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All sources NASA NTRS DOE OSTI

DOE OSTI2021

Octane Index Applicability over the Pressure-Temperature Domain

Modern boosted spark-ignition (SI) engines and emerging advanced compression ignition (ACI) engines operate under conditions that deviate substantially from the conditions of conventional autoignition metrics, namely the research and motor octane numbers (RON and MON). The octane index (OI) is an emerging autoignition metric based on RON and MON which was developed to better describe fuel knock resistance over a broader range of engine conditions. Prior research at Oak Ridge National Laboratory (ORNL) identified that OI performs reasonably well under stoichiometric boosted conditions, but inconsistencies exist in the ability of OI to predict autoignition behavior under ACI strategies. Instead, the autoignition behavior under ACI operation was found to correlate more closely to fuel composition, suggesting fuel chemistry differences that are insensitive to the conditions of the RON and MON tests may become the dominant factor under these high efficiency operating conditions. This investigation builds on earlier work to study autoignition behavior over six pressure-temperature (PT) trajectories that correspond to a wide range of operating conditions, including boosted SI operation, partial fuel stratification (PFS), and spark-assisted compression ignition (SACI). A total of 12 different fuels were investigated, including the Co-Optima core fuels and five fuels that represent refinery-relevant blending streams. It was found that, for the ACI operating modes investigated here, the low temperature reactions dominate reactivity, similar to boosted SI operating conditions because their PT trajectories lay close to the RON trajectory. Additionally, the OI metric was found to adequately predict autoignition resistance over the PT domain, for the ACI conditions investigated here, and for fuels from different chemical families. This finding is in contrast with the prior study using a different type of ACI operation with different thermodynamic conditions, specifically a significantly higher temperature at the start of compression, illustrating that fuel response depends highly on the ACI strategy being used.

02 PETROLEUM↗

NASA NTRS2017

Transient Thermal Analyses of Passive Systems on SCEPTOR X-57

As efficiency, emissions, and noise become increasingly prominent considerations in aircraft design, turning to an electric propulsion system is a desirable solution. Achieving the intended benefits of distributed electric propulsion (DEP) requires thermally demanding high power systems, presenting a different set of challenges compared to traditional aircraft propulsion. The embedded nature of these heat sources often preclude the use of traditional thermal management systems in order to maximize performance, with less opportunity to exhaust waste heat to the surrounding environment. This paper summarizes the thermal analyses of X-57 vehicle subsystems that don't employ externally air-cooled heat sinks. The high-power battery, wires, high-lift motors, and aircraft outer surface are subjected to heat loads with stringent thermal constraints. The temperature of these components are tracked transiently, since they never reach a steady-state equilibrium. Through analysis and testing, this report demonstrates that properly characterizing the material properties is key to accurately modeling peak temperature of these systems, with less concern for spatial thermal gradients. Experimentally validated results show the thermal profile of these systems can be sufficiently estimated using reduced order approximations.

Thermal Analyses↗

NASA NTRSDate not supplied

Space Launch System Payload Stage Capability for Ultra-High Characteristic Energy Missions

