A non-noble front metallization process
The optimization, evaluation, and demonstration of a solar cell metallization system is discussed. Screen printing, air firing, reducted atmospheres, and conductive air coating were studied.
Garcia, A., III↗
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Results for “Fire Systems”
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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Probe Measures Fouling As In Heat Exchangers
Combustion deposits reduce transfer of heat. Instrument measures fouling like that on gas side of heat exchanger in direct-fired boiler or heat-recovery system. Heat-flux probe includes tube with embedded meter in outer shell. Combustion gases flow over probe, and fouling accumulates on it, just as fouling would on heat exchanger. Embedded heat-flow meter is sandwich structure in which thin Chromel layers and middle alloy form thermopile. Users determine when fouling approaches unacceptable levels so they schedule cleaning and avoid decreased transfer of heat and increased drop in pressure fouling causes. Avoids cost of premature, unnecessary maintenance.
Marner, Wilbur J.↗
Ion mass spectrometer measurements from the Space Shuttle
Ion-mass-spectrometer measurements made, as part of the University of Iowa's Plasma Diagnostic Package, on the STS-3 and Spacelab 2 missions, sampled a variety of positive ion composition perturbations in response to gas emissions from the vehicle. A background of contaminant ion species (mostly relating to water) always exists in the vicinity of the Shuttle. The measured number fluxes of the contaminant ions vary differently from those of the ambient ions in response to changes in the spectrometer and spacecraft angles of attack. There is a near-Shuttle wake cavity in the contaminant ion distributions which has a different spatial configuration than the wake of the ambient ions. Although water dumps produce the longest term ion perturbations, the most well defined effects were observed from measurements taken during the short firings of the reaction-control-system thrusters.
Grebowsky, J. M.↗
Dynamics and control of the Space Station Freedom docking/array feathering maneuver
Analysis performed at Lewis Research Center has indicated that it is possible to fail a photovoltaic array of the Space Station Freedom during a Shuttle approach, due to impingements by Shuttle attitude jet firing plumes. A solution to this potential problem is the feathering of the arrays. This study deals with fine adjustments in feathered position for extra plume load relief. A mathematical model for fine feathering is described. The Shuttle is treated as a single rigid body, with prescribed jet firings. Freedom is treated as a system of rigid bodies, with high-fidelity gimbal dynamics. Uncertainty is found in disturbances, plume dynamic pressure, gimbal friction and misalignments. Assumptions, model structure and analysis test plan are presented.
Graham, Ronald E.↗
Magnetic Gimbal Proof-of-Concept Hardware performance results
The Magnetic Gimbal Proof-of-Concept Hardware activities, accomplishments, and test results are discussed. The Magnetic Gimbal Fabrication and Test (MGFT) program addressed the feasibility of using a magnetic gimbal to isolate an Electro-Optical (EO) sensor from the severe angular vibrations induced during the firing of divert and attitude control system (ACS) thrusters during space flight. The MGFT effort was performed in parallel with the fabrication and testing of a mechanically gimballed, flex pivot based isolation system by the Hughes Aircraft Missile Systems Group. Both servo systems supported identical EO sensor assembly mockups to facilitate direct comparison of performance. The results obtained from the MGFT effort indicate that the magnetic gimbal exhibits the ability to provide significant performance advantages over alternative mechanically gimballed techniques.
Stuart, Keith O.↗
STS-113 Flight Day 3 Highlights
This video shows the activities of the STS-113 crew (Jim Wetherbee, Commander; Paul Lockhart, Pilot; Michael Lopez-Alegria, John Herrington, Mission Specialists) during flight day 3. The major tasks of flight day 3 were rendezvous and docking with the ISS (International Space Station), the transfer of the Expedition 6 crew (Kenneth Bowersox, Commander; Donald Pettit, Nikolai Budarin, Flight Engineers) to the ISS, and preparations for an EVA (extravehicular activity) scheduled for the following day. The approach of Space Shuttle Endeavour to the ISS is shown in detail, including the firing of the Left Orbital Maneuvering System, and the aiming maneuvers the orbiter makes to dock with the ISS. There are centerline views of the ISS before and during the final docking maneuver. The new ISS crew is received by the Expedition 5 crew (Valeri Korzun, Commander; Peggy Whitsun, Sergei Treschev; Flight Engineers), and the transfer of EVA suits is shown. Earth views include a pan along a reddish Earth limb, and the Pacific Ocean with Endeavour's Canadarm robotic arm in the foreground.
