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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

3D Woven Mid-Density Carbon Phenolic (3MDCP) Thermal Protection System Development

3-Dimensionally Woven, Mid-Density, Carbon Phenolic (3MDCP) Thermal Protection System (TPS) material is derived from the dual layer 3D woven Heatshield for Extreme Entry Environment Technology (HEEET) material. The baseline 3MDCP design is a single piece thermal protection system that avoids the manufacturing and certification challenges associated with a tiled configuration. 3MDCP is targeted for very aggressive entry environments such as high-speed sample return missions to Earth and missions to Saturn, Venus and the ice giants. A 3MDCP heatshield begins as a flat woven preform that is formed to a given heatshield shape and then infused with phenolic resin. NASA Ames, in collaboration with TEAM Inc. (weaving) and Fiber Materials Inc. (both Spirit AeroSystems Companies) have been developing and demonstrating the manufacturing processes to fabricate a 3MDCP heatshield at a diameter of 1.25 meters. The process of forming the flat woven preform into the final heatshield shape, a sphere-cone geometry, involves local movement of the yarns in the weave. This results in a single piece heatshield with continuous fibers, albeit with property variations between different regions on the heatshield. This presentation will provide a high-level status of 3MDCP development. This will include an overview of the manufacturing processes, with an emphasis on the impact of forming on fiber orientation, material properties and performance. The presentation will layout the plan for testing to assess the impact of forming on properties and review preliminary data comparing properties of flat to formed materials.

Thermal Protection System↗
DOE OSTI2021

Hydrothermal Liquid Recovery of Rare Earth Elements and Critical Materials

This project demonstrated the technical viability of using tunable hydrothermal liquid (HTL) solutions to recover valuable minerals from a range of source materials. The effort focused upon rare earth elements (REE) and other minerals critical to the industrial security of the United States. This effort demonstrated, for the first time, that s, supercritical water (SCW) in particular, can: Extract critical and valuable minerals from a range of matrices ranging from rock ore to biomass; The process can be used to recover a wide range of minerals; This novel extraction chemistry can be cheap, simple, and nontoxic/”green”: The chemical extraction uses water, the cheapest industrial acid (sulfuric), and simple salts (i.e. sodium sulfate). However, other acids, salts, and additives could be used as appropriate. This Laboratory Directed Research and Development (LDRD) project identified that the process is complex with many interacting factors, but the benefits are significant if the complexities can be resolved. Challenges remain in the development of this technology and are described in this report. However, the results are positive, and commercial partners have already expressed interest. In summary, a novel, green, inexpensive mineral extraction process has been developed and demonstrated in a small batch reactor system. The effort provided information for an invention disclosure, proposal to DOE, and will support future business development efforts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2019

GRCop-42 Development and Hot-fire Testing Using Additive Manufacturing Powder Bed Fusion for Channel-Cooled Combustion Chambers

GRCop-42 is a high conductivity, high-strength dispersion strengthened copper-alloy for use in high heat flux applications such as liquid rocket engine combustion devices. This alloy is part of the family of NASA-developed GRCop, copper-chrome-niobium alloys. GRCop alloys were developed for harsh environments specific to regeneratively-cooled combustion chambers and nozzles with good oxidation resistance. Significant development was completed on the GRCop-84 and GRCop-42 alloys in the extruded wrought form demonstrating feasibility for combustion chambers. NASA has recently developed a process for additive manufacturing, specifically Powder Bed Fusion (PBF) or Selective Laser Melting (SLM), of GRCop-42 to establish parameters, characterize the material, and complete testing of components with complex internal features. This evolution of the GRCop-42 was based on the successful predecessor development work using GRCop-84 with the motivation of establishing a new copper-alloy option for use in NASA, government, and industry programs with SLM. A few advantages have been shown with the GRCop-42 that include higher conductivity and faster build speeds over the GRCop-84, and a simplified powder supply chain. Initial property development has shown that it is possible to produce high density builds with strengths equivalent to wrought GRCop-42 and a conductivity greater than GRCop-84. The GRCop-42 has completed process development and initial properties have been established. Several demonstrator combustion chambers have also been fabricated with the SLM GRCop-42 that include integral channels and closeouts. Additional test units have been fabricated and are completing substantial hot-fire testing to demonstrate performance of the material, process, and design.