The Space Launch System (SLS) vehicle is NASA’s cornerstone capability for a new era of human and robotic exploration of deep space. The unrivalled performance of SLS provides the capability to launch the first woman and next man to walk on the lunar surface and to support development of a sustained human presence in cislunar space, and ultimately human missions to Mars. As an evolvable capability with unique launch performance, the opportunities enabled by SLS also include game-changing benefits for science missions, including probes to the outer solar system and beyond. For the last two years, the SLS Program has worked with the Interstellar Probe team at the Johns Hopkins University Applied Physics Laboratory(APL) to provide data that describe how SLS could support a mission that would break through the boundary of the heliosphere and into pristine interstellar space only a decade after launch, enabling earlier science return and greatly increasing spacecraft life in the interstellar medium. In record-breaking time, the ISP as launched on SLS may answer questions raised by the extended mission of NASA’s Voyager spacecraft. While SLS and its efficient Exploration Upper Stage (EUS) offer benefits for exploration of the outer planets, adding one or more additional stages to this architecture makes it even more capable for missions beyond our solar system, offering more realistically appealing flight times that would allow the mission scientists to reap the rewards of exploration. During the time the SLS Program has been working with the Interstellar Probe team, it has identified an expedited path to the Block 2 capability planned for the Interstellar Probe mission, and further matured performance numbers for diverse multi-stage configurations using a combination of commercially available liquid hydrogen (LH2)/liquid oxygen (LOX) upper stages and solid motor kick stages. That work has demonstrated the SLS payload stage capability provides significant benefits and opens trade space for multiple missions in consideration during planning for the next Planetary Science and Astrobiology Decadal Survey. This presentation details the significant benefits SLS can provides for very high characteristic (C3) energy missions by coupling the capabilities of SLS to current commercial rocket propulsion stage systems. These capabilities are explored specifically in the context of an Interstellar Probe architecture in which a small, capable science probe, coupled with carefully tailored mission design trajectories, could be used to explore the outer solar system and the interstellar medium. The presentation will also address the operational logistics of integrating such a mission, explaining the options available for “non-standard” SLS payloads, including processing those with radioisotope power generators or additional propulsion stages. An SLS system overview and capabilities will be presented, along with vehicle configuration and orbit performance capability studies, explaining how SLS is enabling for a variety of high-energy science mission profiles, including launching an exploratory probe bound for interstellar space only a decade after launch.

Rob Stough↗

NASA NTRS1994

System and process for detecting and monitoring surface defects

A system and process for detecting and monitoring defects in large surfaces such as the field joints of the container segments of a space shuttle booster motor. Beams of semi-collimated light from three non-parallel fiber optic light panels are directed at a region of the surface at non-normal angles of expected incidence. A video camera gathers some portion of the light that is reflected at an angle other than the angle of expected reflectance, and generates signals which are analyzed to discern defects in the surface. The analysis may be performed by visual inspection of an image on a video monitor, or by inspection of filtered or otherwise processed images. In one alternative embodiment, successive predetermined regions of the surface are aligned with the light source before illumination, thereby permitting efficient detection of defects in a large surface. Such alignment is performed by using a line scan gauge to sense the light which passes through an aperture in the surface. In another embodiment a digital map of the surface is created, thereby permitting the maintenance of records detailing changes in the location or size of defects as the container segment is refurbished and re-used. The defect detection apparatus may also be advantageously mounted on a fixture which engages the edge of a container segment.

Mueller, Mark K.↗

NASA NTRS2023

Quiet Spacecraft Cabin Ventilation Fan: Vibration Measurements Results

Quiet, efficient fans with minimal vibrations are needed to maximize the mechanical life of atmospheric revitalization system fans used for human life support systems for long duration space exploration missions. Several metal spacecraft cabin ventilation fan prototypes have been designed, built, and tested at the NASA Glenn Research Center Acoustical Testing Laboratory. Tests performed in 2021 of the first prototype of the metal fan measured vibrations greater than desired at design point speed and backpressure conditions. To try to reduce those vibrations, a second prototype of the fan design was developed which included a new lighter rotor with a tighter balance tolerance, a new collet to attach the rotor to the motor shaft more securely and repeatably, and a new bracket to center and hold the motor in the fan centerbody more precisely. The second prototype of the fan was tested in 2023 and the vibrations were measured with the fan operating at design point speeds in isolation but not throttled to design point back pressure conditions since it was not installed with inlet and exhaust ducting. Peak vibration was reduced from 4 mm/s to 1 mm/s. This paper is part of a series of reports documenting the performance of the prototype fan.

