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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 sources NASA NTRS DOE OSTI

NASA NTRS1979

Thermal analyses of a materials processing furnace being developed for use with heat pipes

A special materials processing furnace is being developed for the forthcoming Spacelab missions to study the solidification under closely controlled conditions of various sample materials in the absence of gravity. The samples are to be rod shaped and subjected to both heating and cooling simultaneously. The thermal model is based on a developed Thermal Analyzer computer program. The model was developed to be very general to enable the simulation of variations in the furnace design and, hence, serve as an aid in finalizing the design. The thermal model is described and a user's guide given. Some preliminary results obtained in testing the model are also given.

Mcanally, J. V.↗

NASA NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗

DOE OSTI2020

Data Services for Visualization and Analysis - ASC Level II Milestone (7186)

A new in transit Data Service is presented and compared to the traditional file-based workflow and the newly refactored in situ Catalyst workflow. Each workflow is enabled by the IOSS mesh interface equipped with data management layers for Exodus and CGNS (file-based), Catalyst (in situ), and FAODEL (in transit). FAODEL is a distributed object store that can transmit data across MPI allocations. Catalyst is a Para View-based visualization capability developed as part of the CSSE Data Services effort. The workflows considered here take SPARC data into Catalyst for visualization post-processing. Although still in unoptimized form, we show that the in transit approach is a viable alternative to file-based and in situ workflows and offers several advantages to both simulation and post-processing developers. Since IOSS is a mature interface with wide adoption across Sandia and externally, each workflow can be reconfigured to use different simulations that generate mesh data and post-processing tools that consume it.

97 MATHEMATICS AND COMPUTING↗

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 NTRS1986

Fundamentals and advances in the development of remote welding fabrication systems

Operational and man-machine issues for welding underwater, in outer space, and at other remote sites are investigated, and recent process developments are described. Probable remote welding missions are classified, and the essential characteristics of fundamental remote welding tasks are analyzed. Various possible operational modes for remote welding fabrication are identified, and appropriate roles for humans and machines are suggested. Human operator performance in remote welding fabrication tasks is discussed, and recent advances in the development of remote welding systems are described, including packaged welding systems, stud welding systems, remotely operated welding systems, and vision-aided remote robotic welding and autonomous welding systems.

Agapakis, J. E.↗

DOE OSTI2025

Using X-ray radiography to study oxygen flow in a proton exchange membrane electrolyzer operating under balanced pressure conditions

Of the various water electrolyzer technologies, the proton exchange membrane electrolyzer (PEMWE) is one of the best solutions for producing clean hydrogen without releasing CO 2 . In order to allow for widespread use of clean hydrogen, it is necessary to decrease its cost, which is intrinsically related to system operation. Current PEMWE plants operate in differential mode, directly pressurizing hydrogen and benefiting from thermodynamic compression, which increases overall system efficiency. However, high differential pressure above 30 bar can cause membrane stress, resulting in membrane creeping and failure. Pressurizing the water and operating at balanced pressure allows hydrogen to be produced at higher pressures while preserving the integrity of the membrane and porous layers. Nevertheless, the impact of pressurizing water on PEMWE performance must be better understood to maximize performance under balanced pressure conditions. Here, this study examined the impact of water pressure on two-phase flow. A high-pressure electrolyzer setup was developed to perform operando X-ray radiography and examine oxygen transport with high temporal resolution. The imaging segmentation process, developed to capture bubble properties in the channel, was applied to a specific experiment. The results clearly showed that as pressure increased up to 30 bars, the initial bubbly flow transitioned to slug flow, which led to channel saturation with oxygen. This work demonstrates that two-phase flow in an electrolyzer can be studied using X-ray radiography, which has the advantages of fast measurements and the ability to probe dense materials, such as those required for pressurized electrolyzers.

Balanced high pressure operation↗

DOE OSTI2022

Cryo-electron Microscopy of Adeno-associated Virus

Adeno-associated virus (AAV) has a single-stranded DNA genome encapsidated in a small icosahedrally symmetric protein shell with 60 subunits. AAV is the leading delivery vector in emerging gene therapy treatments for inherited disorders, so its structure and molecular interactions with human hosts are of intense interest. A wide array of electron microscopic approaches have been used to visualize the virus and its complexes, depending on the scientific question, technology available, and amenability of the sample. Approaches range from subvolume tomographic analyses of complexes with large and flexible host proteins to detailed analysis of atomic interactions within the virus and with small ligands at resolutions as high as 1.6 Å. Analyses have led to the reclassification of glycan receptors as attachment factors, to structures with a new-found receptor protein, to identification of the epitopes of antibodies, and a new understanding of possible neutralization mechanisms. AAV is now well-enough characterized that it has also become a model system for EM methods development. Heralding a new era, cryo-EM is now also being deployed as an analytic tool in the process development and production quality control of high value pharmaceutical biologics, namely AAV vectors.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

