Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Process Development and Demonstration”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Controlling the breakdown delay time in pulsed gas discharge

Abstract In experiment and 2D3V PIC MCC simulations, the breakdown development in a pulsed discharge in helium is studied for U = 3.2 kV and 10 kV and P = 100 Torr. The breakdown process is found to have a stochastic nature, and the electron avalanche develops in different experimental and simulation runs with time delays ranging from 0.3 to 8 μ s. Nevertheless our experiments demonstrate that the breakdown delay time distribution can be controlled with a change of the pulse discharge frequency. The simulation results show that the breakdown process can be distinguished in three stages with (a) the ionization by seed electrons, (b) the ions drift to the cathode and (c) the enhanced ionization within the cathode sheath by the electrons emitted from the cathode. The effects of variation of seed electron concentrations, voltage rise times, voltage amplitudes and ion–electron emission coefficients on the breakdown development in the pulsed gas discharge are reported.

Schweigert, I. V. (ORCID:0000000223641228)↗
NASA NTRSDate not supplied

Simultaneous Development and Robust Optimization of a Microstructure Dependent Material

Recent microstructure characterization techniques combined with Symbolic Regression(SR)analysis has been proven to generate white box plasticity models well suited for incorporation into FEA software.The current work builds upon those efforts and demonstrates the applicability of Sequential Monte-Carlo (SMC) methods within SR analysis to condense model development and robust optimization into a single, co-dependent process. In this project, SMC methods provide a mechanism through which the observed microstructure features and associated variability can be incorporated into the discovery phase of model development and simultaneously recover approximate parameter distributions through SR analysis. The demonstration utilized a data set consisting of tensile test results from a limited number of sample specimens with corresponding EBSD data from which microstructure features were characterized.The maximum threshold stress model in the Visco-Plastic Self-Consistent (VPSC) code developed by Los Alamos National Laboratories was calibrated using mechanical test data.Synthetic volume elements with statistically equivalent microstructure were generated with DREAM3Dbased on the observed EBSD data. VPSC was used to simulate the corresponding tensile test response for each of the synthetic volume elements. The simulated microstructure and tensile test data was used astraining datafor SMC-SR algorithm and the resulting model was validated with data from the original empirical data set.

Karl Garbrecht↗
NASA NTRSDate not supplied

Additive Manufacturing (AM) for Propulsion Component and System Applications

NASA MSFC is developing several areas of additive manufacturing (AM) for propulsion component and system applications. These developments include new AM process and material development, large-scale AM pathfinder component fabrication and hot-fire testing, AM-centric design methodology, modeling and simulation, post-processing advancements, and new design applications of AM in aerospace. Some specific areas NASA has focused is the development and commercial infusion of AM supply chain for materials such as copper-alloy GRCop (Cu-Cr-Nb), Hydrogen-resistant alloys (NASA HR-1, JBK-75), refractory-based alloys (C-103, W, Mo, new formulations), and bimetallic and multi-metallic AM processes. Additional efforts have been focused on large scale AM demonstrating complex thin-wall structures up to 60” diameter using directed energy deposition. Material characterization, properties and component hot-fire testing has been completed using many of these newly developed AM alloys/processes. NASA has also focused on improvements to post-processing including powder removal, surface enhancements, and support removal to further realize cost and schedule benefits to the overall supply chain. These developments are part of the NASA Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Low Cost Upper Stage Propulsion (LCUSP) and Long Life Additive Manufacturing (LLAMA) projects, in addition to internal IRAD, and external collaborations.

Additive Manufacturing↗
NASA NTRSDate not supplied

The Trash Compaction Processing System (TCPS) Technology Demonstrations and Risk Reduction Activities 2023-2024

The Trash Compactor Processing System (TCPS) employs heat and pressure to safely compress spacecraft trash. The Next STEP Phase B Appendix 2 contract was awarded to Sierra Space for the development of ground and flight demonstration hardware, slated for testing on the International Space Station in 2026. Meanwhile, Ames Research Center is actively engaged in risk reduction activities related to in-house hardware, fine-tuning science objectives and test procedures.This paper will discuss the updated TCPS requirements and present the results of the risk reduction activities, which include moisture analysis, component offgas, and aerosol analysis.