Fan↗

NASA NTRSDate not supplied

Multidisciplinary Optimization of A Transonic Truss-Braced Wing Aircraft Using Aviary

The continuous push to decrease fuel burn of single-aisle commercial aircraft has led to interest in a Transonic Truss-Braced Wing (TTBW) concept vehicle. Sporting high-slung wings that are long and slender to increase aerodynamic efficiency, a TTBW can also accommodate higher-bypass turbine engines. The combination of these two changes potentially leads to an overall decrease in fuel consumption. In this paper, a TTBW concept vehicle is assembled in the Aviary open-source tool for conceptual aircraft design. The conceptual-level aerodynamics and propulsion systems that come prepackaged with Aviary are replaced with higher-fidelity vortex lattice method for aerodynamics (VSPAERO) and a one-dimensional cycle analysis tool for propulsion (pyCycle). The vehicle is then optimized to minimize fuel burn for a representative commercial mission. Design parameters for the vehicle include the electrified turbine size, the size of the electric motors which are used for takeoff and climb assist, and battery capacity. The TTBW concept vehicle presented in this paper represents the first application of Aviary to an aircraft design problem.

Optimization↗

NASA NTRS1993

Miniature Long-life Space Cryocoolers

TRW has designed, built, and tested a miniature integral Stirling cooler and a miniature pulse tube cooler intended for long-life space application. Both efficient, low-vibration coolers were developed for cooling IR sensors to temperatures as low as 50 K on lightsats. The vibrationally balanced nonwearing design Stirling cooler incorporates clearance seals maintained by flexure springs for both the compressor and the drive displacer. The design achieved its performance goal of 0.25 W at 65 K for an input power to the compressor of 12 W. The cooler recently passed launch vibration tests prior to its entry into an extended life test and its first scheduled flight in 1995. The vibrationally balanced, miniature pulse tube cooler intended for a 10-year long-life space application incorporates a flexure bearing compressor vibrationally balanced by a motor-controlled balancer and a completely passive pulse tube cold head.

Tward, E.↗

DOE OSTI2020

Jamaican Domestic Ethanol Fuel Feasibility and Benefits Analysis

The Government of Jamaica asked the National Renewable Energy Laboratory (NREL) to determine if the use of domestically produced ethanol motor fuel could help them achieve their goals to develop its economy and to reduce greenhouse gas (GHG) emissions. The first step was to determine how much ethanol could be used by Jamaican vehicles in blends of 10% (E10 – current blend level), 15% (E15), or 25% (E25). All blend levels make for feasible automotive fuels and are being used or pursued in multiple countries. Building on gross domestic product (GDP)-related projections made by the Johnson et al. (2019) business as usual scenario, the quantity of ethanol to be used in future years and blend levels is shown in Table ES1. All blend levels are assumed to achieve the same volumetric fuel economy because of verified efficiency improvements enabled by increased octane levels.

09 BIOMASS FUELS↗

NASA NTRS2010

Ares I-X Flight Test Development Challenges and Success Factors

The NASA Constellation Program's Ares I-X rocket launched successfully on October 28, 2009 collecting valuable data and providing risk reduction for the Ares I project. The Ares I-X mission was formulated and implemented in less than four years commencing with the Exploration Systems Architecture Study in 2005. The test configuration was founded upon assets and processes from other rocket programs including Space Shuttle, Atlas, and Peacekeeper. For example, the test vehicle's propulsion element was a Shuttle Solid Rocket Motor. The Ares I-X rocket comprised a motor assembly, mass and outer mold line simulators of the Ares I Upper Stage, Orion Spacecraft and Launch Abort System, a roll control system, avionics, and other miscellaneous components. The vehicle was 327 feet tall and weighed approximately 1,800,000 pounds. During flight the rocket reached a maximum speed of Mach 4.8 and an altitude of 150,000 feet. The vehicle demonstrated staging at 130,000 feet, tested parachutes for recovery of the motor, and utilized approximately 900 sensors for data collection. Developing a new launch system and preparing for a safe flight presented many challenges. Specific challenges included designing a system to withstand the environments, manufacturing large structures, and re-qualifying heritage hardware. These and other challenges, if not mitigated, may have resulted in test cancellation. Ares I-X succeeded because the mission was founded on carefully derived objectives, led by decisive and flexible management, implemented by an exceptionally talented and dedicated workforce, and supported by a thorough independent review team. Other major success factors include the use of proven heritage hardware, a robust System Integration Laboratory, multi-NASA center and contractor team, concurrent operations, efficient vehicle assembly, effective risk management, and decentralized element development with a centralized control board. Ares I-X was a technically complex test that required creative thinking, risk taking, and a passion to succeed.

