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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 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Blood Pump Having a Magnetically Suspended Rotor

A blood pump preferably has a magnetically suspended rotor that rotates within a housing. The rotor may rotate about a stator disposed within the housing. Radial magnetic bearings may be defined within the stator and the rotor in order to suspend the rotor. The radial magnetic bearings may be passive magnetic bearings that include permanent magnets disposed within the stator and the rotor or active magnetic bearings. The pump may further include an axial magnetic bearing that may be either a passive or an active magnetic bearing. A motor that drives the rotor may be disposed within the housing in order to more easily dissipate heat generated by the motor. A primary flow path is defined between the rotor and the stator, and a secondary flow path is defined between the stator and the rotor. Preferably, a substantial majority of blood passes through the primary flow path. The secondary flow path is large enough so that it provides adequate flushing of the secondary flow path while being small enough to permit efficient operation of the radial magnet bearings across the secondary flow path.

James F Antaki↗
NASA NTRS2012

Development in High-Density Cobra Fiber Positioners for the Subaru Telescope's Prime Focus Spectrometer

The Prime Focus Spectrograph (PFS) is a fiber fed multi-object spectrometer for the Subaru Telescope that will conduct a variety of targeted surveys for studies of dark energy, galaxy evolution, and galactic archaeology. The key to the instrument is a high density array of fiber positioners placed at the prime focus of the Subaru Telescope. The system, nicknamed "Cobra", will be capable of rapidly reconfiguring the array of 2394 optical fibers to the image positions of astronomical targets in the focal plane with high accuracy. The system uses 2394 individual "SCARA robot" mechanisms that are 7.7mm in diameter and use 2 piezo-electric rotary motors to individually position each of the optical fibers within its patrol region. Testing demonstrates that the Cobra positioner can be moved to within 5 micrometers of an astronomical target in 6 move iterations with a success rate of 95%. The Cobra system is a key aspect of PFS that will enable its unprecedented combination of high-multiplex factor and observing efficiency on the Subaru telescope. The requirements, design, and prototyping efforts for the fiber positioner system for the PFS are described here as are the plans for modular construction, assembly, integration, functional testing, and performance validation.

Cobra↗
NASA NTRS2014

Prediction of Acoustic Environments from Horizontal Rocket Firings

In recent years, advances in research and engineering have led to more powerful launch vehicles which can reach areas of space not yet explored. These more powerful vehicles yield acoustic environments potentially destructive to the vehicle or surrounding structures. Therefore, it has become increasingly important to be able to predict the acoustic environments created by these vehicles in order to avoid structural and/or competent failure. The current industry standard technique for predicting launch-induced acoustic environments was developed by Eldred in the early 1970's and is published in NASA SP-80721. Recent work2 has shown Eldred's technique to be inaccurate for current state-of-the-art launch vehicles. Due to the high cost of full-scale and even sub-scale rocket experiments, very little rocket noise data is available. Furthermore, much of the work thought to be applicable to rocket noise has been done with heated jets. Tam3,4 has done an extensive amount of research on jets of different nozzle exit shape, diameter, velocity, and temperature. Though the values of these parameters, especially exit velocity and temperature, are often very low compared to these values in rockets, a lot can be learned about rocket noise from jet noise literature. The turbulent nature of jet and rocket exhausts is quite similar. Both exhausts contain turbulent structures of varying scale-termed the fine and large scale turbulence by Tam. The finescale turbulence is due to small eddies from the jet plume interacting with the ambient atmosphere. According to Tam et al., the noise radiated by this envelope of small-scale turbulence is statistically isotropic. Hence, one would expect the noise from the small scale turbulence of the jet to be nearly omni-directional. The coherent nature of the large-scale turbulence results in interference of the noise radiated from different spatial locations within the jet. This interference-whether it is constructive or destructive-results in highly directional noise radiation. Tam3 has proposed a model to predict the acoustic environment due to jets and while it works extremely well for jets, it was found to be inappropriate for rockets8. A model to predict the acoustic environment due to a launch vehicle in the far-field which incorporates concepts from both Eldred and Tam was created. This was done using five sets of horizontally fired rocket data, obtained between 2008 and 2012. Three of these rockets use solid propellant and two use liquid propellant. Through scaling analysis, it is shown that liquid and solid rocket motors exhibit similar spectra at similar amplitudes. This model is accurate for these five data sets within 5 dB of the measured data for receiver angles of 30deg to 160deg (with respect to the downstream exhaust centerline). The model uses the following vehicle parameters: nozzle exit diameter and velocity, radial distance from source to receiver, receiver angle, mass flow rate, and acoustic efficiency.

