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At least 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Hydrogen Component Leak Rate Quantification for System Risk and Reliability Assessment through QRA and PHM Frameworks: Preprint

The National Renewable Energy Laboratory's (NREL) Hydrogen Safety Research and Development (HSR&D) program in collaboration with the University of Maryland's Systems Risk and Reliability Analysis Laboratory (SyRRA) are working to improve reliability and reduce risk in hydrogen systems. This approach strives to use quantitative data on component leaks and failures, together with Prognosis and Health Management (PHM), and Quantitative Risk Assessment (QRA) to identify at-risk components, reduce component failures and downtime, and predict when components require maintenance. Hydrogen component failures increase facility maintenance cost, facility downtime, and reduce public acceptance of hydrogen technologies, ultimately increasing facility size and cost because of potentially overly conservative requirements. Leaks are a predominant failure mode for hydrogen components. However, uncertainties in the amount of hydrogen emitted from leaking components and the frequency of those failure events limit the understanding of the risks that they present under real-world operational conditions. NREL has deployed a test fixture, the Leak Rate Quantification Apparatus (LRQA), to quantify the mass flow rate of leaking gases from medium and high-pressure components that have failed while in service. Quantitative hydrogen leak rate data from this system could ultimately be used to better inform risk assessment and Regulation Codes and Standards (RCS). Parallel activity explores the use of PHM and QRA techniques to assess and reduce risk, thereby improving safety and reliability of hydrogen systems. The results of QRAs could further provide a systematic and science-based foundation for the design and implementation of RCS, as in the latest versions of the NFPA 2 code for gaseous hydrogen stations. Alternatively, data-driven techniques of PHM could provide new damage diagnosis and health-state prognosis tools. This research will help end users, station owners and operators, and regulatory bodies move towards risk-informed preventative maintenance versus emergency corrective maintenance, reducing cost and improving reliability. Predictive modelling of failures could improve safety and affect RCS requirements such as setback distances at liquid refuelling sites. The combination of leak rate quantification research, PHM, and QRA can lead to better informed models enabling data-based decision to be made for hydrogen system safety improvements.

codes and standards↗
NASA NTRS2004

Analysis of the Spread Across Liquid-5 (SAL-5) Experiment Failure to Fill Properly During Flight

When a pool of flammable liquid is ignited, the flame spread rate can vary widely depending on the initial fuel temperature, pool geometry, ambient atmospheric conditions, and gravitational level. There is substantial decades-old debate in the scientific literature about the role of gravity in these phenomena. The objective of the research was to measure ignition and flame spread across liquid pools in both normal and microgravity with and without forced airflow, and to obtain detailed thermal and velocity field data for comparison to a predictive numerical model that is concurrently being developed. To that end, an experiment known as Spread Across Liquids 5 (SAL 5) was designed to be conducted in a low-gravity environment on a sounding rocket. Unfortunately, during the sounding rocket flight the fuel tray for the experiment failed to fill properly prior to ignition. The primary cause of the failure to fill properly is the geometry of the fuel tray; that is, the presence of the gaps on the side walls and the sharp edge around the thermocouple through-holes. The contamination resulting from the cleaning process is a strong secondary factor which would have prevented proper, timely filling had the primary cause not been present.

Allen, Jeffrey Stuart↗
DOE OSTI2021

Simulation of hardened cement degradation and estimation of uncertainty in predicted failure times with peridynamics

Modeling the degradation of cement-based infrastructure due to aqueous environmental conditions continues to be a challenge. In order to develop a capability to predict concrete infrastructure failure due to chemical degradation, here we created a chemomechanical model of the effects of long-term water exposure on cement paste. The model couples the mechanical static equilibrium balance with reactive–diffusive transport and incorporates fracture and failure via peridynamics (a meshless simulation method). The model includes fundamental aspects of degradation of ordinary Portland cement (OPC) paste, including the observed softening, reduced toughness, and shrinkage of the cement paste, and increased reactivity and transport with water induced degradation. This version of the model focuses on the first stage of cement paste decalcification, the dissolution of portlandite. Given unknowns in the cement paste degradation process and the cost of uncertainty quantification (UQ), we adopt a minimally complex model in two dimensions (2D) in order to perform sensitivity analysis and UQ. We calibrate the model to existing experimental data using simulations of common tests such as flexure, compression and diffusion. Then we calculate the global sensitivity and uncertainty of predicted failure times based on variation of eleven unique and fundamental material properties. We observed particularly strong sensitivities to the diffusion coefficient, the reaction rate, and the shrinkage with degradation. Also, the predicted time of first fracture is highly correlated with the time to total failure in compression, which implies fracture can indicate impending degradation induced failure; however, the distributions of the two events overlap so the lead time may be minimal. Extension of the model to include the multiple reactions that describe complete degradation, viscous relaxation, post-peak load mechanisms, and to three dimensions to explore the interactions of complex fracture patterns evoked by more realistic geometry is straightforward and ongoing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Optimization models for integrated biorefinery operations