Askins, Bruce↗

NASA NTRS1992

Multi-dimensional analysis of combustion instabilities in liquid rocket motors

A three-dimensional analysis of combustion instabilities in liquid rocket engines is presented based on a mixed finite difference/spectral solution methodology for the gas phase and a discrete droplet tracking formulation for the liquid phase. Vaporization is treated by a simplified model based on an infinite thermal conductivitiy assumption for spherical liquid droplets of fuel in a convective environment undergoing transient heating. A simple two parameter phenomenological combustion response model is employed for validation of the results in the small amplitude regime. The computational procedure is demonstrated to capture the phenomena of wave propagation within the combustion chamber accurately. Results demonstrate excellent amplitude and phase agreement with analytical solutions for properly selected grid resolutions under both stable and unstable operating conditions. Computations utilizing the simplified droplet model demonstrate stable response to arbitrary pulsing. This is possibly due to the assumption of uniform droplet temperature which removes the thermal inertia time-lag response of the vaporization process. The mixed-character scheme is sufficiently efficient to allow solutions on workstations at a modest increase in computational time over that required for two-dimensional solutions.

Grenda, Jeffrey M.↗

DOE OSTI2020

A Custom Machine to Convey Radiologically Impacted Cohesive Soils to the Orion ScanSortSM System - 20382

An established method to reduce the volume of material required to be disposed of as radioactive waste is conveyor-based sorting of potentially radiologically impacted soils. With the Orion ScanSortSM system, potentially impacted soils are conveyed beneath radiation detectors and sorted into above and below criteria bins based on the detectors' response. Confident measurements can only be efficiently achieved when the soil column being conveyed has a reasonably consistent geometry. Highly cohesive soils present a very significant challenge as they tend to clump and adhere to the conveyor hopper, strike-off bar, and belt skirting. This causes voids and valleys in the soil column that affect the measurement geometry and reduce the confidence in the measurement. The reduction in confidence necessitates a longer residence time (i.e. reduction in conveyor belt speed and processing rates) or that the soils in highly unfavorable geometries be dispositioned as impacted or segregated for resurvey (should site logistics support that option). These outcomes may increase the volume of material required to be dispositioned as radiological waste and have a negative impact on project cost and schedule. To minimize impact to sorting operations, Wood designed and built a customized Extruder, to optimize the soil column prior to assay. The design was developed and refined to minimize the volume of highly cohesive soils presented in highly unfavorable geometries in the soil column in order to confidently assess and disposition such soils in a high-production environment. The Extruder is a customized 90 cm wide flat conveyor that has an oversized hopper with a pair of motor-driven rollers that force the soils in the hopper through an opening of adjustable height. The soils are extruded through the opening to produce a soil column that is ∼75 cm wide and ∼8-18 cm deep with a design rate of 225 metric tons/hr. The Extruder was recently deployed with the Orion ScanSort{sup SM} System to a site in northeast Ohio. The site has highly cohesive soils that result from the weathering of glacial sediments and consist of clay and clay loam, resulting in poor drainage and high moisture content. The project infrastructure only supported two bins of material (above and below criteria), which necessitated that soils with unfavorable geometries be discharged into the above criteria bin, along with material determined to have been contaminated. The Extruder was extremely successful in producing a stable soil column with favorable geometries for radiological assay. During production, less than 0.5% (by mass) of the soils processed were presented in unsatisfactory geometries requiring disposition as radioactive waste. The Extruder did not get clogged due to the cohesive soils (as is typical with conventional conveyors) and required very little maintenance, again minimizing impacts to sorting operations. The conveyor belt speed was operated at 14 cm/s with a typical belt loading of ∼109 kg/m resulting in a mean process rate of ∼49 metric tons/hr. The process rate was constrained by other project logistics, rather than by the capabilities of the Extruder, which was operated at less than 20% of the maximum design speed (75 cm/s). It is concluded that the Extruder is highly likely to produce a stable highly cohesive soil column suitable for efficient and confident radiological assay in production environments of 250 short tons/hr or more. The Extruder has the capability to drastically reduce the duration and costs of projects with radiologically impacted highly cohesive soils. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2005

