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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 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Channel Wall Nozzle Manufacturing Technology Advancements for Liquid Rocket Engines

A regeneratively-cooled nozzle is a critical component for expansion of the hot gases to enable high temperature and performance liquid rocket engines systems. Channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design is challenging to fabricate leading to extended lead times and higher costs. Some of these challenges include: 1) unique and high temperature materials, 2) Tight tolerances during manufacturing and assembly to contain high pressure propellants, 3) thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) along with U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements being evaluated for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on powder bed fusion, but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are being used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication techniques. This paper will present an overview of the various processes and materials being evaluated and the results from the hot-fire testing. Future development and technology focus areas will also be discussed relative to channel wall nozzle manufacturing.

Gradl, Paul R.↗
NASA NTRS2018

Spacecraft Common Deployable Boom Hinge Deploy and Latching Mechanisms

JPL is developing deployable radio frequency (RF) reflector booms for spaceflight usage on two different earth orbiter projects scheduled to launch in the early 2020’s. The static alignment and thermal stability requirements for these RF reflector booms are challenging. A common mechanism design has been developed for the deployment and latching of boom hinges which avoids significant parasitic loads on the alignment critical structures after completion of mechanism function. The mechanism design includes a high-aspect ratio torsion spring with viscous damper for hinge closure as well as an actuator-driven flexured hook and roller latch for joint preloading. This paper describes noteworthy mechanism design details, test results, challenges, and lessons learned during the development effort.

Renson, Marcel↗
NASA NTRSDate not supplied

Advancement of Entry System Modeling to Support Exploration of Giant Planets

This paper describes NASA’s efforts to advance entry system modeling and simulation capabilities to support future exploration of Giant planets. The Giant planets are key destinations of interest to the planetary science community for their potential to provide insight into the formation and evolution of our Solar System, as well as extrasolar planetary systems. To date, the Galileo atmospheric probe is the only purpose-built entry probe to a Giant planet. Post-flight analysis of Galileo’s performance showed that there was significant recession of the thermal protection system (TPS), well beyond what was anticipated on the flank, and this was due in part to insufficiently accurate capability for estimating the flight environment and TPS response. While Galileo ultimately survived its flight, the example serves to highlight the great challenge of designing successful missions for environments that are poorly understood or where models have not yet been validated. An important means to reduce mission risks is the incorporation of physics-based modeling with well-quantified uncertainties. The emphasis on physics-based modeling – in contrast to empirically-driven models – is motivated by the fact that it is impossible to completely replicate entry environments through ground tests and, therefore, extrapolation to the flight environment is required. Basing analysis in fundamental physics removes the bias of ground test limitations, though one must then be careful to properly characterize model inputs, simplifying assumptions, and the limits wherein the model is valid. NASA’s Entry Systems Modeling (ESM) Project is tasked with investigating such considerations for planetary science missions across the Solar System, and in recent years has begun to do so for Giant planets. The most distinctive features of the Giant planets, from an entry system perspective, are the atmospheres composed primarily of hydrogen and helium. The entry velocities of proposed missions are generally very large and can therefore be expected to result in significant convective and radiative heating generated by the vehicle’s shock layer. Yet thermochemical behavior of the hydrogen-helium system is not well understood under such conditions. The ESM project is leading efforts to develop accurate thermochemical databases based on state-of-the-art measurements in the Electric Arc Shock Tube and detailed computational chemistry. The large heat fluxes anticipated by missions has driven interest in new TPS materials, in particular woven materials, which may be enabling but have never been flown before. Consequently, multiscale models are in development to describe properties and performance of the materials from micro- to system-scale. The goal is to not only provide accurate thermal response but also to inform thermostructural reliability predictions for extreme entries. Additionally, new computational models have been developed to evaluate performance of non-destructive evaluation techniques which are vital to establishing acceptance of systems to be free of manufacturing faults like material cracking, voids, and debonding. Finally, in the area of guidance and control, aerocapture has been shown conceptually to provide a number of mission benefits, including reducing transit time and increasing payload fraction. The ESM project is building a launch-to-landing trajectory simulation capability to enable detailed studies of aerocapture maneuvers in the context of Giant planets missions. The final presentation and paper will describe each of these topics in detail, including discussion of specific gaps and the technical approach to solving them. In addition, the final paper will briefly discuss ongoing coordination between ESM project work and an ESA-funded technology development activity comprised of validation testing in the Oxford T6, IRS PWK and IST ESTHER tunnels, as well as state-to-state modeling of the shock layer to better represent non-Boltzmann energy distributions leading to non-equilibrium radiation.