Gradl, Paul R.↗
DOE OSTI2022

Methane Pyrolysis for CO2-free H2 and Carbon Nanomaterials (Abstract)

We propose to continue to develop a new process for producing CO2-free hydrogen (H2) from inexpensive and domestically-abundant natural gas (NG), while simultaneously reducing H2’s net production cost to $1.0/kg through the sale of valuable crystalline solid carbon co-product. Producing clean hydrogen at this price is a DOE Hydrogen Energy Earthshot goal. Cost effective production of clean H2 is also of commercial relevance to project partners Southern California Gas Company (SoCalGas) and startup company C4-MCP, who aim to further develop, demonstrate at scale, and ultimately deploy the new process technology developed on this project in order to meet regulatory demands in the State of California. In the current project we have focused on i) understanding the catalyst science for thermocatalytic decomposition of methane (TCD), which resulted in the development of a patent pending bimetallic catalyst offering favorable activity, stability, and selectivity under industrially relevant process conditions, ii) developing a novel, patent pending process to enable the separation of produced carbon and catalyst, and re-synthesis of the catalyst using recycled materials, iii) performing limited characterization of the produced carbon materials, and iv) performing detailed process modeling in order to perform techno economic assessment. The additional scope proposed here will accelerate the commercial deployment of TCD for CO2-free H2 and valuable solid carbon nanotubes (CNT) co-product, by i) scaling up the production of CNT co-product using a scalable, fluidized bed reactor (25 g catalyst scale versus the 1 g catalyst scale demonstrated to-date), ii) producing at least 40 g of CNT product, produced via multiple cycles of TCD, carbon-catalyst separation, and catalyst re-synthesis, to enable the production of sufficient quantities of solid carbon so as to explore its market potential, iii) understanding the quality of the co-product CNTs, produced at larger scale, through advanced characterization, and iv) beginning to explore multiple promising high volume carbon product applications (thermoplastics, automotive composites, battery, and cement reinforcement applications).

08 HYDROGEN↗
NASA NTRS1991

Telerobotic electronic materials processing experiment

The Office of Commercial Programs (OCP), working in conjunction with NASA engineers at the Goddard Space Flight Center, is supporting research efforts in robot technology and microelectronics materials processing that will provide many spinoffs for science and industry. The Telerobotic Materials Processing Experiment (TRMPX) is a Shuttle-launched materials processing test payload using a Get Away Special can. The objectives of the project are to define, develop, and demonstrate an automated materials processing capability under realistic flight conditions. TRMPX will provide the capability to test the production processes that are dependent on microgravity. The processes proposed for testing include the annealing of amorphous silicon to increase grain size for more efficient solar cells, thin film deposition to demonstrate the potential of fabricating solar cells in orbit, and the annealing of radiation damaged solar cells.

Ollendorf, Stanford↗
DOE OSTI2024

High performance heat exchangers for next generation hybrid cooler (CRADA NFE-19-07891 Final Report)