Satellite Propellant Pump Research

NASA Glenn initiated a satellite propellant pump technology demonstration program. The goal was to demonstrate the technologies for a 60 percent efficient pump at 1 gpm flow rate and 500 psia pressure rise. The pump design and analysis used the in-house developed computer codes named PUMPA and HPUMP3D. The requirements lead to a 4-stage impeller type pump design with a tip diameter of 0.54 inches and a rotational speed of 57,000 rpm. Analyses indicated that flow cavitation was not a problem in the design. Since the flow was incompressible, the stages were identical. Only the 2-stage pump was designed, fabricated, assembled, and tested for demonstration. Water was selected as the surrogate fluid for hydrazine in this program. Complete mechanical design including stress and dynamic analyses were conducted. The pump was driven by an electric motor directly coupled to the impellers. Runs up to 57,000 rpm were conducted, where a pressure rise of 200 psia at a flow rate of 0.8 gpm was measured to validate the design effort.

Schneider, Steven J.↗

DOE OSTI2022

Design and Verification of An Open-Circuit Electro-Hydraulic Actuator System with An Integrated Electro-Hydraulic Unit

This paper proposes an electro-hydraulic actuator (EHA) system, and two novel-designed electro-hydraulic units (EHU) consisting of a fixed-displacement hydraulic pump and a variable-speed electric motor. Both the novel EHU designs integrate an electric machine and a hydraulic machine in a single unit, featuring compactness and power density. However, they differ for salient aspects such as power and electric machine cooling system. The EHA system features an open circuit design, where hydraulic hoses connect the EHU with a tank, a valve manifold, and the hydraulic cylinder. In this way, the proposed EHA technology can be used to implement distributed hydraulic actuation in a vehicle without requiring changes to the hydraulic actuators or at the overall layout of the hydraulic components with respect to the original vehicle design. A dedicated test rig is developed to verify the performance of the proposed EHA system. The efficiency of the EHA is measured in a steady state and under a realistic duty cycle of a commercial compact loader. The measured efficiency of the system can reach 54% with up to 20kN load and 6kW power level.

42 ENGINEERING↗

DOE OSTI2024

OpenFacadeControl: enabling integration of automated facades with other building systems

Automated facades are, for the most part, still considered as separate from other building systems throughout the design, installation, commissioning, operation, and maintenance cycle. This takes place despite the fact that their energy and comfort performance are deeply interlinked with the operation of lighting and HVAC systems. Over the last two decades, research has shown that there are significant advantages from operating facades as an integrated system with the rest of the building. Nevertheless, significant barriers prevent this type of integration becoming more common. One of them is the lack of a platform that is inexpensive to implement and that easily allows the practical implementation of integrated control algorithms across fenestration and other building systems, using a variety of communications protocols. This is particularly challenging when automated facades are installed in existing buildings, where interaction with legacy building systems that were installed over the past lifetime of the building can require a high degree of interoperability. OpenFacadeControl (OFC) is an open-source controls framework aimed at unified control of facades and other building systems, including the sharing of third-party sensor information. Through leveraging the Volttron controls platform, it allows the integration of systems and sensors that are manufactured by different companies and that use different communications protocols into an ensemble that functions as a single system. OFC is designed to enable integrated control algorithms of varying degrees of complexity, ranging from simple, heuristic controls to more sophisticated approaches like model-predictive control. Use of a research version to test advanced lighting and shading strategies in a full-scale experimental testbed has demonstrated the ease of deploying advanced control solutions using OpenFacadeControl. This paper presents the structure of OpenFacadeControl and a demonstration case showing the use of OFC in laboratory tests of advanced lighting and fenestration controls that coordinated motorized shades communicating via the BACnet building communications standard and lights communicating via internet-protocol-based application programming interface (API), based on the readings of a shared light level sensor communicating via a different API.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1988

