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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Mo-100 Disk Structural Integrity Tests II

This report is a continuation of the work performed in the report, Mo-100 Disk Structural Integrity Tests I [1]. The NorthStar pressed and sintered 29 mm diameter, 0.5 mm thick Mo-100 disks will be subjected to large temperature gradients when in-beam during production. These large temperature gradients cause high stress and deformation within the disks that could prove detrimental to the target assembly’s cooling performance. Disk fracture is also a possibility that must be understood. Therefore, disk structural integrity tests were performed to understand the thermal induced behavior of these disks. In order to replicate the in-beam conditions, the Mo-100 disks were subjected to large temperature gradients using a 30kW induction heater and coil. A series of transient tests were conducted in a similar fashion as the previous work, as well as an attempt to create steady state conditions for more accurate temperature gradients. The transient thermal test setup and results are described in this report.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Power systems for production, construction, life support and operations in space

As one looks to man's future in space it becomes obvious that unprecedented amounts of power are required for the exploration, colonization, and exploitation of space. Activities envisioned include interplanetary travel and LEO to GEO transport using electric propulsion, Earth and lunar observatories, advance space stations, free-flying manufacturing platforms, communications platforms, and eventually evolutionary lunar and Mars bases. These latter bases would start as camps with modest power requirements (kWes) and evolve to large bases as manufacturing, food production, and life support materials are developed from lunar raw materials. These latter activities require very robust power supplies (MWes). The advanced power system technologies being pursued by NASA to fulfill these future needs are described. Technologies discussed will include nuclear, photovoltaic, and solar dynamic space power systems, including energy storage, power conditioning, power transmission, and thermal management. The state-of-the-art and gains to be made by technology advancements will be discussed. Mission requirements for a variety of applications (LEO, GEO, lunar, and Martian) will be treated, and data for power systems ranging from a few kilowatts to megawatt power systems will be represented. In addition the space power technologies being initiated under NASA's new Civilian Space Technology Initiative (CSTI) and Space Leadership Planning Group Activities will be discussed.

Sovie, Ronald J.↗
NASA NTRS1988

Power systems for production, construction, life support, and operations in space

As one looks to man's future in space it becomes obvious that unprecedented amounts of power are required for the exploration, colonization, and exploitation of space. Activities envisioned include interplanetary travel and LEO to GEO transport using electric propulsion, earth and lunar observatories, advance space stations, free-flying manufacturing platforms, communications platforms, and eventually evolutionary lunar and Mars bases. These latter bases would start as camps with modest power requirements (kWes) and evolve to large bases as manufacturing, food production, and life support materials are developed from lunar raw materials. These latter activities require very robust power supplies (MWes). The advanced power system technologies being pursued by NASA to fulfill these future needs are described. Technologies discussed will include nuclear, photovoltaic, and solar dynamic space power systems, including energy storage, power conditioning, power transmission, and thermal management. The state-of-the-art and gains to be made by technology advancements will be discussed. Mission requirements for a variety of applications (LEO, GEO, lunar, and Martian) will be treated, and data for power systems ranging from a few kilowatts to megawatt power systems will be represented. In addition the space power technologies being initiated under NASA's new Civilian Space Technology Initiative (CSTI) and Space Leadership Planning Group Activities will be discussed.

Sovie, Ronald J.↗
NASA NTRS1994

Carbon-Carbon Heat Pipe Testing and Evaluation

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

Juhasz, Albert J.↗
DOE OSTI2024

Report on Initial Sodium Testing on the Thermal Hydraulic Experimental Test Article (THETA) (Fiscal Year 2024 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that is used to develop sodium components and instrumentation as well as to acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility simulates nominal thermal hydraulic conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field may be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility was designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary coolant and secondary coolant system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. In fiscal year 2023, thermal stratification tests were completed with the primary system online, while the secondary system was being constructed [1]. These tests had shown that the core barrel and intermediate heat exchanger (IHX) outlet required increased thermal insulation. The THETA primary system was removed from METL, cleaned, thermal insulators installed, and then inserted into METL Test Vessel 4. At the time of this writing the THETA primary and secondary system are operational. During this fiscal year 100+ hours of testing was completed to characterize thermal hydraulic phenomena associated with steady state and transient conditions in a pool type liquid metal cooled reactor. A majority of the testing campaign was completed to satisfy the experimental data acquisition requirements for the GAIN Voucher with Oklo, CRADA 2021-21121. THETA is still operational at the time of this publication and future testing is planned for fiscal year 2025. Work is underway to publish existing and future data to an online database to facilitate collaboration with SFR engineers looking to validate their systems code or computational fluid dynamics models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRSDate not supplied

Thermal Vacuum Testing Strategy and Thermal Desktop Model Correlation for the Moon to Mars Planetary Autonomous Construction Technologies (MMPACT) Robotic Terrestrial Arm

This paper discusses the initial thermal vacuum testing of the MMPACT robotic terrestrial arm. The robotic arm is part of a construction system designed for the lunar south pole surface. The first thermal vacuum test was a risk mitigation test to ensure the arm could operate in vacuum, with all other data collection as secondary priorities. 44 thermocouples (TCs) were attached to the arm. Installation was done with additional care to account for both the extra wiring harness weight on the arm with the TC wires and increased focus on stabilizing the TC attachments to the moving components. Thermal steady state of <= 0.01°C/hour was reached for the hot set of testing conditions. This data was used to correlate the Thermal Desktop (TD) model to the test results within +/- 5°C.