National Cost-Effectiveness of ANSI/ASHRAE/IES Standard 90.1–2019

The purpose of this analysis is to examine the cost-effectiveness of the 2019 edition of ANSI/ASHRAE/IES Standard 90.1, which is developed by the ASHRAE Standard Standing Project Committee (SSPC) 90.1, and is the model energy standard for all commercial buildings and multifamily residential buildings over three floors. PNNL analyzed the cost-effectiveness of changes in Standard 90.1-2019, compared to the previous 90.1-2016 edition, as applied in commercial buildings across the United States. In reviewing proposed changes to Standard 90.1, the SSPC considers the cost-effectiveness of individual changes (addenda). Due to the continuous nature of the development process, however, ASHRAE does not evaluate the entire package of addenda from one edition of the standard to the next, which is of particular interest to adopting state and local governments. Providing states with an analysis of cost-effectiveness facilitates a more comprehensive understanding of the impacts associated with updated model energy codes, informs the state decision-making process and its authorities, and ultimately encourages greater adoption of updated of energy codes. This information also informs the development of future editions of Standard 90.1.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1980

Understanding the LANDSAT market in developing countries

The constraints on the growth of the market which stem from the development process itself and from a country's technical, political, and institutional attributes were examined. Four competing factors guide the development of policy regarding an operational land remote sensing system and are summarized. The factors are: there is a need to boost U.S. experts in areas where the U.S. holds a technological lead; the need to develop user applications in developing countries on their terms coincides with foreign policy; developing countries desire to take control of their own development; and the U.S. government wants to enlist the participation of major companies in the management, operation, and ownership of the operational system.

Willard, M. R.↗

NASA NTRS2007

Effect of Electron Beam Freeform Fabrication (EBF3) Processing Parameters on Composition of Ti-6-4

The Electron Beam Freeform Fabrication (EBF3) process developed at NASA Langley Research Center was evaluated using a design of experiments approach to determine the effect of processing parameters on the composition and geometry of Ti-6-4 deposits. The effects of three processing parameters: beam power, translation speed, and wire feed rate, were investigated by varying one while keeping the remaining parameters constant. A three-factorial, three-level, fully balanced mutually orthogonal array (L27) design of experiments approach was used to examine the effects of low, medium, and high settings for the processing parameters on the chemistry, geometry, and quality of the resulting deposits. Single bead high deposits were fabricated and evaluated for 27 experimental conditions. Loss of aluminum in Ti-6-4 was observed in EBF3 processing due to selective vaporization of the aluminum from the sustained molten pool in the vacuum environment; therefore, the chemistries of the deposits were measured and compared with the composition of the initial wire and base plate to determine if the loss of aluminum could be minimized through careful selection of processing parameters. The influence of processing parameters and coupling between these parameters on bulk composition, measured by Direct Current Plasma (DCP), local microchemistries determined by Wavelength Dispersive Spectrometry (WDS), and deposit geometry will also be discussed.

Lach, Cynthia L.↗

NASA NTRS2012

Fabrication and Testing of CERMET Fuel Materials for Nuclear Thermal Propulsion

A first generation Nuclear Cryogenic Propulsion Stage (NCPS) based on Nuclear Thermal Propulsion (NTP) is currently being developed for Advanced Space Exploration Systems. The overall goal of the project is to address critical NTP technology challenges and programmatic issues to establish confidence in the affordability and viability of NTP systems. The current technology roadmap for NTP identifies the development of a robust fuel form as a critical near term need. The lack of a qualified nuclear fuel is a significant technical risk that will require a considerable fraction of program resources to mitigate. Due to these risks and the cost for qualification, the development and selection of a primary fuel must begin prior to Authority to Proceed (ATP) for a specific mission. The fuel development is a progressive approach to incrementally reduce risk, converge the fuel materials, and mature the design and fabrication process of the fuel element. A key objective of the current project is to advance the maturity of CERMET fuels. The work includes fuel processing development and characterization, fuel specimen hot hydrogen screening, and prototypic fuel element testing. Early fuel materials development is critical to help validate requirements and fuel performance. The purpose of this paper is to provide an overview and status of the work at Marshall Space Flight Center (MSFC).

Hickman, Robert↗

NASA NTRS2016

The Quality Control Algorithms Used in the Creation of NASA Kennedy Space Center Lightning Protection System Towers Meteorological Database

An accurate database of meteorological data is essential for designing any aerospace vehicle and for preparing launch commit criteria. Meteorological instrumentation were recently placed on the three Lightning Protection System (LPS) towers at Kennedy Space Center (KSC) launch complex 39B (LC-39B), which provide a unique meteorological dataset existing at the launch complex over an extensive altitude range. Data records of temperature, dew point, relative humidity, wind speed, and wind direction are produced at 40, 78, 116, and 139 m at each tower. The Marshall Space Flight Center Natural Environments Branch (EV44) received an archive that consists of one-minute averaged measurements for the period of record of January 2011 - April 2015. However, before the received database could be used EV44 needed to remove any erroneous data from within the database through a comprehensive quality control (QC) process. The QC process applied to the LPS towers' meteorological data is similar to other QC processes developed by EV44, which were used in the creation of meteorological databases for other towers at KSC. The QC process utilized in this study has been modified specifically for use with the LPS tower database. The QC process first includes a check of each individual sensor. This check includes removing any unrealistic data and checking the temporal consistency of each variable. Next, data from all three sensors at each height are checked against each other, checked against climatology, and checked for sensors that erroneously report a constant value. Then, a vertical consistency check of each variable at each tower is completed. Last, the upwind sensor at each level is selected to minimize the influence of the towers and other structures at LC-39B on the measurements. The selection process for the upwind sensor implemented a study of tower-induced turbulence. This paper describes in detail the QC process, QC results, and the attributes of the LPS towers meteorological database.