Giacomoni, Clothilde↗
DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

42 ENGINEERING↗
DOE OSTI2026

Fleet-Level Fuel Impact of Hybrid-Electric Aircraft in United States

Here, this paper examines the impact of two potential solutions for increasing fuel efficiency and reducing emissions in commercial aviation: hybrid-electric propulsion and the use of drop-in synthetic aviation fuels (SAFs). The authors modeled three representative aircraft employed in the U.S. domestic market: a 70-seat regional turboprop, a 100-seat airliner, and a 180-seat airliner. These aircraft were retrofitted with hybrid-electric propulsion systems that integrate batteries and electric motors to provide additional torque to the propeller or fan. The authors explored various technological scenarios involving different battery specific energies, electric motor specific powers, and other relevant parameters. Flight performance models were used to analyze the range–payload capabilities of these new hybrid-electric aircraft and to compare them with their conventional counterparts. Subsequently, the authors virtually deployed the hybrid-electric aircraft on 2019 U.S. domestic commercial flights to assess the types and lengths of flights that could be serviced by this new fleet. We then compared the resulting fuel consumption, energy use, and emissions with those of a conventional fleet using a combination of jet fuel and SAF.

SAF↗
NASA NTRS1984

Injection module thrust vector control

A three-axis controlled Injection Module propelled by a Star 48 solid rocket motor has been considered for use as a final 'kick' stage to supplement the Inertial Upper Stage in a proposed launch option for the Galileo and International Solar Polar missions. A flight control law for the Injection Module is developed. A position plus rate control law is considered, with integral, path guidance, and derived rate terms added for improved pointing accuracy and fuel efficiency. Selection of control gains is accomplished with the help of analytical limit cycle expressions and verified by computer simulation of the closed loop system. A computer simulation of the flight control system is built around a rigid spacecraft model with gyro dynamics and thruster delays included. Models for pitch/yaw/roll disturbance torques are included. Through simple gain changes the proposed flight control law is shown to accommodate the widely different mass properties of the Galileo and International Solar Polar spacecraft. Pointing accuracies of better than the desired 0.2 degrees are achieved.

Bell, C. E.↗
NASA NTRS1993

Advanced Multi-Phase Flow CFD Model Development for Solid Rocket Motor Flowfield Analysis

It is known that the simulations of solid rocket motor internal flow field with AL-based propellants require complex multi-phase turbulent flow model. The objective of this study is to develop an advanced particulate multi-phase flow model which includes the effects of particle dynamics, chemical reaction and hot gas flow turbulence. The inclusion of particle agglomeration, particle/gas reaction and mass transfer, particle collision, coalescence and breakup mechanisms in modeling the particle dynamics will allow the proposed model to realistically simulate the flowfield inside a solid rocket motor. The Finite Difference Navier-Stokes numerical code FDNS is used to simulate the steady-state multi-phase particulate flow field for a 3-zone 2-D axisymmetric ASRM model and a 6-zone 3-D ASRM model at launch conditions. The 2-D model includes aft-end cavity and submerged nozzle. The 3-D model represents the whole ASRM geometry, including additional grain port area in the gas cavity and two inhibitors. FDNS is a pressure based finite difference Navier-Stokes flow solver with time-accurate adaptive second-order upwind schemes, standard and extended k-epsilon models with compressibility corrections, multi zone body-fitted formulations, and turbulence particle interaction model. Eulerian/Lagrangian multi-phase solution method is applied for multi-zone mesh. To simulate the chemical reaction, penalty function corrected efficient finite-rate chemistry integration method is used in FDNS. For the AL particle combustion rate, the Hermsen correlation is employed. To simulate the turbulent dispersion of particles, the Gaussian probability distribution with standard deviation equal to (2k/3)(exp 1/2) is used for the random turbulent velocity components. The computational results reveal that the flow field near the juncture of aft-end cavity and the submerged nozzle is very complex. The effects of the turbulent particles affect the flow field significantly and provide better prediction of the ASRM performance. The multi-phase flow analysis using the FDNS code in the present research can be used as a design tool for solid rocket motor applications.

