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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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NASA NTRS1988

Failure mode and effects analysis (FMEA) for the Space Shuttle solid rocket motor

The recertification of the Space Shuttle Solid Rocket Booster (SRB) and Solid Rocket Motor (SRM) has included an extensive rewriting of the Failure Mode and Effects Analysis (FMEA) and Critical Items List (CIL). The evolution of the groundrules and methodology used in the analysis is discussed and compared to standard FMEA techniques. Especially highlighted are aspects of the FMEA/CIL which are unique to the analysis of an SRM. The criticality category definitions are presented and the rationale for assigning criticality is presented. The various data required by the CIL and contribution of this data to the retention rationale is also presented. As an example, the FMEA and CIL for the SRM nozzle assembly is discussed in detail. This highlights some of the difficulties associated with the analysis of a system with the unique mission requirements of the Space Shuttle.

Russell, D. L.↗

NASA NTRS2011

Cryogenic Thermal Vacuum Testing with Remote Optical Metrology

Flexure Engineering was awarded an SBIR to research and develop technology needed to build a thermal vacuum chamber made to take laser radar metrology through a window. The XATF test is proof of concept for this, and demonstrated the need for such a chamber. XATF refers to two pieces of critical ground support equipment for NASA's JWST (James Webb Space Telescope) Integrated Science Instrument Module (ISIM), the ISIM Alignment Target Fixture (IATF) and the Master Alignment Target Fixture (MATF). These optical alignment assemblies require characterization while under cryogenic temperature. A thermal vacuum chamber equipped with a shroud cooled with gaseous and liquid nitrogen was used. An inner shroud was cooled with liquid helium to approximately 30K. The XATF assemblies were kinematically mounted and oriented inside the inner shroud such that the optical targets were visible from outside an optical window on one of the chamber ports. Laser radar and theodolite mounted outside the window took measurements of various optical targets. Two cold cycles were completed. A third cycle was aborted. Metrology was successfully taken. There were some problems with the helium system. The cryo pumps were turned off to reduce vibrations during metrology. Many new technologies and testing methods must be developed for JWST and future programs that will require precision measurements. These technologies will be applicable to other cold temperature applications, such as lunar missions and superconductors. Remote metrology technologies can also be applicable to testing in harsh environments. Facilities with remote metrology capability will be valuable.

Boyd, Guinevere↗

NASA NTRS2015

Advanced Oxygen Recovery via Series-Bosch Technology

Oxygen recovery from metabolically-produced carbon dioxide (CO2) is of critical importance for long-duration manned space missions beyond low Earth orbit. On the International Space Station (ISS), oxygen is provided to the crew through electrolysis of water in the Oxygen Generation Assembly (OGA). Prior to 2011, this water was entirely resupplied from Earth. A CO2 Reduction Assembly based on the Sabatier reaction (1) was developed by Hamilton Sundstrand and delivered to ISS in 2010. The unit recovers oxygen by reducing metabolic CO2 with diatomic hydrogen (H2) to produce methane and product water. The water is cleaned by the Water Purification Assembly and recycled to the OGA for continued oxygen production. The methane product is vented overboard.

Abney, Morgan B.↗

NASA NTRS2019

The Large UV/Optical/Infrared Surveyor Decadal Mission Concept Thermal System Architecture

The Large Ultraviolet/Optical/Infrared (LUVOIR) Surveyor is one of four large strategic mission concept studies commissioned by NASA for the 2020 Decadal Survey in Astronomy and Astrophysics. Slated for launch to the second Lagrange point (L2) in the mid-to-late 2030s, LUVOIR seeks to directly image habitable exoplanets around sun-like stars, characterize their atmospheric and surface composition, and search for biosignatures, as well as study a large array of astrophysics goals including galaxy formation and evolution. Two observatory architectures are currently being considered which bound the trade-off between cost, risk, and scientific return: a 15-meter diameter segmented aperture primary mirror in a three-mirror anastigmat configuration, and an 8-meter diameter unobscured segmented aperture design. To achieve its science objectives, both architectures require milli-Kelvin level thermal stability over the optics, structural components, and interfaces to attain picometer wavefront RMS stability. A 270 Kelvin operational temperature was chosen to balance the ability to perform science in the near-infrared band and the desire to maintain the structure at a temperature with favorable material properties and lower contamination accumulation. This paper will focus on the system-level thermal designs of both LUVOIR observatory architectures. It will detail the various thermal control methods used in each of the major components - the optical telescope assembly, the spacecraft bus, the sunshade, and the suite of accompanying instruments - as well as provide a comprehensive overview of the analysis and justification for each design decision. It will additionally discuss any critical thermal challenges faced by the engineering team should either architecture be prioritized by the Astro2020 Decadal Survey process to proceed as the next large strategic mission for development.

