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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 73 records · Page 4

An experimental and computational investigation of the flow field about a transonic airfoil in supercritical flow with turbulent boundary-layer separation

A combined experimental and computational research program for testing and guiding turbulence modeling within regions of separation induced by shock waves incident on turbulent boundary layers is described. Specifically, studies are made of the separated flow over the rear portion of an 18%-thick circular-arc airfoil at zero angle of attack in high Reynolds number supercritical flow. The measurements include distributions of surface static pressure and local skin friction. The instruments employed include high-frequency response pressure cells and a large array of surface hot-wire skin-friction gages. Computations at the experimental flow conditions are made using time-dependent solutions of ensemble-averaged Navier-Stokes equations, plus additional equations for the turbulence modeling.

Rubesin, M. W.↗

Effect of Weld Tool Geometry on Friction Stir Welded Ti-6Al-4V

In this study, flat 0.250" thick Ti-6Al-4V panels were friction stir welded (FSWed) using weld tools with tapered pins. The five different pin geometries of the weld tools included: 0 degree (straight cylinder), 15 degree, 30 degree, 45 degree, and 60 degree angles on the frustum. All weld tools had a smooth 7 degree concave shoulder and were made from microwave sintered tungsten carbide. For each weld tool geometry, the FSW process parameters were optimized to eliminate internal defects. All the welds were produced in position control with a 2.5 degree lead angle using a butt joint configuration for the panels. The process parameters of spindle rpm and travel speed were varied, altering the hot working conditions imparted to the workpiece. Load cells on the FSWing machine allowed for the torque, the plunge force, and the plow force to be recorded during welding. Resulting mechanical properties were evaluated from tensile tests results of the FSWjoints. Variations in the material flow were investigated by use of microstructural analysis including optical microscopy (OM), scanning electron microscopy (SEM), and orientation image mapping (aIM).

Querin, Joseph A.↗

Improved Mechanical Performance in FDM Cellular Frame Structures through Partial Incorporation of Faces

The utilization of lattice-type cellular architectures has seen a significant increase, owing to their predictable shape and the ability to fabricate templated porous materials through low-cost 3D-printing methods. Frames based on atomic lattice structures such as face-centered cubic (FCC), body-centered cubic (BCC), or simple cubic (SC) have been utilized. In FDM, the mechanical performance has been impeded by stress concentration at the nodes and melt-solidification interfaces arising from layer-by-layer deposition. Adding plates to the frames has resulted in improvements with a concurrent increase in weight and hot-pocket-induced dimensional impact in the closed cells formed. In this paper, we explore compressive performance from the partial addition of plates to the frames of a SC-BCC lattice. Compression testing of both single unit cells and 4 × 4 × 4 lattices in all three axial directions is conducted to examine stress transfer to the nearest neighbor and assess scale-up stress transfer. Our findings reveal that hybrid lattice structure unit cells exhibit significantly improved modulus in the range of 125% to 393%, specific modulus in the range of 13% to 120%, and energy absorption in the range of 17% to 395% over the open lattice. The scaled-up lattice modulus increased by 8% to 400%, specific modulus by 2% to 107%, and energy absorption by 37% to 553% over the lattice frame. Parameters that emerged as key to improved lightweighting.

FDM↗

Technology development for phosphoric acid fuel cell powerplant (phase 2)

The status of technology for the manufacturing and testing of 1200 sq. cm cell materials, components, and stacks for on-site integrated energy systems is assessed. Topics covered include: (1) preparation of thin layers of silicon carbide; (2) definition and control schemes for volume changes in phosphoric acid fuel cells; (3) preparation of low resin content graphite phenolic resin composites; (4) chemical corrosion of graphite-phenolic resin composites in hot phosphoric acid; (5) analysis of electrical resistance of composite materials for fuel cells; and (6) fuel cell performance and testing.