Liaw, Paul↗
NASA NTRS2007

Technical Findings, Lessons Learned, and Recommendations Resulting from the Helios Prototype Vehicle Mishap

The Helios Prototype was originally planned to be two separate vehicles, but because of resource limitations only one vehicle was developed to demonstrate two missions. The vehicle consisted of two configurations, one for each mission. One configuration, designated HP01, was designed to operate at extremely high altitudes using batteries and high-efficiency solar cells spread across the upper surface of its 247-foot wingspan. On August 13, 2001, the HP01 configuration reached an altitude of 96,863 feet, a world record for sustained horizontal flight by a winged aircraft. The other configuration, designated HP03, was designed for long-duration flight. The plan was to use the solar cells to power the vehicle's electric motors and subsystems during the day and to use a modified commercial hydrogen-air fuel cell system for use during the night. The aircraft design used wing dihedral, engine power, elevator control surfaces, and a stability augmentation and control system to provide aerodynamic stability and control. At about 30 minutes into the second flight of HP03, the aircraft encountered a disturbance in the way of turbulence and morphed into an unexpected, persistent, high dihedral configuration. As a result of the persistent high dihedral, the aircraft became unstable in a very divergent pitch mode in which the airspeed excursions from the nominal flight speed about doubled every cycle of the oscillation. The aircraft s design airspeed was subsequently exceeded and the resulting high dynamic pressures caused the wing leading edge secondary structure on the outer wing panels to fail and the solar cells and skin on the upper surface of the wing to rip away. As a result, the vehicle lost its ability to maintain lift, fell into the Pacific Ocean within the confines of the U.S. Navy's Pacific Missile Range Facility, and was destroyed. This paper describes the mishap and its causes, and presents the technical recommendations and lessons learned for improving the design, analysis, and testing methods and techniques required for this class of vehicle.

Noll, Thomas E.↗
DOE OSTI2020

Enhanced Sustainability in Treatment of Contaminated Metals for Clearance and Recycling - 20290

Cyclife Sweden AB has, for more than 30 years, provided metal treatment services to the domestic and international nuclear industry with the aim of creating value through metal clearance and recycling. These operations are to a large extent based on the concept that the materials, after pre-treatment, including decontamination, will be melted for clearance. During the melting process, some nuclides separate from the metal while the remaining radioactivity becomes fully homogenized in the metal bath and the resulting ingots, along with the samples taken before casting At a time when activities to fight Climate Challenge are in focus, any savings in energy consumption, in addition to the positive environmental effect of recycling metals back to industry, is more than welcome. If the clearance of certain metallic items can be achieved safely, without using melting, it is the environmentally preferred option provided it carries a reasonable cost. It is even better if an object can go through a decontamination and clearance process prior to re-use inside or outside the nuclear sector. Cyclife Sweden is currently investing in a direct clearance process, to be operated in parallel with the melting process. This new process is expected to be fully operational in the late summer of 2020 and includes pre-treatment, decontamination and heavily shielded clearance measurement installations. The treatment will also allow clearance measurements of larger objects without the need for segmentation, along with allowing objects composed of different materials, like electric motors can be accepted for treatment. This paper gives an overview of the circular economy aspects in a nuclear back-end context, the Cyclife approach to further implement a circular economy approach in the processes, Material Acceptance Criteria for treatment, the facility set-up for the new process and how the melting route and the direct route can be combined in an efficient industrial scale process. To put the new capabilities into perspective, the two different treatment and clearance approaches, i.e. direct clearance and melting, are to be compared. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Low-Mass and High-Efficiency Engine for Medium-Duty Truck Applications

This collaborative multi-year advanced engine technology project summarized in the report is to develop low mass and high efficiency medium-duty truck engine. The project was proposed as a large-scale engine design and demonstration enabled by an advanced materials and manufacturing development program, with a comprehensive plan spanning a period of four years (two phases).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

World’s First Vertical GaN based High Power (200 kW) Multi-level Traction Electric Drive Design

Vertical GaN (vGaN) technology leverages a fully conductive 3D semiconductor structure, enabling superior power density compared to GaN-on-Si and other wide bandgap devices. It offers a pathway to surpass cost and efficiency limitations of Si and SiC devices in traction applications. However, scaling for high-voltage, high-power systems remains challenging. This paper presents the design of an 800V, 200kW traction inverter utilizing vertical GaN devices. The inverter achieves ultra-high efficiency (> 99.5%) through advanced power module integration and employs multilevel neutral-point-less X-type (NPL.X) inverter topology to ensure optimal traction drive system performance. These innovations demonstrate the potential of vGaN for next￾generation electric propulsion systems.