Yang, Kan↗

NASA NTRS2019

The Large UV/Optical/Infrared Surveyor Decadal Mission Concept Thermal System Architecture

Yang, Kan↗

NASA NTRS2020

UV/Vis+ Photochemistry Database: Structure, Content and Applications

The “science-softCon UV/Vis+ Photochemistry Database” (www.photochemistry.org) is a large and comprehensive collection of EUV-VUV-UV–Vis-NIR spectral data and other photochemical information assembled from published peer-reviewed papers. The database contains photochemical data including absorption, fluorescence, photoelectron, and circular and linear dichroism spectra, as well as quantum yields and photolysis related data that are critically needed in many scientific disciplines. This manuscript gives an outline regarding the structure and content of the “science-softCon UV/Vis+ Photochemistry Database”. The accurate and reliable molecular level information provided in this database is fundamental in nature and helps in proceeding further to understand photon, electron and ion induced chemistry of molecules of interest not only in spectroscopy, astrochemistry, astrophysics, Earth and planetary sciences, environmental chemistry, plasma physics, combustion chemistry but also in applied fields such as medical diagnostics, pharmaceutical sciences, biochemistry, agriculture, and catalysis. In order to illustrate this, we illustrate the use of the UV/Vis+ Photochemistry Database in four different fields of scientific endeavor.

Photochemistry↗

NASA NTRS2005

Rotordynamic Analysis and Feasibility Study of a Disk Spin Test Facility for Rotor Health Monitoring

Recently, National Aeronautics and Space Administration (NASA) initiated a program to achieve the significant improvement in aviation safety. One of the technical challenges is the design and development of accelerated experiments that mimic critical damage cases encountered in engine components. The Nondestructive Evaluation (NDE) Group at the NASA Glenn Research Center (GRC) is currently addressing the goal concerning propulsion health management and the development of propulsion system specific technologies intended to detect potential failures prior to catastrophe. For this goal the unique disk spin simulation system was assembled at NASA GRC, which allows testing of rotors with the spinning speeds up to 10K RPM, and at the elevated temperature environment reaching 540 C (1000 F). It is anticipated that the facility can be employed for detection of Low Cycle Fatigue disk cracking and further High Cycle Fatigue blade vibration. The controlled crack growth studies at room and elevated temperatures can be conducted on the turbine wheels, and various NDE techniques can be integrated and assessed as in-situ damage monitoring tools. Critical rotating parts in advanced gas turbine engines such as turbine disks frequently operate at high temperature and stress for long periods of time. The integrity of these parts must be proven by non-destructive evaluation (NDE) during various machining steps ranging from forging blank to finished shape, and also during the systematic overhaul inspections. Conventional NDE methods, however, have unacceptable limits. Some of these techniques are time-consuming and inconvenient for service aircraft testing. Almost all of these techniques require that the vicinity of the damage is known in advance. These experimental techniques can provide only local information and no indication of the structural strength at a component and/or system level. The shortcomings of currently available NDE methods lead to the requirement of new damage detection techniques that can provide global information on the rotating components/system, and, in addition, they do not require direct human access to the operating system. During this period of research considerable effort was directed towards the further development of experimental facility and development of the vibration-based crack detection methodology for rotating disks and shafts. A collection of papers and reports were written to describe the results of this work. The attached captures that effort and represents the research output during the grant period.

Sawicki, Jerzy T.↗

DOE OSTI2020

Rapid Electrochemical Methane Functionalization Involves Pd–Pd Bonded Intermediates

High-valent Pd complexes are potent agents for the oxidative functionalization of inert C-H bonds, and it was previously shown that rapid electrocatalytic methane monofunctionalization could be achieved by electro-oxidation of Pd II to a critical dinuclear Pd III intermediate in concentrated or fuming sulfuric acid. However, the structure of this highly reactive, unisolable intermediate, as well as the structural basis for its mechanism of electrochemical formation, remained elusive. Herein, we use X-ray absorption and Raman spectroscopies to assemble a structural model of the potent methane-activating intermediate as a Pd III dimer with a Pd-Pd bond and a 5-fold O atom coordination by H x SO 4 (x-2) ligands at each Pd center. We further use EPR spectroscopy to identify a mixed-valent M-M bonded Pd 2 II,III species as a key intermediate during the Pd II -to-Pd III 2 oxidation. Combining EPR and electrochemical data, we quantify the free energy of Pd dimerization as <-4.5 kcal/mol for Pd 2 II,III and <-9.1 kcal/mol for Pd III 2 . The structural and thermochemical data suggest that the aggregate effect of metal-metal and axial metal-ligand bond formation drives the critical Pd dimerization reaction in between electrochemical oxidation steps. This work establishes a structural basis for the facile electrochemical oxidation of Pd II to a M-M bonded Pd III dimer and provides a foundation for understanding its rapid methane functionalization reactivity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Metastable doubly threaded [3]rotaxanes with a large macrocycle

