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At least 829 records · Page 46

Development and Characterization of Lightweight Durable Composite Conductor for Cables

Sustainable aviation in the form of electrified propulsion is likely to lead to an increase in the electrical assets contained within a single aircraft. As a result, it is desirable to design light weight conductor materials, thus reducing the payload of components like motor windings, low voltage signal cables, and transmission cables for data and power. One approach involves replacing pure Cu wiring with metalized CNT composites. This paper evaluates a framework for modeling overall conductivity and current sharing within such composites. Processing methods and parameters were refined. Select electroplated samples outperformed pure Cu in conductivity and had comparable ultimate tensile strengths. Tensile strengths are expected to improve with an additional densification step during processing. Acoustic emission data was used to predict the failure mechanism of the composite. Theories explaining improved intrinsic conductivity are discussed, with a focus on chemical and mechanical interactions at the Cu-CNT interface. These include Cu infiltration of CNT crevices, CNT oxidation, activity at defects in CNT walls, and the release of carbide-forming metals from CNT walls. Validating any or all these theories will require further work replicating data, collecting electron micrographs and conducting chemical analyses.

Metalized CNT↗

Development and Application of Weld Track Thermal Analysis for the Exploration Extravehicular Mobility Unit

NASA is studying the next generation of space suit for safe operations in space, from the International Space Station to the lunar surface as part of the Exploration Extravehicular Mobility Unit project. The backplate structure of the portable life support system (PLSS) serves as the attachment point for assembly of the PLSS and contains embedded cooling channels. The thermal loop plumbing assembly and backplate are combined into a single component such that the fluid lines run through the midplane of the backplate. The manufacturing of the Ti-6Al-4V backplate consists of machining channels into a plate, welding cover plates on each channel using an electron beam, and additional machining for excess material removal and final detail. Careful control of the electron beam weld process is necessary to completely seal cover plates, produce consistent weld tracks, and produce channels with uniform cross sections free of debris and defects. The backplate contains multiple weld channels with unique geometries. The weld process parameters include choosing the beam current and focus, accelerating voltage, travel speed, pause times between weld tracks, and sequence of weld tracks. A transient finite element thermal analysis was developed to provide support for choosing and controlling the weld process parameters to maintain a consistent melt pool along each of the weld tracks. A moving distributed heat source is modeled to represent the heat input generated by the electron beam. The heat source model is a critical input to the analysis for accurate temperature predictions during the weld process. A modified conical heat source was developed to account for the change in working distance between the backplate and cover plates. The geometry of the material being welded must be accounted for by the heat source model to define the correct energy input. The weld process control is designed according to the predicted thermal history and melt pool dimensions for each of the weld channels. The analysis model, modified heat source, temperature and melt pool predictions, application of the thermal data to the weld parameters, and comparison with micrograph cross-sections from weld trials will be discussed in this presentation.

Electron Beam Welding↗

Process Optimization of Carbon Electrode Materials Manufacturing by Experimental Study and Machine Learning Techniques

Electrospun carbon fibers from coal have been investigated as electrodes for batteries and supercapacitors. Despite the excellent properties of coal-derived carbon fibers (CCNF) for energy storage devices, there still lacks systematic understanding on how various process parameters affect final electrode performances, which poses challenges to scale from pilot to high volume manufacturing. The goals of this project are twofold. First, we focuse on process optimization for converting a new precursor from powder river basin (PRB) coal, referred to as coal-based polyurethane (CPU) to CCNF using electrospinning. Second, different machine learning techniques will be examined using experimental data from this work and open literature. Specifically, for CPU the following process parameters need to be characterized and optimized in order to produce CCNFs with desirable mechanical integrity and physiochemical properties: precursor composition and viscosity, operating voltage and distance, oxidation and carbonization temperature and duration. Consequently, physiochemical properties of the fibers were characterized to correlate these process parameters with desirable electrochemical performance. Given the complex nature of the fiber production process, ML models are assessed for their ability to capture the nonlinear relationship between process parameters and the electrochemical properties in applications including supercapacitors. As such, we applied various machine learning techniques, to determine which technique produces a model that best predicts device function.