Entry systems↗
NASA NTRS2016

The Habitable Exoplanet (HabEx) imaging mission concept: preliminary science drivers and technical requirements

HabEx is one of 4 possible NASA flagship mission concepts studied for a possible launch in the 2030s. It will be optimized for direct imaging and spectroscopy of habitable exoplanets, and will also enable a wide range of general astrophysics observations. HabEx shall characterize full planetary systems around nearby solar-type stars for the first time, including rocky planets, possible water worlds, gas giants, ice giants, and faint circumstellar debris disks. It will in particular explore our nearest neighbor planetary systems and search for signs of habitability and bio-signatures in the atmospheres of rocky planets. Such high spatial resolution high contrast observations require a large (~3.5 to 8m) stable diffraction- limited optical space telescope, which also opens new unique capabilities for studying the formation and evolution of stars and galaxies. We present here some preliminary science objectives identified for HabEx by our Science and Technology Definition Team (STDT), together with a first look at the key challenges and design trades ahead.

Mennesson, Bertrand↗
NASA NTRSDate not supplied

Thinking Inside the Box: A Hands-On Student Activity for Building a Contamination Containment Glovebox to Encourage Problem Solving in a Collaborative Environment

Contamination containment gloveboxes are sealed containers where operators outside the glovebox can safely manipulate hazardous or contamination-sensitive materials inside the glovebox through glove ports on the container. Containment gloveboxes are used in the space industry to study sample materials returned from space such as lunar, asteroid, and comet materials, to manufacture sensitive instruments and space ight hardware, and to perform contamination-sensitive experiments. A hands-on activity has been developed by contamination control engineer and STEM education experts as part of the Virginia Earth System Science Scholars (VESSS) summer academy program to teach high school students about gloveboxes and about problem solving in a collaborative environment. In this activity, student teams are given a list of common household materials (e.g. plastic bags, plastic straws, aluminum foil, tape, disposable gloves, etc.) for building their own glovebox. Students work together to sketch and design their glovebox before being provided a kit of materials, which they must purchase along with any extra materials with a mock team budget. They are given 30 minutes to build their glovebox, however, they do not know what will be placed inside the glovebox or what operations they will need to perform within the glovebox. At the end of the build time, teams are given a small, sealed paper envelope which they place in the glovebox. Each team selects a team member to be designated as the operator, and the operator places their hands in the gloves of the glovebox. The operator uses their gloves to open the envelope in the glovebox, and they discover they have 20 minutes to assemble a jigsaw puzzle. However, the puzzle is \contaminated" with talcum powder. After the 20 minute time period, teams are judged on how well they completed and cleaned the contaminated puzzle. In a post-activity debrief, teams discuss lessons learned such as how the actual built box di ered from the sketched design, the challenge of managing a budget for materials, how the team dealt with surprises, and if their glovebox allowed enough room for the operator to perform the task. This activity has been part of the VESSS summer academy since 2016, and teaches students teamwork, creativity, hands-on experimentation, communication, and reasoning skills. In a demonstration at IAC, a volunteer from the audience will be chosen to assemble a glovebox during the presentation using the same kit of materials and will demonstrate handling puzzle pieces in the completed glovebox.