Ring size is a critically important parameter in many interlocked molecules as it directly impacts many of the unique molecular motions that they exhibit. Reported herein are studies using one of the largest macrocycles reported to date to synthesize doubly threaded [3]rotaxanes. A large ditopic 46 atom macrocycle containing two 2,6-bis(N-alkyl-benzimidazolyl)pyridine ligands has been used to synthesize several metastable doubly threaded [3]rotaxanes in high yield (65–75% isolated) via metal templating. Macrocycle and linear thread components were synthesized and self-assembled upon addition of iron(II) ions to form the doubly threaded pseudo[3]rotaxanes that could be subsequently stoppered using azide–alkyne cycloaddition chemistry. Following demetallation with base, these doubly threaded [3]rotaxanes were fully characterized utilizing a variety of NMR spectroscopy, mass spectrometry, size-exclusion chromatography, and all-atom simulation techniques. Critical to the success of accessing a metastable [3]rotaxane with such a large macrocycle was the nature of the stopper group employed. By varying the size of the stopper group it was possible to access metastable [3]rotaxanes with stabilities in deuterated chloroform ranging from a half-life of <1 minute to ca. 6 months at room temperature potentially opening the door to interlocked materials with controllable degradation rates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

A high-capacity Sn metal anode for aqueous acidic batteries

Aqueous acidic batteries as a good choice to respond battery diversity, delivering safety, cost, environmental friendliness and high-power necessary for renewable energy storage. However, the practical adoption is greatly challenged by low-voltage and energy density due to the inadequate metal anode materials. Here we report an interfacial regulated Sn metal anode as the solution of the last piece of the puzzle. In this study, the ease of recycling, low potential, fast redox kinetics, and high capacity of Sn perfectly fit the battery system, and the Sn metal shedding critical issue is successfully suppressed by promoting uniform deposition for added interaction from alloying. Consequently, this reversible Sn anode with 442 mAh g -1 matches well to different types of cathodes. The as-assembled acidic batteries also demonstrate sufficient output voltage (up to 1.7 V), energy density (up to 312 Wh kg -1 based on both electrodes), kinetics (up to 24 C) and stability (up to 2400 cycles).

25 ENERGY STORAGE↗

DOE OSTI2024

Development of a high current density, high temperature superconducting cable for pulsed magnets

Abstract A low AC loss Rare Earth Barium Copper Oxide (REBCO) cable, based on the VIPER cable technology has been developed by Commonwealth Fusion Systems for use in high field, REBCO based tokamaks. The new cable is composed of partitioned and transposed copper ‘petals’ shaped to fit together in a circular pattern with each petal containing a REBCO tape stack and insulated from each other to reduce AC losses. A stainless steel jacket adds mechanical robustness—also serving as a vessel for solder impregnation—while a tube runs through the middle for cooling purposes. Additionally, fiber optic sensors are placed under the tape stacks for quench detection. To qualify this design, a series of experiments were conducted as part of the SPARC tokamak Central Solenoid Model Coil program—to retire the risks associated with full scale, fast ramping, high flux HTS Central Solenoid (CS) and Poloidal Field (PF) coils for tokamak fusion power plants and net energy demonstrators. These risk study and risk reduction experiments include (1) AC loss measurement and model validation in the range of ~5 T/s, (2) an IxB electromagnetic loading of over 850 kN/m at the cable level and up to 300 kN/m at the stack level, (3) a transverse compression resilience of over 350 MPa, (4) manufacturability at tokamak relevant speeds and scales, (5) cable to cable joint performance, (6) fiber optic based quench detection speed, accuracy, and feasibility, and (7) overall winding pack integration and magnet assembly. The result is a cable technology, now referred to as PIT VIPER, with AC losses that measure fifteen times lower (at ~5 T/s) than its predecessor technology; a 2% or lower degradation of critical current (Ic) at high IxB electromagnetic loads; no detectable Ic degradation up to 570 MPa of transverse compression on the cable unit cell; end to end magnet manufacturing, consistently producing Ic values within 7% of the model prediction; cable to cable joint resistances at 20 K on the order of ~15 nΩ; and fast, functional quench detection capabilities that do not involve voltage taps. This cable technology will be tested comprehensively in a Central Solenoid Model Coil to prove its readiness for compact, high field tokamak operation.

