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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 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Orion Exploration Flight Test Post-Flight Inspection and Analysis

The multipurpose crew vehicle, Orion, is being designed and built for NASA to handle the rigors of crew launch, sustainment and return from scientific missions beyond Earth orbit. In this role, the Orion vehicle is meant to operate in the space environments like the naturally occurring meteoroid and the artificial orbital debris environments (MMOD) with successful atmospheric reentry at the conclusion of the flight. As a result, Orion's reentry module uses durable porous, ceramic tiles on almost thirty square meters of exposed surfaces to accomplish both of these functions. These durable, non-ablative surfaces maintain their surface profile through atmospheric reentry; thus, they preserve any surface imperfections that occur prior to atmospheric reentry. Furthermore, Orion's launch abort system includes a shroud that protects the thermal protection system while awaiting launch and during ascent. The combination of these design features and a careful pre-flight inspection to identify any manufacturing imperfections results in a high confidence that damage to the thermal protection system identified post-flight is due to the in-flight solid particle environments. These favorable design features of Orion along with the unique flight profile of the first exploration flight test of Orion (EFT-1) have yielded solid particle environment measurements that have never been obtained before this flight.

Miller, J. E.↗
NASA NTRS1999

High Reynolds Number Hybrid Laminar Flow Control (HLFC) Flight Experiment: Suction System Design and Manufacture - Report 4

This document describes the design of the leading edge suction system for flight demonstration of hybrid laminar flow control on the Boeing 757 airplane. The exterior pressures on the wing surface and the required suction quantity and distribution were determined in previous work. A system consisting of porous skin, sub-surface spanwise passages ("flutes"), pressure regulating screens and valves, collection fittings, ducts and a turbocompressor was defined to provide the required suction flow. Provisions were also made for flexible control of suction distribution and quantity for HLFC research purposes. Analysis methods for determining pressure drops and flow for transpiration heating for thermal anti-icing are defined. The control scheme used to observe and modulate suction distribution in flight is described.

Source record↗
DOE OSTI2016

Advanced Drying Process for Lower Manufacturing Cost of Electrodes

For this Vehicle Technologies Incubator/Energy Storage R&D topic, Lambda Technologies teamed with Navitas Systems and proposed a new advanced drying process that promised a 5X reduction in electrode drying time and significant reduction in the cost of large format lithium batteries used in PEV's. The operating principle of the proposed process was to use penetrating radiant energy source Variable Frequency Microwaves (VFM), that are selectively absorbed by the polar water or solvent molecules instantly in the entire volume of the electrode. The solvent molecules are thus driven out of the electrode thickness making the process more efficient and much faster than convective drying method. To evaluate the Advanced Drying Process (ADP) a hybrid prototype system utilizing VFM and hot air flow was designed and fabricated. While VFM drives the solvent out of the electrode thickness, the hot air flow exhausts the solvent vapors out of the chamber. The drying results from this prototype were very encouraging. For water based anodes there is a 5X drying advantage (time & length of oven) in using ADP over standard drying system and for the NMP based cathodes the reduction in drying time has 3X benefit. For energy savings the power consumption measurements were performed to ADP prototype and compared with the convection standard drying oven. The data collected demonstrated over 40% saving in power consumption with ADP as compared to the convection drying systems. The energy savings are one of the operational cost benefits possible with ADP. To further speed up the drying process, the ADP prototype was explored as a booster module before the convection oven and for the electrode material being evaluated it was possible to increase the drying speed by a factor of 4, which could not be accomplished with the standard dryer without surface defects and cracks. The instantaneous penetration of microwave in the entire slurry thickness showed a major advantage in rapid drying of the electrode materials. For the existing electrode materials, the material analysis and cell characterization data from ADP dried electrodes showed equivalent (or slightly better) performance. However, for high loading and thicker electrode materials (for high energy densities) the ADP advantages are more prominent. There was less binder migration, the resistance was lower hence the current capacities and retention of the battery cells were higher. The success of the project has enabled credible communications with commercial end users as well as battery coating line integrators. Goal is to scale ADP up for high volume manufacturing of Li-ion battery electrodes. The implementation of ADP in high volume manufacturing will reduce a high cost production step to bring the overall price of Li-ion batteries down. This will ultimately have a positive impact on the public by making electric and hybrid vehicles more affordable.

25 ENERGY STORAGE↗
NASA NTRS1998

Teaching Engineering Students Team Work

The purpose of this manual is to provide professor's in engineering classes which the background necessary to use student team projects effectively. This manual describes some of the characteristics of student teams and how to use them in class. It provides a set of class activities and films which can be used to introduce and support student teams. Finally, a set of teaching modules used in freshmen, sophomore, and senior aeronautical engineering classes are presented. This manual was developed as part of a NASA sponsored project to improve the undergraduate education of aeronautical engineers. The project has helped to purchase a set of team work films which can be checked out from Cal Poly's Learning Resources Center in the Kennedy Library. Research for this project has included literature reviews on team work and cooperative learning; interviews, observations, and surveys of Cal Poly students from Industrial and Manufacturing Engineering, Aeronautical Engineering and Psychology; participation in the Aeronautical Engineering senior design lab; and interviews with engineering faculty. In addition to this faculty manual, there is a student team work manual which has been designed to help engineering students work better in teams.