Christner, L.↗

NASA Alternative Orion Small Cell Battery Design Support

The NASA Orion Crew Module Reference Design was produced to address large scale thermal runaway (TR) hazard with specific safety controls for the Orion Spacecraft. The design presented provides the description of a full scale battery design reference for implementation as a drop in replacement to meet all spacecraft energy requirements with compatible 120 Vdc electrical and mechanical interface using small cell technology (18650) packaging. The 32V SuperBrick incorporates unique support features and an electrical bus bar arrangement that allows cells negative can insertion into heat sink that is compressively coupled to the battery enclosure to promote good thermal management. The housing design also provides an internal flame suppression "filter tray" and positive venting path internal to the enclosure to allow hot effluent ejecta to escape in the event of single cell TR. Virtual cells (14P Banks) that are supported to provide cell spacing with interstitial materials to prevent side can failures that can produce cell to cell TR propagation. These features were successfully test in four separate TR run with the full scale DTA1 test article in February 2016. Successfully Completed Test Objectives - Four separate TR test runs with Full-Scale DTA1 housing with Two SuperBricks, Two SuperBrick Emulators All Tests resulted in "clean" gas with less than 6 C rise at Battery vent All Tests resulted in less than 2 C temperature rise on cold-plate outlet All Tests resulted in less than 6 psi pressure rise in the battery housing Test Run 1 -One neighbor cell TR, highest remaining neighbor 139 C. Ejecta shorted to bus caused prolonged additional heating, One shorted cell did experience TR after 12 minutes, remaining cells had adequate thermal margin Test Run 2 - No cell to cell propagation, highest neighbor cell 112 C; Test Run 3 - No cell to cell propagation, highest neighbor cell 96 C; Test Run 4 - No cell to cell propagation, highest neighbor cell 101 C; Primary TR testing and analysis were completed and reviewed for endorsement by NASA Engineering and Safety Center team members. All Key Test Objectives were met and the small cell design alternative was demonstrated and selected to be a feasible drop in replacement for the MPCV Orion CM Battery for EM2 mission.

Haynes, Chuck↗

SP-100 Thermoelectric Cell Testing at JPL

Three prototypic SP-100 thermoelectric cells, fabricated by Martin Marietta Astro Space in Valley Forge, Pennsylvania, were tested in vacuum at prototypic temperatures at JPL. Their thermal and electrical performance were characterized with 200, 300, 400, and 500 degree Celsius temperature gradients across the cell. The latter was representative of prototypic operating conditions with a 1050 degree Celsius hot side temperature and a 550 degree Celsius cold side temperature. The initial thermal and electrical performance of all three cells closely matched predictions.

thermoelectric↗

AMTEC cell testing, optimization of rhodium/tungsten electrodes, and tests of other components

Electrodes, current collectors, ceramic to metal braze seals, and metallic components exposed to the high 'hot side' temperatures and sodium liquid and vapor environment have been tested and evaluated in laboratory cells running for hundreds of hours at 1100-1200 K. Rhodium/tungsten electrodes have been selected as the optimum electrodes based on performance parameters and durability. Current collectors have been evaluated under simulated and actual operating conditions. The microscopic effects of metal migration between electrode and current collector alloys as well as their thermal and electrical properties determined the suitability of current collector and lead materials. Braze seals suitable for long term application to AMTEC devices are being developed.

Williams, Roger M.↗

PEP solar array definition study

The conceptual design of a large, flexible, lightweight solar array is presented focusing on a solar array overview assessment, solar array blanket definition, structural-mechanical systems definition, and launch/reentry blanket protection features. The overview assessment includes a requirements and constraints review, the thermal environment assessment on the design selection, an evaluation of blanket integration sequence, a conceptual blanket/harness design, and a hot spot analysis considering the effects of shadowing and cell failures on overall array reliability. The solar array blanket definition includes the substrate design, hinge designs and blanket/harness flexibility assessment. The structural/mechanical systems definition includes an overall loads and deflection assessment, a frequency analysis of the deployed assembly, a components weights estimate, design of the blanket housing and tensioning mechanism. The launch/reentry blanket protection task includes assessment of solar cell/cover glass cushioning concepts during ascent and reentry flight condition.

Source record↗

Second quadrant effects in silicon solar cells

A simple model describing the behavior of a solar cell in the second quadrant of the I-V curve is described. In this mode of operation appreciable power is dissipated in the cell leading to thermal breakdown and the formation of hot spots. These hot spots will be stable in a current limited mode of operation. In addition a simple method is described to locate the hot spots.