Elaine Seasly↗
NASA NTRS2022

Thinking Inside the Box: A Hands-on Student Activity for Building a Contamination Containment Glovebox to Encourage Problem Solving in a Collaborative Environment

Engineers from the National Aeronautics and Space Administration (NASA) and education experts from the Virginia Space Grant Consortium (VSGC) partnered together to create a hands-on student activity to teach students about problem solving, working in a collaborative environment, and about the unique career fields of contamination control and planetary protection. The activity focuses on contamination containment gloveboxes, which are sealed containers where operators outside the glovebox can safely manipulate hazardous or contamination-sensitive materials inside the glovebox through glove ports on the container. The activity utilizes common household materials and teams of students work together to design and build a glovebox using the materials provided. Once the glovebox has been constructed, students perform a task under a time constraint by using their glovebox to assemble a puzzle “contaminated” with corn starch. In a post-activity debrief, teams discuss lessons learned such as how the actual built glovebox differed from the sketched design, the challenge of managing a budget for materials, how the team dealt with surprises, and if their glovebox allowed enough room for the operator to perform the task. This activity has been part of VSGC’s Virginia Earth System Science Scholars (VESSS) summer academy program for high school students since 2016, and has been an engaging method to teach students teamwork, creativity, hands-on experimentation, communication, and reasoning skills while also teaching them about unique engineering fields such as contamination control and planetary protection.

Student activity↗
NASA NTRSDate not supplied

Statistical Engineering Toward Commercial Supersonic Flight: NASA's Quesst Mission

NASA’s Quesst Mission has dual goals of demonstrating low-noise supersonic technology in flight and surveying public reactions to low-noise supersonic overflight. For half a century, commercial aircraft have been required to fly slower than the speed of sound over land to prevent “creating an unacceptable situation” on the ground due to sonic booms. However, aircraft shaping techniques honed through decades of research have dramatically changed the way shockwaves from supersonic flight merge together as they travel to the ground. What used to sound like a boom on the ground will be transformed into a thump. NASA is now building a full-scale, piloted demonstration aircraft called the X-59 to demonstrate low-noise supersonic flight. In 2024, the X-59 aircraft will commence a national series of community overflight surveys to collect data on how people perceive “sonic thumps.” The results will be provided to national and international noise regulators as they consider creating new standards that allow commercial supersonic flight over land at acceptably low noise levels. In this presentation we provide historical context for the current prohibitions on supersonic commercial flight. Using data collected during earlier NASA tests, we demonstrate how generalized linear mixed models can be used to inform the functional dose-response curve. We also illustrate simulation experiments of the variability of sonic thump exposure across the United States. Finally, we discuss some of the challenges in designing the future community studies and generalizing them to a nationally-representative dose-response curve.

Quesst↗
NASA NTRSDate not supplied

Evaluation of Transport-Equations-Based Transition Models for High-Speed Boundary Layers Using OVERFLOW

Accurate modeling of laminar-turbulent transition is crucial for the design of hypersonic flight systems. However, the current transition models used in production CFD codes are insufficient for high-speed flows. Many extensions to low-speed models have been suggested; however, a thorough verification and validation effort is needed before these models can be used in design settings. Challenges include potentially missing details of the model implementation requirements and/or a complete specification of the input parameters needed to replicate the test findings. A meaningful assessment of the generalization capability of these models is also hindered by a lack of information regarding the specific flow configurations and associated grids employed for model calibration. As a key first step toward model verification, we present an independent assessment of two recently proposed models for high-speed transition, namely, a model within the SST-𝛾 framework and a model based on the SST-𝛾 – 𝜈 𝐿 equations. These models are implemented in the NASA OVERFLOW 2.3e solver and their performance in predicting first mode, second mode, and crossflow transition has been evaluated for several test cases in the supersonic and hypersonic regimes. Besides the test cases employed by the model developers, which could have also been used for model calibration, the present assessment includes supplementary configurations that contribute to an unbiased assessment of the models. The outcomes presented in this study indicate the potential for the models to be applied to high-speed flight configurations. Key steps toward future improvements to these models are also outlined.