Cincotta, Robert E.F.↗

Efficient Reversible Operation and Stability of Novel Solid Oxide Cells

This project aims to develop and test novel Reversible Solid Oxide Cells (ReSOCs) specifically designed to yield low area specific resistance, as required to achieve high round trip efficiency in reversible operation at high current density. A key objective is to improve long-term reversible SOC durability; mechanistic degradation models will be used to predict long-term durability using input data from accelerated testing that combines electrochemical life testing with quantitative microstructural and chemical evaluation. The modeling tasks seek to design low-loss, low-cost ReSOC systems using input data from the experimental cell studies. A key challenge is to develop a thermal management strategy that maintains thermally self-sustaining operation while operating the stack at a potential lower than the thermo-neutral steam electrolysis voltage of ~1.3 V, to maintain high efficiency.

08 HYDROGEN↗

Evaluation of distributed gas cooling of pressurized PAFC for utility power generation

Two short stacks were pressure tested at 446 kPa (4.4 atm.) and the pressure gains were more than the theoretically predicted gains. Temperature profiles were observed to be independent of operating pressure. The pressure drop was found to be inversely proportional to operating pressure as expected. Continuous pressurized operation of a stack for 1000 hours verified the compatability of the fuel cell component design. A simple pressurization procedure was also developed. Six separate designs, covering two gas cooling schemes (DIGAS and separated) and two cooling channel geometries (straight through and treed), were analysed on the net voltage output basis. Separated cooling with 5 cells per cooler was recognized to be the best among the designs considered.

Farooque, M.↗

A MHz-repetition-rate hard X-ray free-electron laser driven by a superconducting linear accelerator

The European XFEL is a hard X-ray free-electron laser (FEL) based on a high-electron-energy superconducting linear accelerator. The superconducting technology allows for the acceleration of many electron bunches within one radio-frequency pulse of the accelerating voltage and, in turn, for the generation of a large number of hard X-ray pulses. In this paper, we report on the performance of the European XFEL accelerator with up to 5,000 electron bunches per second and demonstrating a full energy of 17.5 GeV. Feedback mechanisms enable stabilization of the electron beam delivery at the FEL undulator in space and time. The measured FEL gain curve at 9.3 keV is in good agreement with predictions for saturated FEL radiation. Hard X-ray lasing was achieved between 7 keV and 14 keV with pulse energies of up to 2.0 mJ. Using the high repetition rate, an FEL beam with 6 W average power was created.

43 PARTICLE ACCELERATORS↗

Charging rates of metal-dielectric structures

Metal plates partially covered by 0.01-centimeter-thick fluorinated ethylene-propylene (FEP) Teflon were charged in the Lewis Research Center's geomagnetic substorm simulation facility using 5-, 8-, 10-, and 12-kilovolt electron beams. Surface voltage as a function of time was measured for various initial conditions (Teflon discharged or precharged) with the metal plate grounded or floating. Results indicate that both the charging rates and the levels to which the samples become charged are influenced by the geometry and initial charge state of the insulating surfaces. The experiments are described and the results are presented and discussed. NASA charging analyzer program (NASCAP) models of the experiments have been generated, and the predictions obtained are described. Implications of the study results for spacecraft are discussed.

Purvis, C. K.↗

Additional extensions to the NASCAP computer code, volume 1

Extensions and revisions to a computer code that comprehensively analyzes problems of spacecraft charging (NASCAP) are documented. Using a fully three dimensional approach, it can accurately predict spacecraft potentials under a variety of conditions. Among the extensions are a multiple electron/ion gun test tank capability, and the ability to model anisotropic and time dependent space environments. Also documented are a greatly extended MATCHG program and the preliminary version of NASCAP/LEO. The interactive MATCHG code was developed into an extremely powerful tool for the study of material-environment interactions. The NASCAP/LEO, a three dimensional code to study current collection under conditions of high voltages and short Debye lengths, was distributed for preliminary testing.

Mandell, M. J.↗

Evaluation of half wave induction motor drive for use in passenger vehicles

Research performed at the University of Missouri-Columbia to devise and design a lower cost inverter induction motor drive for electrical propulsion of passenger vehicles is described. A two phase inverter motor system is recommended. The new design is predicted to provide comparable vehicle performance, improved reliability and a cost advantage for a high production vehicle, decreased total rating of the power semiconductor switches, and a somewhat simpler control hardware compared to the conventional three phase bridge inverter motor drive system. The major disadvantages of the two phase inverter motor drive are that it is larger and more expensive than a three phase machine, the design of snubbers for the power leakage inductances produce higher transient voltages, and the torque pulsations are relatively large because of the necessity to limit the inverter switching frequency to achieve high efficiency.

