amount of energy is wasted as heat. Some of this heat is recoverable through the use of energy harvesting and can be used for powering on-board systems or for storing energy in batteries to replace auxiliary power units (APUs). As hybrid electric aircraft become more common, the use of energy harvesting will see increasingly more benefit and become commonplace in gas turbine engines. For electric aircraft with motors, TEGs would be beneficial for reclaiming waste heat from electric motors. The primary focus of this work was to evaluate the feasibility of harvesting energy from the hot section of a gas turbine engine (for a single aisle Boeing 737 thrust class) using thermoelectric generators (TEGs). The resulting heat could be used to power on-board actuation mechanisms such as plasma actuators and piezoelectric actuators. The work is a result of a two year NASA Center Innovation Fund from 2009 to 2011. The trade-off between thermoelectric harvesting and blade surface temperature were studied to ensure that blade durability is not adversely impacted by embedding a low thermal conductivity TEG. Calculations show that.5-10 Watts can be harvested per blade depending on flow conditions and on the thermoelectric material chosen. BiTe and SiGe were used for this analysis and future thermoelectric generators or multiferroic alloys could considerably improve power output.

bottoming cycle↗
NASA NTRS1974

A high voltage power supply for the AE-C and D low energy electron experiment

A description is given of the electrical and mechanical design and operation of high voltage power supplies for space flight use. The supply was used to generate the spiraltron high voltage for low energy electron experiment on AE-C and D. Two versions of the supply were designed and built; one design is referred to as the low power version (AE-C) and the other as the high power version (AE-D). Performance is discussed under all operating conditions.

Gillis, J. A.↗
NASA NTRS1996

The Nature of the Energy Source in LINER's

LINER's (low-ionization nuclear emission-line regions) are found in about 30% of all bright galaxies, including luminous infrared galaxies. They form a heterogeneous class powered by a variety of ionizing mechanisms such as low-luminosity AGNs (active galactic nuclei), starbursts, shocks, or any combination of these. In early-type spirals, LINER's are powered by a low-luminosity AGN, or by an AGN surrounded by circumnuclear star-forming regions. In luminous infrared galaxies, LINER's are powered by starbursts with associated wind-related extended shocks, and an AGN may play a minor role, if any. LINER's in some FR I radio galaxies show strong evidence for the presence of a massive central black hole, and there are indications for the existence of shocks in the nuclear disks of these galaxies. Yet, the dominant ionizing mechanism for LINER's in radio-quiet ellipticals and FR I host galaxies is still unclear. Multifrequency high spatial resolution imaging and spectroscopy are essential to discriminate among the different ionizing mechanisms present in LINER's.

Colina, L.↗
NASA NTRS1987

Direct solar-pumped iodine laser amplifier

This semiannual progress report covers the period from March 1, 1987 to September 30, 1987 under NASA grant NAG1-441 entitled 'Direct solar-pumped iodine laser amplifier'. During this period Nd:YAG and Nd:Cr:GSGG crystals have been tested for the solar-simulator pumped cw laser, and loss mechanisms of the laser output power in a flashlamp-pumped iodine laser also have been identified theoretically. It was observed that the threshold pump-beam intensities for both Nd:YAG and Nd:Cr:GSGG crystals were about 1000 solar constants, and the cw laser operation of the Nd:Cr:GSGG crystal was more difficult than that of the Nd:YAG crystal under the solar-simulator pumping. The possibility of the Nd:Cr:GSGG laser operation with a fast continuously chopped pumping was also observed. In addition, good agreement between the theoretical calculations and the experimental data on the loss mechanisms of a flashlamp-pumped iodine laser at various fill pressures and various lasants was achieved.

Han, Kwang S.↗