Sanabria, Charlie (ORCID:0000000150175309)↗

NASA NTRS1977

Space-based solar power conversion and delivery systems study. Volume 5: Economic analysis

Space-based solar power conversion and delivery systems are studied along with a variety of economic and programmatic issues relevant to their development and deployment. The costs, uncertainties and risks associated with the current photovoltaic Satellite Solar Power System (SSPS) configuration, and issues affecting the development of an economically viable SSPS development program are addressed. In particular, the desirability of low earth orbit (LEO) and geosynchronous (GEO) test satellites is examined and critical technology areas are identified. The development of SSPS unit production (nth item), and operation and maintenance cost models suitable for incorporation into a risk assessment (Monte Carlo) model (RAM) are reported. The RAM was then used to evaluate the current SSPS configuration expected costs and cost-risk associated with this configuration. By examining differential costs and cost-risk as a function of postulated technology developments, the critical technologies, that is, those which drive costs and/or cost-risk, are identified. It is shown that the key technology area deals with productivity in space, that is, the ability to fabricate and assemble large structures in space, not, as might be expected, with some hardware component technology.

Source record↗

NASA NTRS1980

Technologies involved in configuring an advanced earth-to-orbit transport for low structural mass

A tradeoff study for a single-stage, earth-to-orbit transport spacecraft configured with low structural mass as the prime objective is presented. Among the major design elements affecting vehicle mass are: maneuverability and re-entry heating, the compatibility of an irregular cargo bay geometry to future mission requirements, the fabrication and assembly of large honeycomb structure fuselage sections, and the development of LOX/LH2 engine extendable nozzles and dual-propulsion schemes. It is shown that vehicle geometry and materials and structural technologies will be the critical areas in the development of such a system.

Macconochie, I. O.↗

NASA NTRS1991

SP-100 space subsystems development progress

The space technology effort related to SP-100 subsystems is described in terms of the areas of primary focus and most significant progress. The SP-100 is briefly compared to the Voyager, and detailed descriptions of the converter subsystem, the heat-transport system, and the heat-rejection subsystem. Progress on the converter subsystem includes a high-voltage insulator composed of a single sapphire crystal, a compliant pad of coated niobium, an SiGe thermoelectric (TE) module, and a TE cell assembly. The test of the Nb1Zr piping related to the heat-transport subsystem is described, and the development is reported for the TEM pump and the gas separator. It is concluded that the critical technical issues related to the technologies have been addressed although further efforts are required. Future testing is described for the three major components of the space subsystems including the converter, pump, and the radiator.

Mondt, Jack F.↗

NASA NTRS2016

Surgical Capabilities for Exploration and Colonization Space Flight - An Exploration Symposium

Surgical capabilities in human space flight, whether on a space-based platform in low Earth orbit or on a long duration planetary exploration mission, will be challenging to conduct for a variety of reasons, some of which will be ameliorated by training, technology, and pre-flight planning. Nevertheless, inherent risks and challenges remain. Early space missions did not have any surgical capability. It was not until NASA's Skylab mission that serious consideration was given to this fundamental medical care capability. Over the past 30 years, subject matter experts have been brought together for discussion on the myriad of challenges and opportunities in this endeavor. The last such meeting was held in 2005 at the NASA Johnson Space Center. As we continue to move forward with human space flight activities for the International Space Station and beyond, the capabilities of information technology, robotics, sensors and imaging have rapidly changed since the last gathering of expertise. In December 2015, through sponsorship of the National Space Biomedical Research Institute (NSBRI), a diverse group of individuals from government, academia, and industry representing three countries gathered at the NSBRI Space 4 Biomedicine facility in Houston, TX. This two day symposia included comprehensive sessions that addressed the challenges that we all face in developing, deploying, and utilizing surgical care capabilities in all human space missions, regardless of mission duration or profile. The symposium benefited from the knowledge and experience of three seasoned NASA physician astronauts, Drs. Jay Buckey, Thomas Marshburn, and Lee Morin. At the end of the first day, the assembled group heard from the crew members about their experiences and their ideas. It is clear that the discussion of surgical capabilities is part of the larger discussion of consideration of advanced healthcare, including critical care, on exploration space missions. This report represents the culmination of the symposium, capturing knowledge, experience, conceptual dialogue, and a narrative that can be used in supporting the development of future programs and potential policy. Each of the presentations that were provided by the guest speakers is included in the appendices. Those presentations that are not included were due to sensitivity of the material or at the request of the speaker. In addition, each speaker was offered an opportunity to provide comments in a 'lightning round' format. All of these comments and speaker abstracts also appear in the appendices. At the conclusion of the second day, a discussion was held that reviewed the priorities that perhaps add value to decision makers. These are also summarized. This report will serve as the final product of this symposium. Additional material may be produced for the peer-reviewed literature.