Thermal analysis↗
NASA NTRSDate not supplied

Thermal Vacuum Testing Strategy and Thermal Desktop Model Correlation for the Moon to Mars Planetary Autonomous Construction Technologies (MMPACT) Robotic Terrestrial Arm

This paper discusses the initial thermal vacuum testing of the MMPACT robotic terrestrial arm. The robotic arm is part of a construction system designed for the lunar south pole surface. The first thermal vacuum test was a risk mitigation test to ensure the arm could operate in vacuum, with all other data collection as secondary priorities. 44 thermocouples (TCs) were attached to the arm. Installation was done with additional care to account for both the extra wiring harness weight on the arm with the TC wires and increased focus on stabilizing the TC attachments to the moving components. Thermal steady state of <= 0.01°C/hour was reached for the hot set of testing conditions. This data was used to correlate the Thermal Desktop (TD) model to the test results within +/- 5°C.

Thermal analysis↗
DOE OSTI2020

$\mathrm{UPDATED}$ $\mathrm{U3SI2}$ thermal creep model and sensitivity analysis of the $\mathrm{U3SI2-SIC}$ accident tolerant $\mathrm{FUEL}$

U 3 Si 2 is a candidate accident tolerant fuel (ATF) replacement for UO 2 . U 3 Si 2 ’s high uranium density and high thermal conductivity are favorable properties in steady-state and accident conditions. Low power performance of this U3Si2-SiC concept fuel is compared to that of UO 2 -Zr4 fuels by implementing models that describe the properties of U 3 Si 2 and SiC-SiC into Idaho National Laboratory's (INL) fuel performance code, BISON. Included in these material models is a thermal creep model for U 3 Si 2 based on compressive creep data. The simulated results are in keeping with community knowledge that the U 3 Si 2 -SiC concept fuel may serve as a replacement for UO 2 -Zr4 fuels during steady-state operation, provided the mSiC layer remains under compression. Through a moderate power history and three 24-month fuel cycles, the mSiC layer remains under compressive stress through a burnup of 80 MWd/kgU. During low power operation, failure of the mSiC layer generally occurs prior to significant thermal creep in U 3 Si 2 . Generally, U 3 Si 2 creep is temperature sensitive and of little importance at the temperatures and stresses simulated during steady operation and during fuel-to-cladding contact. A parameter variation study including 11,520 individual simulations with variations in nominal fuel thermal creep rate, cladding thermal conductivity, cladding irradiation creep and swelling, cladding gap size, and cladding thickness demonstrated that research priorities for this ATF should revolve around reducing cladding thickness as a means to minimize cladding failure. Generally, despite advances in SiC-SiC compliance, the brittle nature of mSiC excludes U 3 Si 2 -SiC for use where fuel cladding contact may occur.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Modeling of a Generic Pebble Bed High-temperature Gas-cooled Reactor (PB-HTGR) with SAM

This report presents the modeling of the core of a generic pebble-bed reactor (PBR) at the system level using the System Analysis Module (SAM) code. This work is an extension of a previous work by the authors (Ooi et al. (2021)) that used the so-called 2-D ring model approach to model the PBMR-400. With the new approach, the pebble bed of the reactor is modeled with multiple PBCoreChannel components with spherical heat structures which allows the code to calculate thermal fluid parameters with built-in closure relations. The new core-channel approach is an improvement to the 2-D ring model approach as it does not introduce geometric distortions to the model and thus reduces the uncertainties of the predictions. In addition to thermal fluid simulations, point kinetics (PKE) are included to the model. Simulations are performed under a steady-state normal operation condition and a load-following transient scenario. This particular transient scenario is chosen as it tests both the thermal fluid and neutronics aspects of the model. The predicted results from both the steady-state and transient scenarios are compared with the results by Stew- art et al. (2021) who performed similar simulations with a Griffin-Pronghorn coupled tool. Despite the differences between the codes, with SAM being a system-analysis code and Pronghorn being a porous-medium code, both sets of results compare favorably. The over- all profiles and trends of the predicted temperatures and reactivities from the SAM and Griffin/Pronghorn simulations are similar, with some differences in their predicted values. The first part of the report covers the significance of a relatively fast-running approach that is capable of modeling the pebble bed reactor at the system-level while simultaneously capturing the radial thermal behavior of the core. Then, the modeling approach used in this work is discussed in details. Lastly, the results and comparisons with the Griffin/Pronghorn simulation are presented.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