The evaporative cooling process has been successfully deployed in multiple energy conversion processes such as power generation, process cooling, heating, ventilation & cooling (HVAC), and commercial and industrial refrigeration. The heat exchanger is a very common yet extremely critical component of such systems. The device is important since the performance of the overall cooling system heavily relies on the thermal-hydraulic efficiency of the heat exchanger. The possible wet operation as evaporative cooling heat exchanger complicates the issue. Indeed, based on the hybrid nature of operation (fully dry, partially wet, fully wet) the efficiency can vary significantly and can cause performance variation for the whole system. Understanding the importance of the issue, Oak Ridge National Laboratory (Contractor) and Baltimore Aircoil Company (Participant) propose an activity focused on the analysis of the existing heat exchanger technology used in air and evaporative cooling processes and design, development and demonstration of a novel heat exchanger design based on porous materials. The potential candidates include metallic wire meshes and metal foams carefully designed for the proposed application. Prior research has indicated that these materials have great potential for deployment in thermal systems, particularly heat sinks and heat exchangers. It is expected that the successful completion of the project will lead to novel heat exchanger technology for hybrid systems (capable of dry and wet operation) by exploring newly emerging materials and their potential for heat transfer application. The overall goal is to develop a next generation heat exchanger technology which can be deployed in evaporative cooling systems. The impact of the such development is significant since, it will not only make the overall system highly efficient but will also, reduce the total refrigerant charge in the heat exchanger, a critical aspect for the deployment of refrigerants with lower Global Warming Potential (GWP).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities

Improvements in process monitoring and control at water resource recovery facilities (WRRFs) could result in reductions in electricity consumption, chemical inputs, and greenhouse gas emissions, as well as improved energy recovery. Many current WRRF data collection, monitoring, and control approaches use 20th century process monitoring and control systems, which require large design safety factors to ensure reliability in the absence of more advanced, precise controls. Implementation of more modern data-driven control tools could lead to more efficient operations that provide intrinsic reliability with better overall process performance at full-scale. This presentation provides an overview of a recently initiated project "Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities" which will (1) develop and demonstrate data-driven process controls at full-scale facilities for five promising WRRF Applications (i.e., process technologies) that provide whole-plant approaches and offer substantial energy and resource recovery benefits, and (2) create a toolbox of new process control approaches and an implementation guide including five examples for application at utilities. The presentation also provides a detailed overview of the research approach and progress being made on one of the five Applications, namely Application 2: Biological Nutrient Removal (BNR): ammonium-based aeration control (ABAC) / ammonia vs. NOx (AvN) + partial denitration with anammox (PdNA), which is being implemented at Hampton Roads Sanitation District. This project is a collaboration of work being conducted by DC Water, Hampton Roads Sanitation District, Metro Water Recovery, University of Michigan, Northwestern University, US Military Academy - West Point, Black & Veatch, and Oak Ridge National Laboratory. Research partner: U.S. Department of Energy.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

High performance heat exchangers for next generation hybrid cooler (CRADA Final Report)

The evaporative cooling process has been successfully deployed in multiple energy conversion processes such as power generation, process cooling, heating, ventilation & cooling (HVAC), and commercial and industrial refrigeration. The heat exchanger is a very common yet extremely critical component of such systems. The device is important since the performance of the overall cooling system heavily relies on the thermal-hydraulic efficiency of the heat exchanger. The possible wet operation as evaporative cooling heat exchanger complicates the issue. Indeed, based on the hybrid nature of operation (fully dry, partially wet, fully wet) the efficiency can vary significantly and can cause performance variation for the whole system. Understanding the importance of the issue, Oak Ridge National Laboratory (Contractor) and Baltimore Aircoil Company (Participant) propose an activity focused on the analysis of the existing heat exchanger technology used in air and evaporative cooling processes and design, development and demonstration of a novel heat exchanger design based on porous materials. The potential candidates include metallic wire meshes and metal foams carefully designed for the proposed application. Prior research has indicated that these materials have great potential for deployment in thermal systems, particularly heat sinks and heat exchangers. It is expected that the successful completion of the project will lead to novel heat exchanger technology for hybrid systems (capable of dry and wet operation) by exploring newly emerging materials and their potential for heat transfer application. The overall goal is to develop a next generation heat exchanger technology which can be deployed in evaporative cooling systems. The impact of the such development is significant since, it will not only make the overall system highly efficient but will also, reduce the total refrigerant charge in the heat exchanger, a critical aspect for the deployment of refrigerants with lower Global Warming Potential (GWP).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1980