Source record↗
Modeling of Deadbanding DV for the Stardust Earth Return: Calibration, Analysis, Prediction and Performance
On January 15th, 2006, 0556 UTC, the Stardust spacecraft released a 42-kg Sample Return Canister (SRC) along a trajectory intended to impact a target on the Air Force Utah Test and Training Range (UTTR), near Dugway, Utah. Assurances of a successful SRC delivery to UTTR depended on identifying (and mitigating, if possible) a myriad of error sources. These sources included atmospheric effects, maneuver execution, Orbit Determination (OD) uncertainties and (Delta)V induced by the firing of the unbalanced Reaction Control System (RCS) thrusters needed for deadband attitude control. Every mm/s in prediction error at the TCM-19 epoch would amount to missing the target by approximately one kilometer. This paper will describe the work performed in analyzing and predicting the levels of (Delta)V caused by the attitude deadbanding, as well as prediction performance.
Stardust↗
Metallographic Preparation of Space Shuttle Reaction Control System Thruster Electron Beam Welds for Electron Backscatter Diffraction
A Space Shuttle Reaction Control System (RCS) thruster failed during a firing test at the NASA White Sands Test Facility (WSTF), Las Cruces, New Mexico. The firing test was being conducted to investigate a previous electrical malfunction. A number of cracks were found associated with the fuel closure plate/injector assembly (Fig 1). The firing test failure generated a flight constraint to the launch of STS-133. A team comprised of several NASA centers and other research institutes was assembled to investigate and determine the root cause of the failure. The JSC Materials Evaluation Laboratory was asked to compare and characterize the outboard circumferential electron beam (EB) weld between the fuel closure plate (Titanium 6Al-4V) and the injector (Niobium C-103 alloy) of four different RCS thrusters, including the failed RCS thruster. Several metallographic challenges in grinding/polishing, and particularly in etching were encountered because of the differences in hardness, ductility, and chemical resistance between the two alloys and the bimetallic weld. Segments from each thruster were sectioned from the outboard weld. The segments were hot-compression mounted using a conductive, carbon-filled epoxy. A grinding/polishing procedure for titanium alloys was used [1]. This procedure worked well on the titanium; but a thin, disturbed layer was visible on the niobium surface by means of polarized light. Once polished, each sample was micrographed using bright field, differential interference contrast optical microscopy, and scanning electron microscopy (SEM) using a backscatter electron (BSE) detector. No typical weld anomalies were observed in any of the cross sections. However, areas of large atomic contrast were clearly visible in the weld nugget, particularly along fusion line interfaces between the titanium and the niobium. This prompted the need to better understand the chemistry and microstructure of the weld (Fig 2). Energy Dispersive X-Ray Spectroscopy (EDS) was used to confirm the chemical composition of the variations in contrast in these areas. Niobium alloys generally require exposure to more aggressive chemical reagents than titanium alloys for etching because of niobium s chemical resistance; therefore, the titanium portion of the sample was etched first. A five second immersion in Kroll s reagent revealed a general microstructure on the titanium portion of the sample; however, the titanium heat affected zone closest to the weld, was over-etched due to higher concentrations of refined grains and an increase in eta-phase. The Kroll s etchant also revealed some microstructure in the weld nugget itself; the niobium portion of the sample remained unetched.
Martinez, James↗
Status on the Verification of Combustion Stability for the J-2X Engine Thrust Chamber Assembly
Development is underway of the J -2X engine, a liquid oxygen/liquid hydrogen rocket engine for use on the Space Launch System. The Engine E10001 began hot fire testing in June 2011 and testing will continue with subsequent engines. The J -2X engine main combustion chamber contains both acoustic cavities and baffles. These stability aids are intended to dampen the acoustics in the main combustion chamber. Verification of the engine thrust chamber stability is determined primarily by examining experimental data using a dynamic stability rating technique; however, additional requirements were included to guard against any spontaneous instability or rough combustion. Startup and shutdown chug oscillations are also characterized for this engine. This paper details the stability requirements and verification including low and high frequency dynamics, a discussion on sensor selection and sensor port dynamics, and the process developed to assess combustion stability. A status on the stability results is also provided and discussed.