SOFC Prototype System Test

The goal of this U.S. Department of Energy (DOE) sponsored project is to test a 200 kWe thermally self-sustaining atmospheric-pressure solid oxide fuel cell (SOFC) prototype system at a prominent site. Fuel Cell Energy Inc. (FCE) utilized the state-of-the-art SOFC technology of its wholly-owned subsidiary Versa Power Systems (VPS) to design, fabricate and test the 200 kW prototype system. The specific objectives of this project were to achieve an SOFC stack power degradation rate of ≤1.5% per 1000 hours for the 400 kW stand-alone prototype power system undergoing ≥ 5000 hours of steady state tests at thermally self-sustained normal operating conditions (NOC), and to verify the prospects for a high volume SOFC stack production cost below the DOE target of 225 dollars per kilowatt. Achieving these goals enables commercial natural gas fueled SOFC system deployment in the 2020 timeframe, which will eventually lead to SOFC technology that is viable for large scale central power generation applications.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1998

Determining the Absorbance Spectra of Photochromic Materials From Measured Spectrophotometer Data

If a two-state photochromic material is optically bleached, the absorbance spectrum data measured by a spectrophotometer is in general comprised of components from both the ground state and the upper state. Under general conditions, it may be difficult to extract the actual upper state spectrum from the spectrum of the bleached material. A simple algorithm is presented here for the recovery of the pure absorbance spectra of the upper state of a material such as bacteriorhodopsin, given single wavelength bleaching illumination, steady-state conditions, and accurate knowledge of phototransition rates and thermal decay rates.

Downie, John D.↗
NASA NTRS2014

Real-Time Closed Loop Modulated Turbine Cooling

It has been noted by industry that in addition to dramatic variations of temperature over a given blade surface, blade-to-blade variations also exist despite identical design. These variations result from manufacturing variations, uneven wear and deposition over the life of the part as well as limitations in the uniformity of coolant distribution in the baseline cooling design. It is proposed to combine recent advances in optical sensing, actuation, and film cooling concepts to develop a workable active, closed-loop modulated turbine cooling system to improve by 10 to 20 the turbine thermal state over the flight mission, to improve engine life and to dramatically reduce turbine cooling air usage and aircraft fuel burn. A reduction in oxides of nitrogen (NOx) can also be achieved by using the excess coolant to improve mixing in the combustor especially for rotorcraft engines. Recent patents filed by industry and universities relate to modulating endwall cooling using valves. These schemes are complex, add weight and are limited to the endwalls. The novelty of the proposed approach is twofold 1) Fluidic diverters that have no moving parts are used to modulate cooling and can operate under a wide range of conditions and environments. 2) Real-time optical sensing to map the thermal state of the turbine has never been attempted in realistic engine conditions.

turbines↗
NASA NTRS2007

An Investigation of High-Cycle Fatigue Models for Metallic Structures Exhibiting Snap-Through Response

A study is undertaken to develop a methodology for determining the suitability of various high-cycle fatigue models for metallic structures subjected to combined thermal-acoustic loadings. Two features of this problem differentiate it from the fatigue of structures subject to acoustic loading alone. Potentially large mean stresses associated with the thermally pre- and post-buckled states require models capable of handling those conditions. Snap-through motion between multiple post-buckled equilibrium positions introduces very high alternating stress. The thermal-acoustic time history response of a clamped aluminum beam structure with geometric and material nonlinearities is determined via numerical simulation. A cumulative damage model is employed using a rainflow cycle counting scheme and fatigue estimates are made for 2024-T3 aluminum using various non-zero mean fatigue models, including Walker, Morrow, Morrow with true fracture strength, and MMPDS. A baseline zero-mean model is additionally considered. It is shown that for this material, the Walker model produces the most conservative fatigue estimates when the stress response has a tensile mean introduced by geometric nonlinearity, but remains in the linear elastic range. However, when the loading level is sufficiently high to produce plasticity, the response becomes more fully reversed and the baseline, Morrow, and Morrow with true fracture strength models produce the most conservative fatigue estimates.