Diffusion bonded boron/aluminum spar-shell fan blade

Design and process development tasks intended to demonstrate composite blade application in large high by-pass ratio turbofan engines are described. Studies on a 3.0 aspect radio space and shell construction fan blade indicate a potential weight savings for a first stage fan rotor of 39% when a hollow titanium spar is employed. An alternate design which featured substantial blade internal volume filled with titanium honeycomb inserts achieved a 14% potential weight savings over the B/M rotor system. This second configuration requires a smaller development effort and entails less risk to translate a design into a successful product. The feasibility of metal joining large subsonic spar and shell fan blades was demonstrated. Initial aluminum alloy screening indicates a distinct preference for AA6061 aluminum alloy for use as a joint material. The simulated airfoil pressings established the necessity of rigid air surfaces when joining materials of different compressive rigidities. The two aluminum alloy matrix choices both were successfully formed into blade shells.

Carlson, C. E. K.↗
NASA NTRS1979

Space Construction Automated Fabrication Experiment Definition Study (SCAFEDS), part 3. Volume 3: Requirements

The performance, design and verification requirements for the space Construction Automated Fabrication Experiment (SCAFE) are defined. The SCAFE program defines, develops, and demonstrates the techniques, processes, and equipment required for the automatic fabrication of structural elements in space and for the assembly of such elements into a large, lightweight structure. The program defines a large structural platform to be constructed in orbit using the space shuttle as a launch vehicle and construction base.

Source record↗
NASA NTRS1980

Solar photovoltaics: Stand alone applications

The Lewis Research Center involvement in space photovoltaic research and development and in using photovoltaics for terrestrial applications is described with emphasis on applications in which the normal source of power may be a diesel generator, batteries, or other types of power not connected to a utility grid. Once an application is processed, technology is developed and demonstrated with a user who participates in the cost and furnishes the site. Projects completed related to instruments, communication, refrigeration, and highways, are described as well as warning systems, weather stations, fire lookouts, and village power systems. A commercially available photovoltaic powered electric fence charger is the result of Lewis research and development.

Deyo, J. N.↗
NASA NTRS2007

Coherent Lidar Activities at NASA Langley Research Center

NASA Langley Research Center has been developing and using coherent lidar systems for many years. The current projects at LaRC are the Global Wind Observing Sounder (GWOS) mission preparation, the Laser Risk Reduction Program (LRRP), the Instrument Incubator Program (IIP) compact, rugged Doppler wind lidar project, the Autonomous precision Landing and Hazard detection and Avoidance Technology (ALHAT) project for lunar landing, and the Skywalker project to find and use thermals to extend UAV flight time. These five projects encompass coherent lidar technology development; characterization, validation, and calibration facilities; compact, rugged packaging; computer simulation; trade studies; data acquisition, processing, and display development; system demonstration; and space mission design. This paper will further discuss these activities at LaRC.

Kavaya, Michael J.↗
NASA NTRS2002

Tensile Behavior of As-Fabricated and Burner-Rig Exposed SiC/SiC Composites with Hi-Nicalon Type-S Fibers

Tensile stress-strain curves were measured at room temperature and 1315 C for 2D-woven SiC/BN/SiC ceramic matrix composites (CMC) reinforced by two variations of Hi-Nicalon Type-S SiC fibers. These fibers, which contained a thin continuous carbon-rich layer on their as-produced surface, provided the as-fabricated CMC with good composite behavior and an ultimate strength and strain of -350 MPa and -0.5%, respectively. However, after un-stressed burner-rig exposure at 815 C for -100 hrs, CMC tensile specimens with cut edges and exposed interphases showed a significant decrease in ultimate properties with effectively no composite behavior. Microstructural observations show that the degradation was caused by internal fiber-fiber oxide bonding after removal of the carbon-rich fiber surface layer by the high-velocity combustion gases. On the other hand, SiC/BN/SiC CMC with Sylramic-iBN fibers without carbon-rich surfaces showed higher as-fabricated strength and no loss in strength after the same burner rig exposure. Based on the strong role of the carbon layer in these observations, a process method was developed and demonstrated for achieving better strength retention of Hi-Nicalon Type-S CMC during burner rig exposure. Other general approaches for minimizing this current deficiency with as-produced Type-S fibers are discussed.