Justine Tra-my Richardson↗
NASA NTRS1987

High-temperature electronics

In recent years, there was a growing need for electronics capable of sustained high-temperature operation for aerospace propulsion system instrumentation, control and condition monitoring, and integrated sensors. The desired operating temperature in some applications exceeds 600 C, which is well beyond the capability of currently available semiconductor devices. Silicon carbide displays a number of properties which make it very attractive as a semiconductor material, one of which is the ability to retain its electronic integrity at temperatures well above 600 C. An IR-100 award was presented to NASA Lewis in 1983 for developing a chemical vapor deposition process to grow single crystals of this material on standard silicon wafers. Silicon carbide devices were demonstrated above 400 C, but much work remains in the areas of crystal growth, characterization, and device fabrication before the full potential of silicon carbide can be realized. The presentation will conclude with current and future high-temperature electronics program plans. Although the development of silicon carbide falls into the category of high-risk research, the future looks promising, and the potential payoffs are tremendous.

Seng, Gary T.↗
NASA NTRSDate not supplied

Development and Characterization of the Integrally Stiffened Cylinder (ISC) Process for Launch Vehicles and Aircraft Fuselage Structures

Over the past decade, NASA Langley has led development of the Integrally Stiffened Cylinder (ISC) Process, a near-net-shape, flow-forming technology. This innovative process is being evaluated for launch vehicle and commercial aircraft manufacturing. A thick-walled, cylindrical preform is flow-formed using a single operation into a thin-walled barrel with integral longitudinal stiffeners. The one-piece, stiffened barrels offer a direct replacement for conventional multi-piece, welded or riveted structures. A cost-benefit analysis for launch vehicle cryogenic propellant tanks estimated that the ISC process offers up to a 50% reduction in manufacturing costs and a 10% reduction in mass. NASA, the European Space Agency (ESA), and industry partners have teamed to manufacture 3-m(10-ft.) diameter aluminum ISCs. The intent is to demonstrate the commercial viability of the process at a scale relevant to the commercial launch and aircraft industries. Development activities will be presented, including process scale-up, formability assessment, and mechanical property testing.

ISC, flow forming, near net shape↗
NASA NTRS1984

Use of adaptive walls in 2D tests

A new method for computing the wall effects gives precise answers to some questions arising in adaptive wall concept applications: length of adapted regions, fairings with up and downstream regions, residual misadjustments effects, reference conditions. The acceleration of the iterative process convergence and the development of an efficient technology used in CERT T2 wind tunnels give in a single run the required test conditions. Samples taken from CAST 7 tests demonstrate the efficiency of the whole process to obtain significant results with considerations of tridimensional case extension.

Archambaud, J. P.↗
DOE OSTI2023

Physics informed deep neural network embedded in a chemical transport model for the Amazon rainforest

Secondary organic aerosols (SOA) are fine particles in the atmosphere, which interact with clouds, radiation and affect the Earth’s energy budget. SOA formation involves chemistry in gas phase, aqueous aerosols, and clouds. Simulating these chemical processes involve solving a stiff set of differential equations, which are computationally expensive steps for three-dimensional chemical transport models. Deep neural networks (DNNs) are universal function approximators that could be used to represent the complex nonlinear changes in aerosol physical and chemical processes; however, key challenges such as generalizability to extended time periods, preservation of mass balance, simulating sparse model outputs, and maintaining physical constraints have limited their use in atmospheric chemistry. Here, we develop an approach of using a physics-informed DNN that overcomes previous such challenges and demonstrates its applicability for the chemical formation processes of isoprene epoxydiol SOA (IEPOX-SOA) over the Amazon rainforest. The DNN is trained with data generated by simulating IEPOX-SOA over the entire atmospheric column, using the Weather Research and Forecasting Model coupled with Chemistry (WRF-Chem). The trained DNN is then embedded within WRF-Chem to replace the computationally expensive default solver of IEPOX-SOA formation. The trained DNN predictions generalizes well with the default model simulation of the IEPOX-SOA mass concentrations and its size distribution (20 size bins) over several days of simulations in both dry and wet seasons. The embedded DNN reduces the computational expense of WRF-Chem by a factor of 2. Our approach shows promise in terms of application to other computationally expensive chemistry solvers in climate models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Controlled Formation of Conduction Channels in Memristive Devices Observed by X–ray Multimodal Imaging