Variations of physical and chemical characteristics of biomass lead to an uneven flow of biomass in a biorefinery, which reduces equipment utilization and increases operational costs. Uncertainty of biomass supply and high processing costs increase the risk of investing in the US’s cellulosic biofuel industry. We propose a stochastic programming model to streamline processes within a biorefinery. A chance constraint models system’s reliability requirement that the reactor is operating at a high utilization rate given uncertain biomass moisture content, particle size distribution, and equipment failure. The model identifies operating conditions of equipment and inventory level to maintain a continuous flow of biomass to the reactor. Furthermore, the sample average approximation method approximates the chance constraint and a bisection search-based heuristic solves this approximation. A case study is developed using real-life data collected at Idaho National Laboratory’s biomass processing facility. An extensive computational analysis indicates that sequencing of biomass bales based on moisture level, increasing storage capacity, and managing particle size distribution, increases utilization of the reactor and reduces operational costs.

09 BIOMASS FUELS↗
DOE OSTI2026

Directed energy deposition of Haynes 282 nickel superalloy

Laser powder directed energy deposition was employed to fabricate Haynes® 282 Ni-based superalloy for high temperature creep testing. Material was heat treated using a single-step aging heat treatment of 800 °C for 4 h. Microstructural analysis was conducted in the as-deposited, solution-annealed, and age-hardened conditions. γ′ precipitates were absent in the as-deposited and annealed condition but formed during aging with an average size of 48.5 ± 12 nm. γ’ denuded zones ranging in thickness from 73 to 469 nm were observed adjacent to an effectively continuous grain boundary carbide film that covered 72.5% of the measured boundary length. The heat-treated material contained a high-volume fraction of TiC carbides ranging in size from 38 to 457 nm. Electron backscatter diffraction showed partial recrystallization, with 77-83% recrystallized area and a heterogeneous grain-size distribution. Creep testing at 750 °C at 300, 320, and 350 MPa revealed significantly inferior performance compared to wrought material, with higher strain rates, earlier tertiary onset, and shorter rupture lives. Fractography shows that failure was dominated by intergranular rupture. Post rupture microstructural analysis results suggest that the creep behavior was primarily governed by the non-equilibrium interface network rather than the bulk γ/γ’ matrix. In conclusion, the findings indicate that achieving wrought-like creep performance necessitates substantial improvements in the additive process, specifically focusing on enhanced homogenization, full recrystallization, and precise control over the morphology and distribution of carbides.

36 - MATERIALS SCIENCE↗
DOE OSTI2020

Unravelling high-temperature stability of lithium-ion battery with lithium-rich oxide cathode in localized high-concentration electrolyte

Lithium (Li)-rich manganese (Mn)-rich oxide (LMR) cathode materials, despite of the high specific capacity up to 250 mAh g-1 suffer from instability of cathode/electrolyte interfacial layer at high working voltages, causing continuous voltage decay and capacity fading, especially at elevated temperatures. In various battery systems, localized high-concentration electrolytes (LHCEs) have been widely reported as a promising candidate to form effective electrode/electrolyte interphases. Here, an optimized LHCE is studied in graphite (Gr)-based full cells being cycled at 25, 45 and 60 °C with the reference of a conventional LiPF6-based electrolyte. It is revealed that the LHCE can effectively suppress continuous electrolyte decompositions and mitigate the dissolution of Mn ions due to the formation of more protective electrode/electrolyte interphases on both anode and cathode, which, in turn, lead to significantly improved cycling stability and enhanced rate capability under the selected temperatures. The mechanistic understanding on the failure of the conventional LiPF6-containing electrolyte and the function of the LHCE in Gr||LMR cells under high temperatures provides valuable perspectives of electrolyte development for practical application of LMR cathodes in high energy density batteries over a wide temperature range.