Casiano, Matthew↗
Interactions Between Biomass-Burning Aerosols and Clouds over Southeast Asia: Current Status, Challenges, and Perspectives
The interactions between aerosols, clouds, and precipitation remain among the largest sources of uncertainty in the Earth's energy budget. Biomass-burning aerosols are a key feature of the global aerosol system, with significant annually-repeating fires in several parts of the world, including Southeast Asia (SEA). SEA in particular provides a "natural laboratory" for these studies, as smoke travels from source regions downwind in which it is coupled to persistent stratocumulus decks. However, SEA has been under-exploited for these studies. This review summarizes previous related field campaigns in SEA, with a focus on the ongoing Seven South East Asian Studies (7-SEAS) and results from the most recent BASELInE deployment. Progress from remote sensing and modeling studies, along with the challenges faced for these studies, are also discussed. We suggest that improvements to our knowledge of these aerosol/cloud effects require the synergistic use of field measurements with remote sensing and modeling tools.
biomass-burning aerosol↗
Near Real-Time Sub/Seasonal Prediction of Aerosol at NASA Global Modeling and Assimilation Office
A new version of the coupled modeling and analysis system used to produce near real time subseasonal to seasonal forecasts was released over a year ago by the NASA/Goddard Global Modeling and Assimilation Office. The model runs at approximately 1/2 degree globally in the atmosphere and ocean, contains a realistic description of the cryosphere, and includes an interactive aerosol model. The data assimilation used to produce initial conditions is weakly coupled, in which the atmosphere-only assimilated state is coupled to an ocean data assimilation system using a Local Ensemble Transform Kalman Filter. Here will briefly describe the new system, and show results of aerosol-derived air quality from an extensive series of retrospective forecasts. The interactive aerosol is shown to improve seasonal time scale prediction skill during some "forecasts of oppurtunity". Plans for a future version of the system with predicted biomass burning from fires will also be discussed.
Molod, Andrea M.↗
Near Real-Time Sub/Seasonal Prediction of Aerosol and Air Quality at the NASA Global Modeling and Assimilation Office
Version 2 of the coupled modeling and analysis system used to produce near real time subseasonal to seasonal forecasts was released almost two years ago by the NASA/Goddard Global Modeling and Assimilation Office. The model runs at approximately 1/2 degree globally in the atmosphere and ocean, contains a realistic description of the cryosphere, and includes an interactive aerosol model. The data assimilation used to produce initial conditions is weakly coupled, in which the atmosphere-only assimilated state is coupled to an ocean data assimilation system using a Local Ensemble Transform Kalman Filter. Results of aerosol-derived air quality (Particulate Matter) from an extensive series of retrospective forecasts will be shown, with particular focus on the continental United States and eastern Asia. In addition, under some circumstances, the interactive aerosol is shown to improve seasonal time scale prediction skill. Plans for a future version of the system with predicted biomass burning from fires will also be discussed.
Molod, Andrea↗
In-situ Imaging of Pyrolyzing Aerospace Materials
Tracking morphological changes of materials during heating is crucial to understand its response in fire protection, biofuel production, thermal protection systems (TPS) for hypersonic flight. As materials are heated, they undergo physical and chemical changes due to water loss, stretching or shrinking, pyrolysis and chemical reactions in the ambient environment. The effects of these changes can have a profound impact on the material’s performance, indicated by changes in on the porosity and volume. While materials such as wood shrink as they pyrolyze and lose mass, others swell due to their inherent characteristics when exposed to heat [1]. This study focuses on experiments conducted at the Advanced Light Source (ALS) beamline 8.3.2, where in situ micro-computed tomography (µ-CT) is performed on materials as they are being pyrolyzed. Through in situ µ-CT, the change in total volume and porosity can be obtained in real-time, allowing for better understanding of the underlying thermophysical and chemical processes as a function of temperature. This study also focuses on the implementation of the Porous Microstructure Analysis software (PuMA) [2] to obtain thermal conductivity, permeability, and other properties of the material from the 3D tomographies. The information gained from these tomographies will supplement microscale model development of material morphological change and will aid macroscale modeling for high-temperature applications. For this study, Room Temperature Vulcanizing silicone (RTV) [3-5] is heated from room temperature to 1000°C using an infrared lamp heating system, and tomographies are continuously collected as the sample is heated. The tomographies are then segmented to obtain solid and void phases, from which estimates of pore size, porosity and total volume are extracted as a function of temperature. PuMA is deployed on the segmented tomographies to obtain thermal conductivity, permeability, and other properties as a function of temperature. Preliminary results show that RTV first intumesces (swells) as pyrolysis begins, due to build-up of pyrolysis gases in closed pores, and then shrinks significantly as more open pores are formed and the pyrolysis gases outgas. Pore network visualization of the tomographies using OpenPNM [6] showed the increase in pore connectivity with increase in temperature. Future work will focus on using PuMA to obtain macroscopic properties of RTV as a function of temperature.