Hartman, R. A.↗

Numerical and Experimental Examination of Turbulent Mixing of a Heated Jet in Crossflow

The injection of fully-developed turbulent heated air from a tube into a cooler turbulent duct flow is examined, as an analogy to film cooled turbine blades. A LES numerical model is developed and applied in which tube and duct turbulence inflow effects are emulated using a divergence-free synthetic eddy method (SEM). For direct comparison, a hot-wire experiment is conducted within the ERB test cell SW-6 at NASA Glenn Research Center. Results related to velocity, temperature, and heat flux are obtained numerically and experimentally for a blowing ratio of 1.2, involving a 36 K temperature difference. The relative effect on the solutions of tube and duct inflow turbulence is systematically evaluated. The impact of inherent low-pass filtering of temperature measurements and probe wire offset on the experimental results are addressed.

Large Eddy Simulation↗

Lessons from Earth Aerobiology for Venus Astrobiology

Venus’s clouds have often suggested as a possible habitat. The constraints governing putative airborne life in such a habitat in turn inform priorities and strategies for remote and in situ exploration, methods by which resulting biosignatures might be detected, exoplanet habitability assessment, and planetary protection concerns. Lessons drawn from studying Earth’s aerobiosphere can help improve this understanding. There are altitude ranges within Venus’s clouds in which temperature, pressure, particle size, and radiation appear to be within the limits of microbial life on Earth, and life cycles involving S- and Fe-based redox metabolism have been proposed. However, given the lack of a habitable surface reservoir, a long-term stable Venus aerobiosphere would require that the reproduction rate of the airborne microbes be faster than the settling rate of airborne microbes due to gravity, or eventually the population would be depleted; put another way, the mean generation time would need to exceed the mean residence time. This creates a joint constraint of aerosol dynamics, potential nutrient availability and energy influx, and bioenergetic costs such as desiccation and radiation damage. Even at an optimistic estimate of 75% H2SO4, Venus aerosol water activity (aw) is still ~0.02, far below the observed microbial growth limit of ~0.6. Long-term desiccation with brief spurts of repair and growth in response to transient water influx, such as from volcanism, is the most likely model for Earth-like life on Venus – a ‘desert bloom’ scenario. Several high-priority science goals – cloud aerosol composition, internal radiative flux, and aerosol residence time and circulation models – thus will also improve our understanding of Venus in an astrobiology context. In Earth’s troposphere, warm water clouds can carry 103 – 105 cells/mL, some metabolically active. However, Earth’s stratospheric sulfate aerosol layer may be a better analogue: supercooled sulfuric acidaerosols (acid weight fraction 0.6 – 0.85, 0.1 – 1 μm diameter, 0.1 – 1 cm-3) with little water activity, long residence times, high UV radiation, and only sporadic influx from surface particle sources. Though ‘hot spots’ can occur associated with tropospheric mixing, viable cells in stratospheric samples are rare (~102 cells/m3), and primarily inactive forms such as spores. It is not yet clear whether such bioaerosols are associated with sulfate aerosols or simply co-located, and reproduction in situ has not yet been observed. In this model of a sparse, largely dormant Venus ecosystem, a single transect on descent is likely to pass through a low-water, inactive region, missing potential signs of habitability or biosignatures. A targeted strategy would sample through an aerial region with some upwelling from surface sources, andtake multiple transects separated in time and space. This is compatible with other in situ science goals seeking to understand the dynamics and heterogeneities of Venus’s clouds.