Alam, Khorshed [General Motors LLC, Detroit, MI (U↗
NASA NTRS1988

Lunar material transport vehicle

The proposed vehicle, the Lunar Material Transport Vehicle (LMTV), has a mission objective of efficient lunar soil material transport. The LMTV was designed to meet a required set of performance specifications while operating under a given set of constraints. The LMTV is essentially an articulated steering, double-ended dump truck. The vehicle moves on four wheels and has two identical chassis halves. Each half consists of a chassis frame, a material bucket, two wheels with integral curvilinear synchronous motors, a fuel cell and battery arrangement, an electromechanically actuated dumping mechanism, and a powerful microprocessor. The vehicle, as designed, is capable of transporting up to 200 cu ft of material over a one mile round trip per hour. The LMTV is capable of being operated from a variety of sources. The vehicle has been designed as simply as possible with attention also given to secondary usage of components.

Fisher, Charles D.↗
NASA NTRS2012

The Direction of Fluid Dynamics for Liquid Propulsion at NASA Marshall Space Flight Center

Marshall Space Flight Center (MSFC) is the National Aeronautics and Space Administration (NASA)-designated center for the development of space launch systems. MSFC is particularly known for propulsion system development. Many engineering skills and technical disciplines are needed to accomplish this mission. This presentation will focus on the work of the Fluid Dynamics Branch (ER42). ER42 resides in the Propulsion Systems Department at MSFC. The branch is responsible for all aspects of the discipline of fluid dynamics applied to propulsion or propulsion-induced loads and environments. This work begins with design trades and parametric studies, and continues through development, risk assessment, anomaly investigation and resolution, and failure investigations. Applications include the propellant delivery system including the main propulsion system (MPS) and turbomachinery; combustion devices for liquid engines and solid rocket motors; coupled systems; and launch environments. An advantage of the branch is that it is neither analysis nor test centric, but discipline centric. Fluid dynamics assessments are made by analysis, from lumped parameter modeling through unsteady computational fluid dynamics (CFD); testing, which can be cold flow or hot fire; or a combination of analysis and testing. Integration of all discipline methods into one branch enables efficient and accurate support to the projects. To accomplish this work, the branch currently employs approximately fifty engineers divided into four teams -- Propellant Delivery CFD, Combustion Driven Flows CFD, Unsteady and Experimental Flows, and Acoustics and Stability. This discussion will highlight some of the work performed in the branch and the direction in which the branch is headed.

Griffin, Lisa W.↗
DOE OSTI2026

Autonomous Hydrogen Fueling Station

This project “Autonomous Hydrogen Fueling Station” covered the autonomous refueling with both gaseous hydrogen and liquid hydrogen. The part on gaseous hydrogen focused on the development of an autonomous robotic fueling arm that would couple to a fuel cell engine for hydrogen refueling without guidance from the forklift operator and budget period. Research was also covered for the robotic fueling with a commercial vehicle. The second phase of the project created the baseline for an autonomous liquid hydrogen transfer system that would minimize boil off losses by operating at thermodynamically efficient state points. For the development of the robotic fueling arm, testing was conducted to establish a baseline measurement of the accuracy and repeatability of a human operator positioning a lift truck in front of a dispenser. The goal was to establish the range of motion required for an autonomous fueling mechanism to mate a hydrogen nozzle with a receptacle on a fuel cell system installed in a forklift. The final design comprised a selective compliance articulated robot arm (SCARA)-type mechanism with two arms for horizontal motion and a ball screw for vertical movement and color and LIDAR cameras were used for marker identification and proximity awareness to guide the robotic arm to its target receptacle. Initial tests resulted in 199 out of 200 successful attempts at autonomous coupling of the dispensing coupler and a fuel cell engine, without hydrogen. The dispenser prototype was modified to include tubing for both hydrogen fuel and air purge lines, but subsequent tests were confounded by the shoulder motor over current errors which limited the robot from getting to the fully inserted position to achieve a positive latch. Robotic hydrogen refueling was successfully demonstrated over 1.5 hours of testing, Plug completed 29 successful latches with an average number of 4 sequential latches before failure. However, a robot capable of placing the nozzle with more force is required for higher reliability. For budget period two, a small scale (10 kg / transfer) automated control system was designed that would operate valves to control pressure and flow of liquid nitrogen between a source and receiving tank with an aim to minimize boil off losses by operating at the most thermodynamically efficient state points. Control system logic flow and a P&ID were developed prior to system safety characterization via HAZOP. A control narrative and system state points were defined. Delays in approval for a change of project objective and procurement issues precluded the construction and test of the final prototype system.