Yun, H. M.↗
NASA NTRS2017

Oxygen Extraction from Minerals

Oxygen, whether used as part of rocket bipropellant or for astronaut life support, is a key consumable for space exploration and commercialization. In Situ Resource Utilization (ISRU) has been proposed many times as a method for making space exploration more cost effective and sustainable. On planetary and asteroid surfaces the presence of minerals in the regolith that contain oxygen is very common, making them a potential oxygen resource. The majority of research and development for oxygen extraction from minerals has been for lunar regolith although this work would generally be applicable to regolith at other locations in space. This presentation will briefly survey the major methods investigated for oxygen extraction from regolith with a focus on the current status of those methods and possible future development pathways. The major oxygen production methods are (1) extraction from lunar ilmenite (FeTiO3) with either hydrogen or carbon monoxide, (2) carbothermal reduction of iron oxides and silicates with methane, and (3) molten regolith electrolysis (MRE) of silicates. Methods (1) and (2) have also been investigated in a two-step process using CO reduction and carbon deposition followed by carbothermal reduction. All three processes have byproducts that could also be used as resources. Hydrogen or carbon monoxide reduction produce iron metal in small amounts that could potentially be used as construction material. Carbothermal reduction also makes iron metal along with silicon metal and a glass with possible applications. MRE produces iron, silicon, aluminum, titanium, and glass, with higher silicon yields than carbothermal reduction. On Mars and possibly on some moons and asteroids, water is present in the form of mineral hydrates, hydroxyl (-OH) groups on minerals, andor water adsorbed on mineral surfaces. Heating of the minerals can liberate the water which can be electrolyzed to provide a source of oxygen as well. The chemistry of these processes, some key development and demonstration projects, the challenges remaining to be overcome, and possible future directions will be discussed with a goal of increased understanding of these important ISRU technologies and their potential applications to space exploration and settlement.

propellant production↗
NASA NTRSDate not supplied

Enabling Execution of a Legacy CFD Mini Application on Accelerators Using OpenMP

We describe the process and outcome of our efforts to port a legacy Fortran benchmark code to heterogeneous GPU-accelerated computing architectures using OpenMP. The benchmark code is one of the multi-zone NAS Parallel Benchmarks (NPB-MZ) called SP-MZ. This “mini-app” mimics the computation and data movement that is found in popular legacy and modern implicit computational fluid dynamics (CFD)solvers. Our objective was to examine how efficiently legacy Fortran codes can be ported to accelerators by leveraging OpenMP directives. We describe the development and optimization process and demonstrate the performance impact of various code modifications. We show select profiling results from the Nvidia nvvp profiler to help others diagnose and overcome performance issues in their own applications. We present results for two compute systems endowed with Nvidia V100 accelerators.

Ioannis Nompelis↗
DOE OSTI2023

Formate as an Energy Source to Allow Sugar Fermentation with No Net CO2 Generation: Integration of Electrochemistry with Fermentation

This poster summarizes at a high-level the scope of various groups' work on Formate as an Energy Source to Allow Sugar Fermentation with No Net CO2 Generation: Integration of Electrochemistry with Fermentation. The goals of this research are to develop and demonstrate an integrated process that electrochemically generates formate from CO2 and use the formate as an energy source for the fermentation of sugars to fatty acid methyl esters (FAME) without net CO2 generation wherein formate provides reducing equivalents for sugar fermentation and a chemical looping reactor system takes advantage of intermittent low-cost electricity from wind and solar resources.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗
DOE OSTI2026

Traveling Molten Zone Refining Process Development for Innovative Fuel Cycle Solutions

This ARPA-E ONWARDS project successfully developed and demonstrated an innovative immiscibility zone refining process for separating actinides from active fission products in metallic nuclear fuel applications. The technology addresses a critical challenge in advanced nuclear fuel cycles by providing a high-throughput, low-waste alternative to conventional electrorefining.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