Hoft, R. G.↗

Flow Components in a NaK Test Loop Designed to Simulate Conditions in a Nuclear Surface Power Reactor

A test loop using NaK as the working fluid is presently in use to study material compatibility effects on various components that comprise a possible nuclear reactor design for use on the lunar surface. A DC electromagnetic (EM) pump has been designed and implemented as a means of actively controlling the NaK flow rate through the system and an EM flow sensor is employed to monitor the developed flow rate. These components allow for the matching of the flow rate conditions in test loops with those that would be found in a full-scale surface-power reactor. The design and operating characteristics of the EM pump and flow sensor are presented. In the EM pump, current is applied to a set of electrodes to produce a Lorentz body force in the fluid. A measurement of the induced voltage (back-EMF) in the flow sensor provides the means of monitoring flow rate. Both components are compact, employing high magnetic field strength neodymium magnets thermally coupled to a water-cooled housing. A vacuum gap limits the heat transferred from the high temperature NaK tube to the magnets and a magnetically-permeable material completes the magnetic circuit. The pump is designed to produce a pressure rise of 5 psi, and the flow sensor's predicted output is roughly 20 mV at the loop's nominal flow rate of 0.5 GPM.

Polzin, Kurt A.↗

Impact Modeling and Testing of Pouch and Prismatic Cells

Understanding battery response under impact is critical to improve the safety of electrified vehicles. Nevertheless, predicting the impact behaviors of batteries is not straightforward since a battery cell usually contains hundreds of thin layers with dramatically different material properties and multiple physical processes occur simultaneously during cell deformation. Here we utilized both empirical tests and numerical models to capture the failure process of pouch and prismatic cells in various impact scenarios. In each test, a cell was hit once by an indenter dropped from a certain height. During which the cell penetration, loading force, voltage and temperature were monitored to characterize the cell’s response. Meanwhile, numerical models were developed to capture the coupled mechanical, electrical, electrochemical and thermal responses of batteries. In these models, the cell bulk was treated as a homogeneous part to achieve computational efficiency required by large-scale simulations, and it was represented by the geologic cap model that allows both shear and compaction deformation. Simulation results showed agreement with experimental data in essential features of cell behaviors during impact. Details of the test setup, model development and cell failure behaviors are presented in this paper. Additionally, capabilities, limitations and future improvement of the battery safety modeling are discussed.

25 ENERGY STORAGE↗

On the Relationship Between Schottky Barrier Capacitance and Mixer Performance at Cryogenic Temperatures

The flat-band voltage is the Schottky junction voltage required to shrink the depletion width to zero. At cryogenic temperatures, mixer diodes are generally biased and/or pumped beyond the flat-band condition to minimize conversion loss and noise figure. This occurs despite the presumed sharp increase in junction capacitance near flat-band, which should instead limit mixer performance. Past moderate forward bias, the diode C-V relationship is difficult to measure. A simple analytic expression for C(V) is usually used to model and predict mixer performance. This letter provides experimental data on C(V) at 77 K based on a microwave measurement and modeling technique. Data is also provided on the conversion loss of a singly balanced mixer optimized for 77 K operation. The connection between junction capacitance, flat-band potential, and conversion loss is examined. It is shown that the analytic expression greatly overestimates the junction capacitance that occurs as flat-band is approached.

Romanofsky, Robert R.↗

Unveiling a high capacity multi-redox (Nb 5+ /Nb 4+ /Nb 3+ ) NASICON-Nb 2 (PO 4 ) 3 anode for Li- and Na-ion batteries

Sodium superionic conductor (NASICON)-type materials are widely explored as Li- and Na-ion cathodes and solid-state electrolytes but are largely ignored as anodes due to their lower capacities and higher intercalation voltages, which reduce the overall energy densities of Li- and Na-ion batteries (LIBs and SIBs). Herein, we unveil high capacity multi-redox empty NASICON-Nb 2 (PO 4 ) 3 as a potential anode material for LIBs and SIBs, which reversibly delivers 167 and 150 mA h g -1 at the average voltages of 1.86 V vs. Li + /Li 0 and 1.46 V vs. Na + /Na 0 , respectively. The Li and Na intercalation reactions proceed via multiple phase transitions, leading to short-range ordered Li 3 Nb 2 (PO 4 ) 3 and triclinic (P$\overline{1}$ with combining macron]) Na 3 Nb 2 (PO 4 ) 3 , as revealed by in situ X-ray diffraction studies. Our density functional theory calculations are also in agreement with the in situ measurements in predicting a stable Na 3 Nb 2 (PO 4 ) 3 composition in the Na–Nb 2 (PO 4 ) 3 pseudo-binary system. X-ray absorption spectroscopy confirms the participation of multi-redox Nb 5+ /Nb 4+ /Nb 3+ couples. The Nb 2 (PO 4 ) 3 anode delivers capacities greater than 124 and 106 mA h g -1 at 1C rate in Li and Na cells, respectively. In conclusion, pairing Nb 2 (PO 4 ) 3 with suitable cathodes and electrolytes can lead to high energy density batteries.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Modeling Nanosecond-Pulsed Spark Discharge and Flame Kernel Evolution