Description of an oscillating flow pressure drop test rig

A test rig designed to generate heat exchanger pressure drop information under oscillating flow conditions is described. This oscillating flow rig is based on a variable stroke and variable frequency linear drive motor. A frequency capability of 120 hertz and a mean test pressure up to 15 mPA (2200 psi) allows for testing at flow conditions found in modern high specific power Stirling engines. An important design feature of this rig is that it utilizes a single close coupled dynamic pressure transducer to measure the pressure drop across the test sample. This eliminates instrumentation difficulties associated with the pressure sensing lines common to differential pressure transducers. Another feature of the rig is that it utilizes a single displacement piston. This allows for testing of different sample lengths and configurations without hardware modifications. All data acquisition and reduction for the rig is performed with a dedicated personal computer. Thus the overall system design efficiently integrates the testing and data reduction procedures. The design methodology and details of the test rig is described.

Wood, J. Gary↗

NASA NTRS1988

Description of an oscillating flow pressure drop test rig

Wood, J. Gary↗

NASA NTRS1999

A Reassessment of Heavy-Duty Truck Aerodynamic Design Features and Priorities

Between 1973 and 1982, the NASA Dryden Flight Research Center conducted "coast-down" tests demonstrating means for reducing the drag of trucks, buses, and motor homes. Numerous configurations were evaluated using a box-shaped test van, a two-axle truck, and a tractor-semitrailer combination. Results from three configurations of the test van are of interest now in view of a trucking industry goal of a 0.25 drag coefficient for tractor-semitrailer combinations. Two test van configurations with blunt-base geometry, similar to present day trucks (one configuration has square front comers and the other has rounded front comers), quantify the base drag increase associated with reduced forebody drag. Hoemer's equations predict this trend; however, test van results, reinforced by large-scale air vehicle data, indicate that Hoemer's formula greatly underestimates this dependence of base drag on forebody efficiency. The demonstrated increase in base drag associated with forebody refinement indicates that the goal of a 0.25 drag coefficient will not be achieved without also reducing afterbody drag. A third configuration of the test van had a truncated boattail to reduce afterbody drag and achieved a drag coefficient of 0.242. These results are included here and references are identified for other means of reducing afterbody drag.

Saltzman, Edwin J.↗

NASA NTRSDate not supplied

A Gaussian Process Enhancement to Linear Parameter Varying Models

Simulation and analysis for modern engineering systems now routinely requires the merging of multiple disciplines, physical-domains, time-scales, and data sets — all at ever increasing levels. These capabilities are especially needed in the domain of Advanced Air Mobility, where rapidly emerging vehicle designs are significantly more complex, while having to be both cost-effective and safe. To meet these engineering challenges, machine learning methods are an attractive option for merging models and data across multiple areas while providing uncertainty quantification and maintaining computational efficiency. This paper examines the use of Gaussian process machine learning to generalize and enhance the commonly used class of quasi-Linear Parameter Varying models for fast full-envelope simulation while also supporting control system design and analysis with model uncertainty. Gaussian process machine learning is selected because it: can fuse multiple data sets, enables an easy trade-off between data fitting and smoothing, provides model uncertainty quantification, scales well with increasing complexity, and does not generally require starting from a large training data set. To demonstrate the benefits of the approach, a robust stability analysis with Gaussian process uncertainty is shown for a NASA reference design of an electric quad-rotor air-taxi concept vehicle with motor parameter uncertainty.

Gaussian Process↗