Tomography↗
Process Heating Assessments Using DOE’s Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) Tool Suite
Process heating is the most energy-intensive manufacturing process for most sectors of industry. To quantify energy savings from various energy conservation measures, the Department of Energy (DOE) sponsored the development of the Process Heating Assessment and Survey Tool (PHAST) and similar tools for other industrial systems in the early 2000s. It has been used extensively in the Save Energy Now Program’s Energy Savings Assessments and the Better Plants Program’s In-Plant Trainings. Since the initial development of the legacy tools, both computer operating systems and software development have evolved significantly. Thus, DOE has invested in the modernization of PHAST and other legacy software tools to create the Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) tool suite. MEASUR offers a collection of software tools that can aid manufacturing facilities in improving the efficiency of energy systems and equipment (specifically pumps, fans, steam, and process heating) and in conducting “Energy Treasure Hunts”. Eventually, the tool will also add compressed air and process cooling systems. The Process Heating Assessment (PHA) module of MEASUR is an upgrade of the PHAST tool. PHA provides the means to model fuel-fired, steam-based, and electric process heating systems, covering process heating for most industrial plants in manufacturing sector. It also includes several key upgrades, including the ability to consider multi-component charge loads and account for several different areas of energy losses. The new tool includes a comprehensive flue gas calculator to quantify available heat and heat loss for various gaseous, liquid, and solid fuels and new heat loss calculators. It generates a report and a dynamic Sankey diagram to show the energy consumption in various areas of energy use. MEASUR has significantly improved the user experience by adopting a modern software design. This paper details the structure and workflow of PHA and presents a real-world case study to demonstrate energy savings quantification and MEASUR’s outstanding reporting capabilities.
Nimbalkar, Sachin U.↗
Repowering Coal Plants as Pumped Thermal Energy Storage
This conference presentation presents the results from a DOE FE funded study on the integration of a Malta Pumped Heat Energy Storage system with a retiring coal-fired power plant, and the economic benefits to the asset owner and the local community.
20 FOSSIL-FUELED POWER PLANTS↗
A New Application to Facilitate Post-Fire Recovery and Rehabilitation in Savanna Ecosystems
The U.S. government spends an estimated $3billion per year to fight forest fires in the United States. Post-fire rehabilitation activities represent a small but essential portion of that total. The Rehabilitation Capability Convergence for Ecosystem Recovery (RECOVER) system is currently under development for Savanna ecosystems in the western U.S. The prototype of this system has been built and will have realworld testing during the summer 2013 fire season. When fully deployed, the RECOVER system will provide the emergency rehabilitation teams with critical and timely information for management decisions regarding stabilization and rehabilitation strategies.
post-fire↗
Second generation PMR polyimide/fiber composites
A second generation polymerization monomeric reactants (PMR) polyimdes matrix system (PMR 2) was characterized in both neat resin and composite form with two different graphite fiber reinforcements. Three different formulated molecular weight levels of laboratory prepared PMR 2 were examined, in addition to a purchased experimental fully formulated PMR 2 precurser solution. Isothermal aging of graphite fibers, neat resin samples and composite specimens in air at 316 C were investigated. Humidity exposures at 65 C and 97 percent relative humidity were conducted for both neat resin and composites for eight day periods. Anaerobic char of neat resin and fire testing of composites were conducted with PMR 15, PMR 2, and an epoxy system. Composites were fire tested on a burner rig developed for this program. Results indicate that neat PMR 2 resins exhibit excellent isothermal resistance and that PMR 2 composite properties appear to be influenced by the thermo-oxidative stability of the reinforcing fiber.
Cavano, P. J.↗
Flight experience with Apollo spacecraft propulsion systems
Apollo 17 ended the most successful application of rocket propulsion systems in man's history. A total of 23 developmental and manned operational flights were made. Seven hundred and sixty-three spacecraft rocket engines were flown in the program. Over 6 h of manned rocket flights were logged by the spacecraft propulsion systems and approximately one million rocket engine firings were made. One engine failure was encountered on an early unmanned flight as a result of a failure in the guidance programmer which caused the engine to operate in a manner known to cause failures. Numerous operational problems and malfunctions were observed; however, system and component redundancy prevented loss of mission objectives and never jeopardized crew safety. Performance of all systems was usually nominal and most problems were merely nuisances. This paper will present some highlights of Apollo propulsion performance and will provide a bibliography of all flight results.
Thibodaux, J. G., Jr.↗