Doarn, Charles R.↗

NASA NTRS2011

Progress in implementation of the Portable Remote Imaging Spectrometer (PRISM) coastal ocean sensor.

PRISM is a pushbroom imaging spectrometer currently in its second year of development at the Jet Propulsion Laboratory, intended to address the needs of airborne coastal ocean science research. We give an overview of the instrument functionality and then describe progress in component and subsystem fabrication. In the second year, all critical components have been received and most have been integrated into their respective subsystems. The design of the vacuum enclosure has also been completed. We present results from the telescope and spectrometer sub-assemblies, the focal plane electronics, and the overall system assembly implementation.

Yee, K.↗

DOE OSTI2021

In Situ Transmission Electron Microscopy of High-Temperature Inconel-625 Corrosion by Molten Chloride Salts

This paper describes an approach to monitor high temperature molten chloride (MgCl 2 -NaCl-KCl) salt corrosion of Inconel-625 alloy in real time at high spatial resolution. The approach is based on a micro-environmental-cell assembly integrated into a transmission-electron-microscope goniometer to examine in situ the salt-alloy interface during corrosion, employing real time electron diffraction and imaging. It establishes procedures to minimize incorporation of H 2 O or O 2 from atmosphere in the chloride salts during sample fabrication and corrosion, which is critical to understanding the fundamental corrosion mechanisms. A clustering algorithm and a 2D Gaussian fit function are used to determine diffraction spot intensities in in situ diffraction patterns, to quantify alloy corrosion. This facilitates quantitative observation of the evolution of individual grains, in contrast to conventional macroscopic corrosion rate quantification. The isothermal corrosion rate of Inconel-625 in an anhydrous, unoxidized salt-stack is 220 ± 30 μm year -1 at 700 °C and 350 ± 20 μm year -1 at 800 °C. However, the corrosion rate at 700 °C increases five-fold to 1000 ± 170 μm year -1 when the salt stack is air-exposed, indicating the dominant effects of hydrated or oxidized impurities on corrosion acceleration. Furthermore, real time imaging of the microstructure evolution suggests that corrosion is initiated at grain boundaries.

14 SOLAR ENERGY↗

NASA NTRSDate not supplied

Tracking Critical Thermal Metrics throughout the Life Cycle of a Large Observatory Thermal Model

Observatory thermal models for large, complex missions, such as the Wide Field InfraRed Survey Telescope (WFIRST) mission, produce an immense amount of data to be processed. Configuration management of the model throughout the project life cycle has mainly focused on which versions of the subsystem models form the current observatory level configuration. However, the results produced by the model are not nearly as well tracked and traceable. Given the various states of design maturity for each of the components in the WFIRST design, an updated component model is nearly ready to be integrated at the next higher level of assembly about every month or two. With each subsystem model delivery, the observatory model needs to remove the old component, integrate the new one, execute the model, and inspect the results. Usually, this inspection focuses primarily on the newly integrated component. Recently, a Metric Tracking Spreadsheet was developed to help provide a “big picture” view of the entire observatory highlighting key parameters critical to mission performance. This spreadsheet helps track impacts on subsystems by updates of other subsystems that were not intuitively obvious. Metrics tracked include: absorbed environmental loading (to determine effectiveness of sunshield), temperatures of critical avionics, electrical dissipations, heater power predictions, stability of critical optics, parasitic heat leaks in cryogenic region, high level heat flows between elements, and model run time. Producing this data for the same operational configuration with each model update has helped produce a trail of data to evaluate the impact of model updates. While the metrics selected are specific for WFIRST, other large, complex observatories could be well served to establish their own metrics early in the project life cycle to track to quickly assess the impact of any subsystem on other subsystems or the overall system itself.

Thermal Desktop↗