Neuromorphic computing provides a means for achieving faster and more energy efficient computations than conventional digital computers for artificial intelligence (AI). However, its current accuracy is generally less than the dominant software-based AI. The key to improving accuracy is to reduce the intrinsic randomness of memristive devices, emulating synapses in the brain for neuromorphic computing. Here using a planar device as a model system, the controlled formation of conduction channels is achieved with high oxygen vacancy concentrations through the design of sharp protrusions in the electrode gap, as observed by X-ray multimodal imaging of both oxygen stoichiometry and crystallinity. Classical molecular dynamics simulations confirm that the controlled formation of conduction channels arises from confinement of the electric field, yielding a reproducible spatial distribution of oxygen vacancies across switching cycles. Furthermore, this work demonstrates an effective route to control the otherwise random electroforming process by electrode design, facilitating the development of more accurate memristive devices for neuromorphic computing.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Three-dimensional Zn-based alloys for dendrite-free aqueous Zn battery in dual-cation electrolytes

Aqueous zinc-ion batteries, in terms of integration with high safety, environmental benignity, and low cost, have attracted much attention for powering electronic devices and storage systems. However, the interface instability issues at the Zn anode caused by detrimental side reactions such as dendrite growth, hydrogen evolution, and metal corrosion at the solid (anode)/liquid (electrolyte) interface impede their practical applications in the fields requiring long-term performance persistence. Despite the rapid progress in suppressing the side reactions at the materials interface, the mechanism of ion storage and dendrite formation in practical aqueous zinc-ion batteries with dual-cation aqueous electrolytes is still unclear. Herein, we design an interface material consisting of forest-like three-dimensional zinc-copper alloy with engineered surfaces to explore the Zn plating/stripping mode in dual-cation electrolytes. The three-dimensional nanostructured surface of zinc-copper alloy is demonstrated to be in favor of effectively regulating the reaction kinetics of Zn plating/stripping processes. The developed interface materials suppress the dendrite growth on the anode surface towards high-performance persistent aqueous zinc-ion batteries in the aqueous electrolytes containing single and dual cations. This work remarkably enhances the fundamental understanding of dual-cation intercalation chemistry in aqueous electrochemical systems and provides a guide for exploring high-performance aqueous zinc-ion batteries and beyond.

25 ENERGY STORAGE↗
DOE OSTI2022

Engineering-Scale Batch Purification of Ternary MgCl 2 -KCl-NaCl Salt Using Thermal and Magnesium Contact Treatment

High-temperature molten chloride salts are a desirable heat transfer and energy storage media. The NaCl-KCl-MgCl 2 is of particular interest because of its low melting point and relatively inexpensive constituents. Moisture and hydroxides must be removed from the salt to control corrosion at high temperatures. Previous studies have developed and demonstrated various techniques for bench-scale salt purifications. This paper details the system, process, and insight gained in the purification of a 200 kg scale batch of NaCl-KCl-MgCl 2 salt at Oak Ridge National Laboratory.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Scaled up Process Report – Apparatus and Model

Advanced voloxidation with NO 2 is a proposed process for used nuclear fuel head-end reprocessing scheme that converts UO 2 to higher oxides, and it also converts partitioning volatile fission products into the gas phase, thus facilitating fuel dissolution and actinide recovery. NO 2 voloxidation is being studied on small batches of UO 2 Simfuel, but the real test of process feasibility will be when it is scaled up to work with >100 g of irradiated material. This report discusses the aspects of scale-up that must be considered for NO 2 voloxidation, including development of a stirred reactor to promote agitation of the mixture during processing, online process monitoring, and automation controls. Brief details on parallel efforts are also provided in this report, including (a) demonstration of iodine release from Simfuel made by Spark Plasma Sintering, and (b) development of an order-of-magnitude scale-up to react 100 g of UO 2 Simfuel in a metal reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Nion Swift FY2021 phase I Final Technical Report DE-SC0021546

Phase I of the project is an on-going success. The enhanced and extended new application programming interface (API) developed in Phase I is in use at customer sites around the world: Berlin, UK, US, China, France, Austria. The modules developed to demonstrate the new API features are in daily use at these sites for acquiring, processing, and analyzing microscopy data from 4D- and 5D-STEM to single-point spectroscopy at highest resolution.