CFD↗
NASA NTRS2023

Evaluation of Transport-Equation-Based Transition Models for High-Speed Boundary Layers Using OVERFLOW

Accurate modeling of laminar-turbulent transition is crucial for the design of hypersonic flight systems. However, the current transition models used in production CFD codes are insufficient for high-speed flows. Many extensions to low-speed models have been suggested; however, a thorough verification and validation effort is needed before these models can be used in design settings. Challenges include potentially missing details of the model implementation requirements and/or a complete specification of the input parameters needed to replicate the test findings. A meaningful assessment of the generalization capability of these models is also hindered by a lack of information regarding the specific flow configurations and associated grids employed for model calibration. As a key first step toward model verification, we present an independent assessment of two recently proposed models for high-speed transition, namely, a model within the SST-$\gamma$ framework and a model based on the SST-$\gamma-\nu_L$ equations. These models are implemented in the NASA OVERFLOW 2.3e solver and their performance in predicting first mode, second mode, and crossflow transition has been evaluated for several test cases in the supersonic and hypersonic regimes. Besides the test cases employed by the model developers, which could have also been used for model calibration, the present assessment includes supplementary configurations that contribute to an unbiased assessment of the models. The outcomes presented in this study indicate the potential for the models to be applied to high-speed flight configurations. Key steps toward future improvements to these models are also outlined.

High-speed flow↗
NASA NTRS2013

Horizontal Habitability Layout Studies

As our efforts in the 2011-2012 X-Hab Academic Innovation Challenge we designed, developed, constructed and tested a deployable horizontally oriented habitat system for use as an Earth analog. The goals of the project included a short-term goal of an interdisciplinary senior design project to design, build and evaluate a horizontally oriented habitat and a long-term goal to develop capabilities in education, research, and outreach in field of space habitat design. This included both technical engineering and outreach efforts. In the 2011-2012 year, the program involved the following schools at OSU: The Schools of Mechanical and Aerospace Engineering (MAE) and Industrial and Engineering Management (IEM) within the College of Engineering, Architecture and Technology and Design, Housing and Merchandising (DHM) in the College of Human Sciences. We also included the School of Aviation Education (AvED) in the College of Education through the ISNPIRE (Interdisciplinary National Science Project Incorporating Research and Education Experience) program of as part of our outreach efforts.

Jamey D. Jacob↗
NASA NTRSDate not supplied

Environmental Testing Of High Temperature Materials and Coatings

Materials for today′s extreme environments have unique challenges and design requirements that require multi-faceted evaluations. Thermal and mechanical testing and analysis is important in design, but environmental effects are often the limiting factor of materials in service. Degradation modes such as oxidation, recession, erosion, foreign object damage, and chemical corrosion can negatively impact the materials thermo-mechanical behavior. While materials may ultimately fail under thermo−mechanical stresses, environmental effects are many times the root cause. Evaluation of materials systems under relevant conditions are critical.....start by identifying mechanisms and develop corresponding test methods. Comprehensive modeling begins with thermo-mechanical behavior, then considers environmental degradation modes that provide a “knock down” of that behavior.

Thermal testing Mechanical testing↗
NASA NTRS2024

MBSE (SysML) and Digital Twin Integration to Support Engineering Analysis & Design

Problem Statement: The complexity of Gateway systems and of managing the integrated safety analysis have made traditional methods of engineering analysis and design increasingly challenging. To address these challenges, a prototype that integrate Model-Based Systems Engineering (MBSE) with Digital Twin technology has been developed to demonstrate the utilities and functions. Project Goal: Develop a prototype of a Digital Twin Of Gateway ECLSS IMV system to enhance fault management analysis through collaboration, visualization, and simulation. Overall Project Results / Accomplishments: - Developed extension to streamline the integration of SysML models with the Digital Twin platform - Demonstrated the capability to aggregate any relevant information and provide simulation integration within the DT prototype. - Generated digital twin simulation using SysML Activity Diagrams - Implemented a complex trade study use case based on the integrated SysML-Digital Twin infrastructure