Przekop, Adam↗
DOE OSTI2020

Distinct Surface and Bulk Thermal Behaviors of LiNi 0.6 Mn 0.2 Co 0.2 O 2 Cathode Materials as a Function of State of Charge

Understanding how structural and chemical transformations take place in particles under thermal conditions can inform designing thermally robust electrode materials. Such a study necessitates the use of diagnostic techniques that are capable of probing the transformations at multiple length scales and at different states of charge (SOC). In this study, the thermal behavior ofLiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC-622) was examined as a function of SOC, using an array of bulk and surface-sensitive techniques. In general, thermal stability decreases as lithium content is lowered and conversion in the bulk to progressively reduced metal oxides (spinels, rock salt) occurs as the temperature is raised. Hard X-ray absorption spectroscopy (XAS) and X-ray Raman spectroscopy (XRS) experiments, which probe the bulk, reveal that Ni and Co are eventually reduced when partially delithiated samples (regardless of the SOC) are heated, although Mn is not. Surface-sensitive synchrotron techniques, such as soft XAS and transmission X-ray microscopy (TXM), however, reveal that for 50% delithiated samples, apparent oxidation of nickel occurs at particle surfaces under some circumstances. This is partially compensated by reduction of cobalt but may also be a consequence of redistribution of lithium ions upon heating. TXM results indicate the movement of reduced nickel ions into particle interiors or oxidized nickel ions to the surface or both. These experiments illustrate the complexity of the thermal behavior of NMC cathode materials. The study also informs the importance of investigating the surface and bulk difference as a function of SOC when studying the thermal behaviors of battery materials.

25 ENERGY STORAGE↗
NASA NTRS1990

Thermal Conductivity and Temperature Limits of Electron-Beam Physical-Vapor-Deposited ZrO2-7wt%Y2O3 Thermal Barrier Coating

The electron-beam physical-vapor-deposited (EB-PVD) ZrO2-7wt%Y2O3 thermal barrier coating has been widely used to protect engine hot section components in modem aircraft engines. Thermal conductivity and the conductivity increases due to sintering and phase changes are important coating design parameters. There is a need to characterize the coating thermal conductivity behavior and temperature limits, in order to potentially take full advantage of the coating capability. In addition, since the ZrO2-7wt%Y2O3 coating is often used as a baseline coating for the development of advanced lower thermal conductivity and higher temperature capability coatings, a thorough evaluation of the coating conductivity behavior at future higher engine operating temperatures will be useful for more accurately assessing the benefit gained from the new coating systems. In this study, thermal conductivity behavior of EB-PVD ZrO2-7wt%Y2O3 coating has been systematically investigated as a function of temperature (up to 2600 F) and time under steady-state and cyclic test conditions using a laser heat-flux technique. Thermal conductivity change kinetics were determined under realistic engine high temperature thermal gradient conditions, and correlated to the coating microstructural and phase changes. The thermal conductivity prediction models have been established in terms of heat flux, time, and testing temperatures.

Zhu, Dongming↗
NASA NTRS2009

Stability of Detached Solidification

Bridgman crystal growth can be conducted in the so-called "detached" solidification regime, where the growing crystal is detached from the crucible wall. A small gap between the growing crystal and the crucible wall, of the order of 100 micrometers or less, can be maintained during the process. A meniscus is formed at the bottom of the melt between the crystal and crucible wall. Under proper conditions, growth can proceed without collapsing the meniscus. The meniscus shape plays a key role in stabilizing the process. Thermal and other process parameters can also affect the geometrical steady-state stability conditions of solidification. The dynamic stability theory of the shaped crystal growth process has been developed by Tatarchenko. It consists of finding a simplified autonomous set of differential equations for the radius, height, and possibly other process parameters. The problem then reduces to analyzing a system of first order linear differential equations for stability. Here we apply a modified version of this theory for a particular case of detached solidification. Approximate analytical formulas as well as accurate numerical values for the capillary stability coefficients are presented. They display an unexpected singularity as a function of pressure differential. A novel approach to study the thermal field effects on the crystal shape stability has been proposed. In essence, it rectifies the unphysical assumption of the model that utilizes a perturbation of the crystal radius along the axis as being instantaneous. It consists of introducing time delay effects into the mathematical description and leads, in general, to stability over a broader parameter range. We believe that this novel treatment can be advantageously implemented in stability analyses of other crystal growth techniques such as Czochralski and float zone methods.

Mazuruk, K.↗
NASA NTRS1970

A thermal model for analysis of infrared images

A mathematical model derived from the equation of heat conduction was developed to assist in interpreting thermal infrared images acquired from aircraft and spacecraft. The model assumes steady state boundary conditions. It contains parameters of rock and soil properties, atmospheric effects, site location, and season. The results predicted provide an explanation for the thermal differences among granite, limestone, and dolomite recorded in the December 1968 daytime and predawn flights over the Mill Creek, Oklahoma test site, during which representative thermal inertia and albedo values were used. A second test of the model made use of data acquired during the June 1970 predawn overflight of Mill Creek. A simple model of transient heating of the ground was constructed as an extension of the overall model, in order to examine the effects of atmospheric perturbations. The results obtained are consistent with those of ground observations made at the time of the overflight.

Watson, K.↗