Localized high-concentration electrolyte, Lithium-↗
DOE OSTI2022

The Natural and Accelerated Evolution of EVA Adhesion Through Intermediate Exposures

Ethylene vinyl acetate (EVA) encapsulants comprise the majority of the encapsulants currently in use; much work has been done to understand and model the adhesive characteristics of EVA-encapsulated modules, but limited work has provided reliable insight into adhesion during the intermediate stages of exposure, limiting the ability to validate model predictions in this range. We provide the adhesion energy measurements for EVA adhesion after nearly six years of field aging and 10 000 h of accelerated aging. Both field and accelerated aging reveal a distinct plateau that emerges during the intermediate exposure periods (after one year in the field and after 1000 h in a chamber). At 10 000 h, adhesion within accelerated aged minimodules falls to a level generally seen after long-term field exposures (>15 years). Previous modeling predicted that adhesion would steadily decrease over the lifetime of a module, but these current results uncover an intermediate plateauing trend that is important to accurately modeling the evolution of adhesion and predicting adhesive failure. Based on these findings, three key model refinements concerning the rate of UV-radical formation and subsequent β-scission, the rate and acceleration of hydrolytic depolymerization, and the profile of the plasticity contribution over time are implemented and discussed.

14 SOLAR ENERGY↗
DOE OSTI2021

Theoretical Analysis and Experimental Validation of Flying-Capacitor Multilevel Converters Under Short-Circuit Fault Conditions

Addressing the increasing demand for high- efficiency and high-power-density converters, the flying-capacitor multilevel converter has shown itself as a promising topology. A key advantage of this topology is the reduced voltage rating of the switches, though also makes it vulnerable to device failure during short-circuit conditions. Despite large interest in fault-tolerant operation of these converters, alongside detailed descriptions of flying capacitor balancing, little research has focused on the converter short-circuit fault analysis, which may cause a switch failure if not properly designed for. Therefore, this work presents a comprehensive model describing the large- signal short-circuit switching behavior of a general N -level flying- capacitor multilevel converter. Highly simplified models used to predict the evolution of the switch current and voltage stress during the fault are proposed, targeted at practicing engineers for conservative design guidelines. These models are used to determine the critical time for remedial action of the converter before reaching some predefined maximum conditions. A 2-to-10- level fully-configurable flying-capacitor multilevel converter and a fault circuit hardware prototype are used to experimentally perform different short-circuit tests that show a good match to the measured behavior.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

High-Strain Rate Spall Strength Measurement for CoCrFeMnNi High-Entropy Alloy

In this study, we experimentally investigate the high stain rate and spall behavior of Cantor high-entropy alloy (HEA), CoCrFeMnNi. First, the Hugoniot equations of state (EOS) for the samples are determined using laser-driven CoCrFeMnNi flyers launched into known Lithium Fluoride (LiF) windows. Photon Doppler Velocimetry (PDV) recordings of the velocity profiles find the EOS coefficients using an impedance mismatch technique. Following this set of measurements, laser-driven aluminum flyer plates are accelerated to velocities of 0.5–1.0 km/s using a high-energy pulse laser. Upon impact with CoCrFeMnNi samples, the shock response is found through PDV measurements of the free surface velocities. From this second set of measurements, the spall strength of the alloy is found for pressures up to 5 GPa and strain rates in excess of 106 s−1. Further analysis of the failure mechanisms behind the spallation is conducted using fractography revealing the occurrence of ductile fracture at voids presumed to be caused by chromium oxide deposits created during the manufacturing process.

36 MATERIALS SCIENCE↗
NASA NTRS1980

An accelerated test design for use with synchronous orbit

The Naval Weapons Support Center at Crane, Indiana has conducted a large scale accelerated test of 6.0 Ah Ni-Cd cells. Data from the Crane test have been used to develop an equation for the description of Ni-Cd cell behavior in geosynchronous orbit. This equation relates the anticipated time to failure for a cell in synchronous orbit to temperature and overcharge rate sustained by the cell during the light period. A test design is suggested which uses this equation for setting test parameters for future accelerated testing.