Lower atmosphere↗

Novel Thermotolerant Siderophilic Filamentous Cyanobacterium that Produces Intracellular Iron-Rich Phases

Cyanobacteria are the main producers of organic compounds in iron-depositing hot springs despite photosynthetically generated-oxygen and the abundance of reduced iron (Fe2+) that likely leads to enormous oxidative stress within cyanobacterial cells. Therefore, the study of cyanobacterial diversity, phylogeny, and biogeochemical activity in iron-depositing hot springs will not only provide insights into the contribution of CB to iron redox cycling in these environments, but it could also provide insights into CB evolution. This study characterizes the phylogeny, morphology, and physiology of isolate JSC-1, a novel filamentous CB isolated from an iron-depositing hot spring. While isolate JSC-1 is morphologically similar to the CB genus Leptolyngbya, 16S rDNA sequence data indicated that it shares 95 percent sequence similarity to the type strain L. boryanum. Strain JSC-1 fixes N2 and exhibited an unusually high ratio between photosystem (PS) I and PS II and was capable of complementary chromatic adaptation. Further, it synthesized only chlorophyll a and a unique set of carotenoids. Strain JSC-1 not only required high levels of Fe for growth (greater than or equal to 40 microM), but it also accumulated large amounts of extracellular ferrihydrite and generated intracellular ferric phosphates. Strain JSC-1 was found to secrete 2-oxoglutaric acid and possesses one ortholog and one paralog of bacterioferritin. Surprisingly, the latter has 70.13 % identity with a bacterioferritin in marine-proteobacterium HTCC 2080 and has joint node with bacterioferritins found in enterobacteria. Collectively, these observations provide insights into the physiological strategies that might have allowed CB to develop and proliferate in Fe-rich environments. Based on its genotypic and phenotypic characterization of strain, JSC-1 represents a new operational taxonomical unit (OTU) JSC-1.

Broun, Igor I.↗

Compressible convection in a viscous Venusian mantle

Finite element simulations of axisymmetric spherical shell compressible convection were carried out to investigate the effect of various surface boundary conditions in a Venusian mantle, employing a thermal expansivity alpha which decreased with depth, a uniform viscosity an order of magnitude greater than the earth's, and zero and chondric quantities of internal heating. As long as hot plumes from the core-mantle boundary were strong, the convection pattern was typical of that for variable alpha flow; that is, it was characterized by steady upflowing regions, unsteady collections of downflowing plumes, and large aspect ratio cells. Increases in the internal heating or the temperature T0 at the top of the convecting layer weakened the hot plumes and, therefore, decreased the width of the cells. A rigid surface increased the internal temperature and also decreased the width of convection cells. Extensive regions of subadiabaticity were found in the mantle. These results are compared with those for fully three-dimensional convection under similar conditions (Schubert et al., 1990).

Leitch, A. M.↗

Experimental investigation of recirculating cells in laminar coaxial jets.

Utilizing several unique means of introducing smoke into the flow field for careful visualization in addition to hot-wire techniques, experiments are performed in a specially designed facility producing laminar flows up to considerably high Reynolds numbers. Characteristics of the cells and the flow conditions that bring them about are documented by smoke photographs in the Reynolds number velocity ratio plane and the results are compared to previous analytical predictions. The cells are found to fall into three categories with different flow characteristics involving unsteadiness in position, and shear layer instabilities which result in higher mixing with the outer streams.-

Warpinski, N. R.↗

Acoustic near field and local flow properties associated with broadband shock noise

Shock noise associated with unheated supersonic jets were investigated using a near field microphone array and a single sensor wedge shaped hot-film probe. Both over and underexpanded cases were investigated using Mach 1.5 and 2.0 convergent-divergent nozzles. Correlation measurements through each shock cell of a single underexpanded case with the Mach 1.5 nozzle were obtained between the hot-film probe and microphone array. The results show for the Mach number cases selected that the probe's response is primarily sensitive to velocity. The results of the hot-film near field microphone correlations show general agreement with certain theoretical models as to the location for shock noise production, although they demonstrate the existence of some large perhaps turbulent structure that collectively interacts and phases the motion of the downstream shocks. The near field microphone correlations demonstrate that downstream shocks dominate shock noise production, and suggests the existence of a Doppler effect in near field of the sources. In addition broadband shock noise is found to also propagate at small angles to the jet axis.