MBSE↗
DOE OSTI2020

Multiphase Reacting Flow Simulations and Optimization of Commercial-Scale Aerobic Bioreactors

Aerobic bioreactors are widely used in the synthesis of value-added products in pharmaceutical and biotechnology industries, wherein microbial bioreactions aid in the conversion of sugars to macromolecules. These reactors are also being actively investigated as a cost-effective pathway for the production of low-value commodities such as biofuels and animal feed. Reactor scale-up is one of the important challenges when designing these systems. Gas and liquid phase transport, mass-transfer, and mixing physics at large length scales can significantly affect microbial conversion rates, particularly when the microbial reaction requires a narrow set of conditions. These phenomena are difficult to study in small-scale bench-top reactors that are typically well-mixed. Predictive computational fluid dynamics (CFD) based simulations can therefore aid in the design and optimization of these reactors. This work presents multiphase Euler-Euler CFD simulations of commercial-scale (~ 500 m3) aerobic bioreactors. Our mathematical model treats the gas and liquid as interpenetrating phases. This approach reduces the computational complexity of tracking individual gas bubbles that are several orders of magnitude smaller than reactor dimensions. We solve the Reynolds averaged Navier-Stokes (RANS) multiphase equations that account for phase and chemical species transport, interphase mass and momentum transfer and uses a phenomenological model for oxygen uptake by microbes. We use a customized solver derived from open-source CFD toolbox, OpenFOAM, to perform these simulations, which has been validated against small-scale reactors in our previous work. This work examines the performance of three different reactor designs, viz. bubble column reactor, airlift reactor with an internal draft tube, and a stirred-tank reactor with Rushton impellers. Reactor oxygen mass-transfer coefficient, gas hold-up, and oxygen distribution are critically analyzed among reactors, and sensitivity studies pertaining to gas flow rates and reactor geometry will be presented.

09 BIOMASS FUELS↗
DOE OSTI2020

Evaluating turbulence models at high energy densities

The RESHOCK campaign at Lawrence Livermore National Laboratory has been working on increasing our understanding of the evolution of turbulent, unstable plasma interfaces which are applicable in various HED applications including ICF implosions. A common approach to model such interfaces involves the use of Renolds-Averaged-Navier-Stokes (RANS) models whose parameters have been constrained by theory and experiments. These parameter sets are not unique and the applicability of one set of tuned model parameters to systems with differing shock strengths or material densities has not been well tested. Our new NIF experiments, along with related studies of turbulent shear flows, provide data and model validation for plasma interfaces in the HED regime. Our experiments measure mixing-layer width at an unstable interface in the plasma regime and are specifically designed to challenge mix models of the Reynolds-Averaged-Navier-Stokes (RANS) type where turbulence is assumed to be fully developed, i.e. the flow exhibits a broad spectrum of length scales without memory of the initial condition.4 We utilize precise control of the initial interface conditions (densities on both sides of the interface, an initial rippled perturbation pattern consisting of equally weighted wavelengths between 10 and 20 microns, and initial material compositions) along with a repeatable drive history

36 MATERIALS SCIENCE↗
DOE OSTI2021

The Tracking Machine Learning challenge : Throughput phase

This paper reports on the second "Throughput" phase of the Tracking Machine Learning (TrackML) challenge on the Codalab platform. As in the first "Accuracy" phase, the participants had to solve a difficult experimental problem linked to tracking accurately the trajectory of particles as e.g. created at the Large Hadron Collider (LHC): given O($10^5$) points, the participants had to connect them into O($10^4$) individual groups that represent the particle trajectories which are approximated helical. While in the first phase only the accuracy mattered, the goal of this second phase was a compromise between the accuracy and the speed of inference. Both were measured on the Codalab platform where the participants had to upload their software. The best three participants had solutions with good accuracy and speed an order of magnitude faster than the state of the art when the challenge was designed. Although the core algorithms were less diverse than in the first phase, a diversity of techniques have been used and are described in this paper. The performance of the algorithms are analysed in depth and lessons derived.