Mcdermott, P. P.↗
NASA NTRS1988

Internal erosion rates of a 10-kW xenon ion thruster

A 30 cm diameter divergent magnetic field ion thruster, developed for mercury operation at 2.7 kW, was modified and operated with xenon propellant at a power level of 10 kW for 567 h to evaluate thruster performance and lifetime. The major differences between this thruster and its baseline configuration were elimination of the three mercury vaporizers, use of a main discharge cathode with a larger orifice, reduction in discharge baffle diameter, and use of an ion accelerating system with larger acceleration grid holes. Grid thickness measurement uncertainties, combined with estimates of the effects of reactive residual facility background gases gave a minimum screen grid lifetime of 7000 h. Discharge cathode orifice erosion rates were measured with three different cathodes with different initial orifice diameters. Three potential problems were identified during the wear test: the upstream side of the discharge baffle eroded at an unacceptable rate; two of the main cathode tubes experienced oxidation, deformation, and failure; and the accelerator grid impingement current was more than an order of magnitude higher than that of the baseline mercury thruster. The charge exchange ion erosion was not quantified in this test. There were no measurable changes in the accelerator grid thickness or the accelerator grid hole diameters.

Rawlin, Vincent K.↗
NASA NTRS1988

Internal erosion rates of a 10-kW xenon ion thruster

A 30 cm diameter divergent magnetic field ion thruster, developed for mercury operation at 2.7 kW, was modified and operated with xenon propellant at a power level of 10 kW for 567 h to evaluate thruster performance and lifetime. The major differences between this thruster and its baseline configuration were elimination of the three mercury vaporizers, use of a main discharge cathode with a larger orifice, reduction in discharge baffle diameter, and use of an ion accelerating system with larger acceleration grid holes. Grid thickness measurement uncertainties, combined with estimates of the effects of reactive residual facility background gases gave a minimum screen grid lifetime of 7000 h. Discharge cathode orifice erosion rates were measured with three different cathodes with different initial orifice diameters. Three potential problems were identified during the wear test: the upstream side of the discharge baffle eroded at an unacceptable rate; two of the main cathode tubes experienced oxidation, deformation, and failure; and the accelerator grid impingement current was more than an order of magnitude higher than that of the baseline mercury thruster. The charge exchange ion eroison was not quantified in this test. There were no measurable changes in the accelerator grid thickness or the accelerator grid hole diameters.

Rawlin, Vincent K.↗
NASA NTRS1990

A simulation evaluation of the engine monitoring and control system display

The Engine Monitoring and Control System (E-MACS) display is a new concept for an engine instrument display, the purpose of which is to provide an enhanced means for a pilot to control and monitor aircraft engine performance. It provides graphically-presented information about performance capabilities, current performance, and engine component or subsystem operational conditions relative to nominal conditions. The concept was evaluated by sixteen pilot-subjects against a traditional, state-of-the-art electronic engine display format. The results of this evaluation showed a substantial pilot preference for the E-MACS display relative to the traditional display. The results of the failure detection portion of the evaluation showed a 100 percent detection rate for the E-MACS display relative to a 57 percent rate for the traditional display. From these results, it is concluded that by providing this type of information in the cockpit, a reduction in pilot workload and an enhanced ability for detecting degraded or off-nominal conditions is probable, thus leading to an increase in operational safety.

Abbott, Terence S.↗
NASA NTRS2002

The Effect of Heating on the Degradation of Ground Laboratory and Space Irradiated Teflon(r) FEP

The outer most layer of the multilayer insulation (MLI) blankets on the Hubble Space Telescope (HST) is back surface aluminized Teflon(R) FEP (fluorinated ethylene propylene). As seen by data collected after each of the three servicing missions and as observed during the second servicing mission (SM2), the FEP has become embrittled in the space environment, leading to degradation of the mechanical properties and severe on-orbit cracking of the FEP. During SM2, a sample of aluminized-FEP was retrieved from HST that had cracked and curled, exposing its aluminum backside to space. Because of the difference in optical properties between FEP and aluminum, this insulation piece reached 200 C on-orbit, which is significantly higher than the nominal MLI temperature extreme of 50 C. This piece was more brittle than other retrieved material from the first and third servicing missions (SM1 and SM3A, respectively). Due to this observation and the fact that Teflon thermal shields on the solar array bi-stems were heated on-orbit to 130 C, experiments have been conducted to determine the effect of heating on the degradation of FEP that has been irradiated in a ground laboratory facility or in space on HST. Teflon FEP samples were X-ray irradiated in a high vacuum facility in order to simulate the damage caused by radiation in the space environment. Samples of pristine FEP, X-ray irradiated FEP and FEP retrieved from the HST during SM3A were heat treated from 50 to 200 C at 25 intervals in a high vacuum facility and then tensile tested. In addition, samples were tested in a density gradient column to determine the effect of the radiation and heating on the density of FEP. Results indicate that although heating does not degrade the tensile properties of non-irradiated Teflon, there is a significant dependence of the percent elongation at failure of irradiated Teflon as a function of heating temperature. Irradiated Teflon was found to undergo increasing degradation in the elongation at failure as temperature was increased from room temperature to 200 C. Rate of degradation changes, which were consistent with the glass I transition temperatures for FEP, appeared to be present in both tensile and density data. The results indicate the significance of the on-orbit temperature of Teflon FEP with respect to its degradation in the low Earth orbital space environment.