Lovejoy, Tracy↗
NASA NTRS1980

Determination of instrumentation errors from measured data using maximum likelihood method

The maximum likelihood method is used for estimation of unknown initial conditions, constant bias and scale factor errors in measured flight data. The model for the system to be identified consists of the airplane six-degree-of-freedom kinematic equations, and the output equations specifying the measured variables. The estimation problem is formulated in a general way and then, for practical use, simplified by ignoring the effect of process noise. The algorithm developed is first applied to computer generated data having different levels of process noise for the demonstration of the robustness of the method. Then the real flight data are analyzed and the results compared with those obtained by the extended Kalman filter algorithm.

Keskar, D. A.↗
NASA NTRS1990

High temperature acoustic and hybrid microwave/acoustic levitators for materials processing

The physical acoustics group at the Jet Propulsion Laboratory developed a single mode acoustic levitator technique for advanced containerless materials processing. The technique was successfully demonstrated in ground based studies to temperatures of about 1000 C in a uniform temperature furnace environment and to temperatures of about 1500 C using laser beams to locally heat the sample. Researchers are evaluating microwaves as a more efficient means than lasers for locally heating a positioned sample. Recent tests of a prototype single mode hybrid microwave/acoustic levitator successfully demonstrated the feasibility of using microwave power as a heating source. The potential advantages of combining acoustic positioning forces and microwave heating for containerless processing investigations are presented in outline form.

Barmatz, Martin↗
NASA NTRS1991

A globally convergent matrix-free algorithm for implicit time-marching schemes arising in finite element analysis in fluids

A solution procedure for solving nonlinear time-marching problems is presented. The nonsymmetric systems of equations arising from a Newton-type linearization of these time-marching problems are solved using an iterative strategy based on the generalized minimal residual (GMRES) algorithm. Matrix-free techniques leading to reduction in storage are presented. Incorporation of a linesearch algorithm in the Newton-GMRES scheme is discussed. An automatic time-increment control strategy is developed to increase the stability of the time-marching process. High-speed flow computations demonstrate the effectiveness of these algorithms.

Johan, Zdenek↗
NASA NTRS1992

Microstructural design of fiber composites

The optimum performance design of composite microstructures is discussed. The forces driving progress in fiber composites are examined, and recent developments in the mechanics of laminated composites are surveyed, emphasizing thick laminates, hygrothermal effects, and thermal transient effects. The strength of continuous-fiber composites is discussed, presenting analyses of local load redistribution due to fiber breakages and treatments of statistical tensile strength theories. Modes of failure of laminated composites are examined. Elastic, physical, and viscoelastic properties as well as the strength and fracture behavior of short-fiber composites are studied, and it is shown how the performance of composites can be controlled by selecting material systems and their geometric distributions. 2D textile structural composites based on woven, knitted, and braided preforms are considered, and techniques for analyzing and modeling the thermomechanical behavior of 2D textile composites are presented. Recent developments in the processing of 3D textile preforms are introduced and the processing-microstructure relationship is demonstrated. Finite elastic deformation of flexible composites is addressed.

Chou, Tsu-Wei↗
NASA NTRS1995

The International Space Station Alpha (ISSA) End-to-End On-Orbit Maintenance Process Flow

As a tool for construction and refinement of the on-orbit maintenance system to sustain the International Space Station Alpha (ISSA), the Mission Operations Directorate (MOD) developed an end to-end on-orbit maintenance process flow. This paper discusses and demonstrates that process flow. This tool is being used by MOD to identify areas which require further work in preparation for MOD's role in the conduct of on-orbit maintenance operations.

Zingrebe, Kenneth W., II↗