Dilute combustion, either using exhaust gas recirculation or with excess air, is considered a promising strategy to improve the thermal efficiency of internal combustion engines. However, the dilute air-fuel mixture, especially under intensified turbulence and high-pressure conditions, poses significant challenges for ignitability and combustion stability, which may limit the attainable efficiency benefits. In-depth knowledge of the flame kernel evolution to stabilize ignition and combustion in a challenging environment is crucial for effective engine development and optimization. To date, a comprehensive understanding of ignition processes that result in the development of fully predictive ignition models usable by the automotive industry does not yet exist. Spark-ignition consists of a wide range of physics that includes electrical discharge, plasma evolution, joule-heating of gas, and flame kernel initiation and growth into a self-sustainable flame. In this study, an advanced approach is proposed to model spark-ignition energy deposition and flame kernel growth. To decouple the flame kernel growth from the electrical discharge, a nanosecond-pulsed high-voltage discharge is used to trigger spark-ignition in an optically accessible small ignition test vessel with a quiescent mixture of air and methane. Initial conditions for the flame kernel, including its thermodynamic state and species composition, are derived from a plasma-chemical equilibrium calculation. The geometric shape and dimension of the kernel are characterized using a multi-dimensional thermal plasma solver. Here, the proposed modeling approach is evaluated using a high-fidelity computational fluid dynamics procedure to compare the simulated flame kernel evolution against flame boundaries from companion Schlieren images.

42 ENGINEERING↗

Relation between near field and far field acoustic measurements

Several approaches to the problem of determining the far field directivity of an acoustic source located in a reverberant environment, such as a wind tunnel, are investigated analytically and experimentally. The decrease of sound pressure level with distance is illustrated; and the spatial extent of the hydrodynamic and geometric near fields, the far field, and the reverberant field are described. A previously-prosposed analytical technique for predicting the far field directivity of the acoustic source on the basis of near field data is investigated. Experiments are conducted with small acoustic sources and an analysis is performed to determine the variation with distance from the source of the directionality of the sound field. A novel experiment is conducted in which the sound pressure measured at various distances from an acoustic driver located in the NASA Ames 40 x 80 ft wind tunnel is crosscorrelated with the driver excitation voltage.