deGroh, Kim K.↗
NASA NTRS1986

Blood Pressure Control

Engineering Development Laboratory developed a system for the cardiovascular study of weightless astronauts. This was designed to aid people with congestive heart failure and diabetes. While in space, astronauts' blood pressure rises, heart rate becomes unstable, and there are sometimes postflight lightheadedness or blackouts. The Baro-Cuff studies the resetting of blood pressure. When a silicone rubber chamber is strapped to the neck, the Baro-Cuff stimulates the carotid arteries by electronically controlled pressure application. Blood pressure controls in patients may be studied.

Source record↗
NASA NTRS2002

Optimized Vertex Method and Hybrid Reliability

A method of calculating the fuzzy response of a system is presented. This method, called the Optimized Vertex Method (OVM), is based upon the vertex method but requires considerably fewer function evaluations. The method is demonstrated by calculating the response membership function of strain-energy release rate for a bonded joint with a crack. The possibility of failure of the bonded joint was determined over a range of loads. After completing the possibilistic analysis, the possibilistic (fuzzy) membership functions were transformed to probability density functions and the probability of failure of the bonded joint was calculated. This approach is called a possibility-based hybrid reliability assessment. The possibility and probability of failure are presented and compared to a Monte Carlo Simulation (MCS) of the bonded joint.

Smith, Steven A.↗
NASA NTRS2003

Internal Flow Thermal/Fluid Modeling of STS-107 Port Wing in Support of the Columbia Accident Investigation Board

As part of the aero-thermodynamics team supporting the Columbia Accident Investigation Board (CAB), the Marshall Space Flight Center was asked to perform engineering analyses of internal flows in the port wing. The aero-thermodynamics team was split into internal flow and external flow teams with the support being divided between shorter timeframe engineering methods and more complex computational fluid dynamics. In order to gain a rough order of magnitude type of knowledge of the internal flow in the port wing for various breach locations and sizes (as theorized by the CAB to have caused the Columbia re-entry failure), a bulk venting model was required to input boundary flow rates and pressures to the computational fluid dynamics (CFD) analyses. This paper summarizes the modeling that was done by MSFC in Thermal Desktop. A venting model of the entire Orbiter was constructed in FloCAD based on Rockwell International s flight substantiation analyses and the STS-107 reentry trajectory. Chemical equilibrium air thermodynamic properties were generated for SINDA/FLUINT s fluid property routines from a code provided by Langley Research Center. In parallel, a simplified thermal mathematical model of the port wing, including the Thermal Protection System (TPS), was based on more detailed Shuttle re-entry modeling previously done by the Dryden Flight Research Center. Once the venting model was coupled with the thermal model of the wing structure with chemical equilibrium air properties, various breach scenarios were assessed in support of the aero-thermodynamics team. The construction of the coupled model and results are presented herein.

Sharp, John R.↗
NASA NTRS2011

Gear Mesh Loss-of-Lubrication Experiments and Analytical Simulation

An experimental program to determine the loss-of-lubrication (LOL) characteristics of spur gears in an aerospace simulation test facility has been completed. Tests were conducted using two different emergency lubricant types: (1) an oil mist system (two different misted lubricants) and (2) a grease injection system (two different grease types). Tests were conducted using a NASA Glenn test facility normally used for conducting contact fatigue. Tests were run at rotational speeds up to 10000 rpm using two different gear designs and two different gear materials. For the tests conducted using an air-oil misting system, a minimum lubricant injection rate was determined to permit the gear mesh to operate without failure for at least 1 hr. The tests allowed an elevated steady state temperature to be established. A basic 2-D heat transfer simulation has been developed to investigate temperatures of a simulated gear as a function of frictional behavior. The friction (heat generation source) between the meshing surfaces is related to the position in the meshing cycle, the load applied, and the amount of lubricant in the contact. Experimental conditions will be compared to those from the 2-D simulation.

Handschuh, Robert F.↗