Orcutt, John M.↗

NASA NTRSDate not supplied

Metal Additive Manufacturing for Spaceflight

Metal additive manufacturing (AM) is changing how complex aerospace parts are being designed and manufactured for rocket engines and launch vehicles. NASA has been leading AM efforts since the late 2000’s to mature specialty alloys for AM, advance AM processes, develop standards and infuse AM into rocket engines and the commercial supply chain. There are many types of AM processes and alloys in-use and this presentation will provide an overview of how NASA is applying these for rocket engines and the potential opportunities for AM in the future.

Additive Manufacturing↗

DOE OSTI2024

Recovery of Zr from ZrCl 4 by Electrolysis in Fused Salts and Ionic Liquids: Literature Review and Test Plan

This report reviewed the current status on the research and development of Zr electrodeposition in high temperature molten salts and room temperature ionic liquids from ZrCl 4 , which is the product of the chlorination process developed for recycling the Zr claddings of the spent nuclear fuels. Due to the pyrophoricity issue, the Zr metal product from the electrodeposition process is desired to be of coarse, dense crystalline or plates (instead of powder or loose, fine crystals) that are not to be easily oxidized. The findings based on the literature review are included in the report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2020

Technology Advancements for Channel Wall Nozzle Manufacturing In Liquid Rocket Engines

A regeneratively-cooled or dump-cooled nozzle is a critical component for expansion of hot gases to enable high temperature and performance in liquid rocket engines systems. Regeneratively-cooled 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 can be challenging to fabricate which results in extended lead times and higher costs. Some of these challenges include: 1) Unique and high temperature materials, 2) Tight tolerances on large parts 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 complex tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) and 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 under evaluation for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on laser powder bed fusion (L-PBF), 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 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 technique. This publication presents an overview of the various channel wall nozzle manufacturing processes and materials under evaluation including results from the hot-fire testing. Future development and technology focus areas is also discussed relative to channel wall nozzle manufacturing.

Additive manufacturing↗

DOE OSTI2024

Carbon Ore-Derived Critical Materials for Clean Energy Technologies

Conference presentation at American Institute of Chemical Engineers (AIChE) Annual Meeting, San Diego, California, October 27–31, 2024. Trends in the manufacture of electric vehicles that use graphite-based LIBs are rising steeply in the United States and globally, but the U.S. domestic supply chains for graphite, the largest component in an LIB by mass, is severely limited and faces complicated geopolitical dynamics with foreign sources. Consequently, the United States has designated graphite as a critical mineral to focus attention and resources to develop technologies to meet the challenge of limited domestic graphite supply chains. Results obtained so far based on the UCOP process have successfully validated the technology at the laboratory scale, with the produced graphite material showing up to 95% degree of graphitization, high carbon purity of ~99.98%, residual ash content of ≤0.02%, negligible moisture, low trace elements, and high electrochemical stability. These results suggest that the emerging UCOP technology is a promising approach to effectively synthesize high-quality graphite from abundant coal and coal waste resources in the United States to create a sustainable domestic critical graphite supply chain. A brief description of the status of UCOP process development and representative results will be presented.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

Compositional Reasoning for Hierarchical State Machines

Harel statecharts and its derivatives are popular graphical languages for specifying discrete control systems via hierarchical state machines. Separately, there has been a long line of work on specifying concurrent systems with process calculi which come equipped with an algebraic theory, the ability reason compositionally about various temporal properties, and strong type systems. While these two approaches to modeling systems are tantalizingly similar, the integrated reasoning principles that exist for process calculi have not been demonstrated in hierarchical state machines. A key issue is that operational theories for process calculi do not behave like control systems, and thus, there is virtually no tool support for modeling control systems with such languages. For a control system designer, bringing the integrated, more scalable reasoning from the process calculi to state-machine languages would enable the specification of more complex systems and a more modular systems development process. Our insight is that we can recover many important results from the process calculi in hierarchical state machines with local scope. We employ a structural operational semantics, which is ubiquitous in process and 𝜆-calculi but uncommon in hierarchical statemachine formalizations, to enable inductive reasoning about behavior. Taking inspiration from the structure of process calculi metatheories, we define a calculus of refinement and equivalence that we prove sound with respect to local notion of (bi)simulation. Furthermore, we prove that the calculus preserves the behavioral properties of reactivity, observational determinism, traces, and linear temporal properties. Our results are mechanized in the Rocq proof assistant.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1975

Developing the plan

The basic sequence in the planning development process is discussed. Alternative ways of satisfying estimated needs, and the selection of an alternative are described along with the development of a plan to implement the selected alternative.

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