08 HYDROGEN↗
NASA NTRS1989

A numerical study of chemically reacting flow in nozzles

The space station uses small rocket motors, called thrusters, for orientation control. Because of the lack of viable design tools for small rockets, the initial thruster design was basically a very small version of a large rocket motor. Thrust measurements of the initial design were lower than predicted. To improve predictions it was decided to develop a verison of the RPLUS2D reacting flow code for thruster calculations. RPLUS2D employs an implicit finite volume, lower-upper symmetric successive overrelaxation (LU-SSOR) scheme for solving the complete two-dimensional Navier-Stokes equations and species transport equations in a coupled and very efficient manner. The combustion processes are modeled by a 9-species, 18 step finite-rate chemistry model, and the turbulence is simulated by a Baldwin-Lomax algebraic model. The code is extended to handle multiple subsonic inlet conditions where the total mass flow is governed by conditions calculated at the thruster-throat. Results are shown for a thruster design where the overall mixture ratio is hydrogen rich. A calculation of a large area ratio divergent nozzle is also presented.

Vanoverbeke, Thomas J.↗
NASA NTRS1989

A numerical study of chemically reacting flow in nozzles

The Space Station uses small rocket motors, called thrusters, for orientation control. Because of the lack of viable design tools for small rockets, the initial thruster design was basically a very small version of a large rocket motor. Thrust measurements of the initial design were lower than predicted. To improve predictions it was decided to develop a version of the RPLUS2D reacting flow code for thruster calculations. RPLUS2D employs an implicit finite volume, lower-upper symmetric successive overrelaxation (LU-SSOR) scheme for solving the complete two-dimensional Navier-Stokes equations and species transport equations in a coupled and very efficient manner. The combustion processes are modeled by a 9-species, 18 step finite-rate chemistry model, and the turbulence is simulated by a Baldwin-Lomax algebraic model. The code is extended to handle multiple subsonic inlet conditions where the total mass flow is governed by conditions calculated at the thruster-throat. Results are shown for a thruster design where the overall mixture ratio is hydrogen rich. A calculation of a large area ratio divergent nozzle is also presented.

Vanoverbeke, Thomas J.↗
NASA NTRS1985

A rotating superconducting solenoid for 100 kWh energy storage

Two concentric superconducting solenoids, one rotating, the other stationary are analyzed for energy storage in space. Energy is transferred from the rotating mass through a shaft coupled to a motor-generator. The inner windings interact with the magnetic field of the outer solenoid to cancel the centrifugal and self-field forces of the flywheel rim. Current is induced in the inner solenoid thus requiring no separate power supply, while the current in the outer solenoid must vary with the angular velocity of the flywheel. The effect of the gap and scaling laws are developed. The efficiency in energy per unit mass is marginally attractive.

Waynert, J.↗
NASA NTRS1987

Plasma motor/generator reference system designs for power and propulsion

Four Plasma Motor/Generator (PMG) Reference Systems, hollow cathode-based versions of the electrodynamic tether concept which are to be used in study and analysis of future propulsion and power applications, are discussed. These systems are equally applicable for use as electric generators to provide power to a spacecraft or as electric motors using power from the spacecraft. Operating at relatively high current and low voltage, the PMGs avoid requirements for technological advances to handle very high voltages. Permanent deployment with passive I x B control of tether dynamics eliminates the complexity and weight of a TSS style tether reel. A 20 kW PMG uses 10 km of number two aluminum wire, weighs 1200 kg, and has an electrical efficiency of 93 percent. A larger 200 kW system uses 20 km of number 00 aluminum wire, weighs 4200 kg, and operates at 87 percent efficiency.

Mccoy, James E.↗