Amrouche, Sabrina↗
DOE OSTI2021

Coupled Microbial-Conversion and Computational-Fluid-Dynamics (CFD) Models for Butanediol Production in Micro-Aerated Reactors

Microbial conversion of substrates to macromolecules has been widely used in the synthesis of value-added products in pharmaceutical and biotechnology industries. These bioreactions are also being investigated in the production of low-value commodities such as biofuels [1]. Gas-liquid mass-transfer and transport-reaction coupling are important challenges when designing and scaling up these reactor systems. Experiments in wellmixed small-scale reactors have enabled characterization of microbial reactivity, while their coupling with macroscale transport remains relatively unexplored. In this work, we use a coupled metabolic-CFD model to study the action of a genetically engineered microbe Zymomonas mobilis [2] on sugars to produce 2,3-Butanediol (BDO). BDO is an important hydrocarbon intermediate that can be catalytically upgraded to several fuels and chemicals [3]. An important aspect to this particular microbial conversion is the need for micro-aerated environments as opposed to traditional aerobic fermentation. Slight variations in oxygen concentration can result in competing reaction pathways that disable BDO production. Hence, gas-liquid mass transfer and transport need to be optimized in large-scale reactors to maximize BDO production, for which CFD is a valuable tool. The aerobic-fermentation CFD model previously developed by the authors [5] for simulating bubble-column and airlift reactors at scale was used in this study. The Reynolds-averaged mass, momentum and energy transport equations for interpenetrating gas and liquid phase are solved in this model along with the transport and interphase mass transfer of oxygen. Our previous work used a phenomenological model for microbial oxygen uptake that neglected microbial growth and other reaction pathways. In this work, a detailed metabolic model enabled prediction of product formation and inhibition pathways. In order to manage computational cost, we used a subcycling technique [6] that takes advantage of the clear separation in transport (~ 200 sec) and reaction (~ 2-3 hours) timescales. The CFD model is first solved to steady state, after which the metabolic model is advanced at every cell in the computational domain using the local oxygen concentration. The CFD model is then run to achieve a new steady state that provides a new oxygen distribution for the metabolic model. This process, where reaction and fluid updates are interleaved together, is iterated until reactants are completely exhausted. This work will examine the performance of different reactor designs such as bubble column and airlift reactors at scale (250-500 m3). Oxygen mass-transfer coefficient and distribution are critically analyzed among reactors, and optimization studies pertaining to aeration is presented. Furthermore, it has been observed in experiments that high BDO production may be achieved by manipulating the aerobic environment over the course of reaction, such that oxygen concentration is high during the growth phase, and very low as sugar is depleted. This characteristic will be addressed by our simulations for which a timedependent scheduling strategy for aeration is presented that maximizes BDO production. [1] Humbird, D., Davis, R., and McMillan, J., Aeration costs in stirred-tank and bubble column bioreactors, Biochemical Engineering Journal, 127, 161—166, 2017 [2] Yang, S., Mohagheghi, A., Franden, M. A., Chou, Y.-C., Chen, X., Dowe, N., Himmel, M. E., and Zhang, M., Metabolic engineering of zymomonas mobilis for 2, 3-butanediol production from lignocellulosic biomass sugars. Biotechnology for biofuels, 9(1):189, 2016 [3] Kim, S. J., Sim, H. J., Kim, J. W., Lee, Y. G., Park, Y. C., and Seo, J. H., Enhanced production of 2,3-butanediol from xylose by combinatorial engineering of xylose metabolic pathway and cofactor regeneration in pyruvate decarboxylase-deficient Saccharomyces cerevisiae. Bioresource Technology, 245:1551–1557, 2017 [4] Weller, H., Tabor, G., Jasak, H. and Fureby, C., A tensorial approach to computational continuum mechanics using object-oriented techniques, Computers in physics, 12, 6, 620--631, 1998

29 ENERGY PLANNING, POLICY, AND ECONOMY↗