Bies, D. A.↗

Power Systems Evaluated for Solar Electric Propulsion Vehicles

Solar electric propulsion (SEP) mission architectures are applicable to a wide range NASA missions including the robotic exploration of the outer planets in the next decade and the human exploration of Mars within the next 2 decades. SEP enables architectures that are very mass efficient with reasonable power levels (1-MW class) aerobrake and cryogenic upper-stage transportation technologies are utilized. In this architecture, the efficient SEP stage transfers the payload from low Earth orbit (LEO) High Energy Elliptical Parking Orbit (HEEPO) within a period of 6 to 12 months. highthrust, cryogenic upper stage and payload then separate from the SEP vehicle for injection to the planetary target, allowing for fast heliocentric trip times. This mission architecture offers a potential reduction in mass to LEO in comparison to alternative all-chemical nuclear propulsion schemes. Mass reductions may allow launch vehicle downsizing enable missions that would have been grounded because of cost constraints. The preceding figure illustrates a conceptual SEP stage design for a human Mars mission. Researchers at the NASA Glenn Research Center at Lewis Field designed conceptual SEP vehicle, conceived the mission architecture to use this vehicle, and analyzed the vehicle s performance. This SEP stage has a dry mass of 35 metric tons (MT), 40 MT of xenon propellant, and a photovoltaic array that spans 110 m, providing power to a cluster of eight 100-kW Hall thrusters. The stage can transfer an 80-MT payload and upper stage to the desired HEEPO. Preliminary packaging studies show this space-station-class SEP vehicle meets the proposed "Magnum" launch vehicle and volume requirements with considerable margin. An SEP vehicle for outer planetary missions, such as the Europa Mapper Mission, would be dramatically smaller than human Mars mission SEP stage. In this mission architecture, the SEP power system with the payload to provide spacecraft power throughout the mission. Several photovoltaic array design concepts were considered for the SEP vehicle power system for the human mission to Mars. These include a space station derivative, a SCARLET (Solar Concentrator Arrays with Refractive Linear Element Technology) derivative, and a hybrid inflatable-deployable thin polymer membrane array with thin-film solar cells (as shown in the concept illustration). This concept is based on a design developed for the Next Generation Space Telescope Sun shield. The array is divided into 16 independent electrical sections with 500-V, negative-grounded solar cell strings. The power system employs a channelized, 500-Vdc power management and distribution (PMAD) architecture with lithium ion batteries for energy storage for vehicle and payload secondary loads (the high-power Hall thrusters do not operate in eclipse periods). The 500-V PMAD voltage permits "direct-drive" thruster operation, greatly reducing the power processing unit size, complexity, and power loss. Similar power system architecture, designs, and technology are assumed for the Europa Mapper Mission SEP vehicle. The primary exceptions are that the photovoltaic array is assumed to consist of two rectangular wings and that the power system rating is 15 kW in Earth orbit and 200 W at Europa. To size the SEP vehicle power system, a dedicated Fortran code was developed to predict detailed power system performance, mass, and thermal control requirements. This code also modeled all the relevant Earth orbit environments; that is, the particulate radiation, plasma, meteoroids and debris, ultraviolet radiation, contamination, and thermal conditions. Analysis results for the Human Mars Mission SEP vehicle show a power system mass of 9-MT and photovoltaic array area of 5800-square meters for the thin-membrane design concept with CuInS2 thin-film cells. Power processing unit input power for a thin-membrane array design with three-junction, amorphous SiGe solar cells is shown in the graph. Power falls off rapidly inhe first weeks of the mission because of light-induced (Staebler-Wronksi) solar cell losses. During the next 200 days, power decreases steadily as the SEP stage spirals through the proton belts and sustains the bulk of the mission radiation damage. Once the vehicle apogee is above approximately four Earth radii, little additional degradation is incurred. From 400 to 800 days, a 1100-km "parking" orbit is maintained to await the next payload transfer opportunity. This orbit is below the main proton belt, and thus, little radiation dose is accumulated during this time period. During the second LEO-to-HEEPO transfer, power degrades somewhat further, but power requirements are still met. In comparison, the Europa Mapper SEP vehicle power system had a mass of 150 kg and a thin membrane array area of 100 square meters.

Kerslake, Thomas W.↗

Rotating spokes, potential hump and modulated ionization in radio frequency magnetron discharges

Here, in this work, the transition from the gradient drift instability (GDI) into an m = 1 rotating spoke in the radio frequency magnetron discharge was studied by means of the two-dimensional axial-azimuthal (z–y) particle-in-cell/Monte Carlo collision method. The kinetic model combined with the linear analysis of the perturbation revealed that the cathode sheath (axial) electric field E z triggers the GDI, deforming the local potential until the instability condition is not fulfilled and the fluctuation growth stops in which moment the instability becomes saturated. The potential deformation consequently leads to the formation of the potential hump, surrounding which the azimuthal electric field E y is present. The saturation level of E y was found to be synchronized with and proportional to the time-changing voltage applied at the cathode, resulting in the RF-modulation of the electron heating in the E y due to $\nabla B$ drift. In the saturated stage of the instability, it was shown that the rotation velocity and direction of the spoke present in the simulations agree well with the experimental observation (Panjan 2019 J. Appl. Phys.125 203303). In the instability linear stage, the instability mode wavelength and the growth rate were also found to be in good agreement with the prediction of the GDI linear fluid theory.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

TID Effects in Space-like Variable Dose Rates

The degradation of the LM193 dual voltage comparator has been studied with different types of TID dose rates. These include several different constant dose rates and a variable dose rate that simulates the behavior of a solar flare. The varying dose rate of a solar flare is the type of real total dose exposure that a space mission might see in lunar or Martian orbit. A comparison of these types of dose rates is made to explore how well the constant dose rates used for typical part testing predicts the performance during a simulated space-like mission.

enhanced low dose rate sensitivity (ELDRS)↗