Seiner, J. M.↗

Evaluation Studies of a 800W Solid Oxide-Based Fuel Cells Stack for Electrical Power in Aviation

As both NASA and the aeronautics industry recognize the need for higher fuel efficiency and lower carbon emissions in both commercial airline and private aviation applications, development of all-electric or hybrid electric aircraft have garnered renewed interest in the aviation community. For the particular example of the hybrid-electric option, the solid oxide fuel cell (SOFC) is an attractive option for the power source, due to its potential to utilize aviation fuels thereby having minimal impact to aviation infrastructure. SOFC stack performance depends upon many factors, one of the most important is the way the oxidant and fuel gases are delivered to the fuel cells. System modeling of various aircraft configurations for FUELEAP (Fostering Ultra-Efficient, Low-Emitting Aviation Power) point to the need to operate SOFC stacks at high current densities. This creates challenges in the thermal profile of the stacks with potential to create large thermal gradients and hot spots. This study investigates two types of commercial solid oxide fuel cell stacks, the cross flow and co-flow gas designs, both convectively cooled with cathode air. High fuel utilization factors were also employed under varying electrical loads expected from the demands of flight. In addition, performance, range of operation and endurance were investigated under conditions of high current loads and thermal cycling. Evaluations include the study of gas kinetic using electrochemical spectroscopy. Testing took place at the facilities of NASA Glenn using a commercial test system (FuelCon AG, Magdeburg Germany). These studies are crucial to the Glenn Research Center's ability to conduct research, evaluation and development of the next-generation SOFC based stacks for cutting-edge energy technologies for aerospace applications. This study supports NASA's Convergent Aeronautics Solutions' (CAS) FUELEAP project.

Goldsby, Jon C.↗

Liquid Oxygen/Liquid Methane Test Summary of the RS-18 Lunar Ascent Engine at Simulated Altitude Conditions at NASA White Sands Test Facility

Tests were conducted with the RS18 rocket engine using liquid oxygen (LO2) and liquid methane (LCH4) propellants under simulated altitude conditions at NASA Johnson Space Center White Sands Test Facility (WSTF). This project is part of NASA s Propulsion and Cryogenics Advanced Development (PCAD) project. "Green" propellants, such as LO2/LCH4, offer savings in both performance and safety over equivalently sized hypergolic propellant systems in spacecraft applications such as ascent engines or service module engines. Altitude simulation was achieved using the WSTF Large Altitude Simulation System, which provided altitude conditions equivalent up to approx.120,000 ft (approx.37 km). For specific impulse calculations, engine thrust and propellant mass flow rates were measured. Propellant flow rate was measured using a coriolis-style mass-flow meter and compared with a serial turbine-style flow meter. Results showed a significant performance measurement difference during ignition startup. LO2 flow ranged from 5.9-9.5 lbm/sec (2.7-4.3 kg/sec), and LCH4 flow varied from 3.0-4.4 lbm/sec (1.4-2.0 kg/sec) during the RS-18 hot-fire test series. Thrust was measured using three load cells in parallel. Ignition was demonstrated using a gaseous oxygen/methane spark torch igniter. Data was obtained at multiple chamber pressures, and calculations were performed for specific impulse, C* combustion efficiency, and thrust vector alignment. Test objectives for the RS-18 project are 1) conduct a shakedown of the test stand for LO2/methane lunar ascent engines, 2) obtain vacuum ignition data for the torch and pyrotechnic igniters, and 3) obtain nozzle kinetics data to anchor two-dimensional kinetics codes.

Melcher, John C., IV↗

Heat recovery subsystem and overall system integration of fuel cell on-site integrated energy systems

The best HVAC (heating, ventilating and air conditioning) subsystem to interface with the Engelhard fuel cell system for application in commercial buildings was determined. To accomplish this objective, the effects of several system and site specific parameters on the economic feasibility of fuel cell/HVAC systems were investigated. An energy flow diagram of a fuel cell/HVAC system is shown. The fuel cell system provides electricity for an electric water chiller and for domestic electric needs. Supplemental electricity is purchased from the utility if needed. An excess of electricity generated by the fuel cell system can be sold to the utility. The fuel cell system also provides thermal energy which can be used for absorption cooling, space heating and domestic hot water. Thermal storage can be incorporated into the system. Thermal energy is also provided by an auxiliary boiler if needed to supplement the fuel cell system output. Fuel cell/HVAC systems were analyzed with the TRACE computer program.

Mougin, L. J.↗