Levi, Daniel↗
NASA NTRS1989

Advanced Fuel-Cell Modules

Modules designed for long life, light weight, reliability, and low cost. Stack of alkaline fuel cells based on modules, consisting of three fuel cells and cooler. Each cell includes following components: ribbed carbon fine-pore anode electrolyte-reservoir plate; platinum-on-carbon catalyst anode; potassium titanate matrix bonded with butyl rubber; gold-plated nickel-foil electrode substrates; and silver plated, gold-flashed molded polyphenylene sulfide cell holder. Each cell has active area of 1ft to the 2nd power (0.09 m to the 2nd power). Materials and configurations of parts chosen to extend life expectancy, reduce weight and manufacturing cost, and increase reliability.

Bell, William F., III↗
NASA NTRS1991

The status of lightweight photovoltaic space array technology based on amorphous silicon solar cells

Ultralight, flexible photovoltaic (PV) array of amorphous silicon (a-Si) was identified as a potential low cost power source for small satellites. A survey was conducted of the status of the a-Si PV array technology with respect to present and future performance, availability, cost, and risks. For existing, experimental array blankets made of commercial cell material, utilizing metal foil substrates, the Beginning of Life (BOL) performance at Air Mass Zero (AM0) and 35 C includes total power up to 200 W, power per area of 64 W/sq m and power per weight of 258 W/kg. Doubling of power per weight occurs when polyimide substrates are used. Estimated End of Life (EOL) power output after 10 years in a nominal low earth orbit would be 80 pct. of BOL, the degradation being due to largely light induced effects (-10 to -15 pct.) and in part (-5 pct.) to space radiation. Predictions for the year 1995 for flexible PV arrays, made on the basis of published results for rigid a-Si modules, indicate EOL power output per area and per weight of 105 W/sq m and 400 W/kg, respectively, while predictions for the late 1990s based on existing U.S. national PV program goals indicate EOL values of 157 W/sq m and 600 W/kg. Cost estimates by vendors for 200 W ultralight arrays in volume of over 1000 units range from $100/watt to $125/watt. Identified risks include the lack of flexible, space compatible encapsulant, the lack of space qualification effort, recent partial or full acquisitions of US manufacturers of a-Si cells by foreign firms, and the absence of a national commitment for a long range development program toward developing of this important power source for space.

Hanak, Joseph J.↗
DOE OSTI2018

New Developments and Applications of Superheated Emulsions: Warhead Verification and Special Nuclear Material Interdiction

In recent years, neutron detection with superheated emulsions has received renewed attention thanks to improved detector manufacturing and read-out techniques, and thanks to successful applications in warhead verification and special nuclear material (SNM) interdiction. Detectors are currently manufactured with methods allowing high uniformity of the drop sizes, which in turn allows the use of optical read-out techniques based on dynamic light scattering. Furthermore, small detector cartridges arranged in 2D matrices are developed for the verification of a declared warhead without revealing its design. For this application, the enabling features of the emulsions are that bubbles formed at different times cannot be distinguished from each other, while the passive nature of the detectors avoids the susceptibility to electronic snooping and tampering. Large modules of emulsions are developed to detect the presence of shielded special nuclear materials hidden in cargo containers ‘interrogated’ with high energy X-rays. In this case, the enabling features of the emulsions are photon discrimination, a neutron detection threshold close to 3 MeV and a rate-insensitive read-out.

d’Errico, Francesco↗
DOE OSTI2025

PV Reference Cells for Outdoor Use: Stability Over Four Years of Deployment

Photovoltaic (PV) reference cells are frequently used to evaluate the performance of PV power plants. They provide a measure of irradiance that strongly correlates with the electrical output of PV modules, which makes them very useful for detecting short-term anomalies or long-term degradation in PV power plant output. One very important quality is long-term stability. This report presents observations about the stability of a set of 22 commercial reference cells that have been in continuous operation for a period of four years at the Solar Radiation Research Laboratory (SRRL) site at the National Renewable Energy Laboratory (NREL). The 22 reference cells at the SRRL represent 10 different models from 6 manufacturers.

14 SOLAR ENERGY↗
NASA NTRS2017

Effects of Contamination and Cleaning on Parachute Structural Textile Elements

Throughout their lifecycle, parachute textiles come into contact with various other substances. This contact may occur during manufacturing and repair, storage and transportation, packing, or actual use. While this interaction does not always result in negative repercussions, it may cause a loss in material strength. This paper examines the strength degradation due to several contaminants as well as the effects of cleaning agents on common parachute materials. Materials tested were: Kevlar cord and webbing, Nylon broadcloth and webbing, and Vectran cord; all of these constitute the major structural elements for CPAS (Capsule Parachute Assembly System), the parachute system for the NASA Orion Crew Module. Contaminants tested were: sewing machine oil, dried stamping ink, dirt, basting glue, Sergene, and rust. Recommendations for cleaning (or not cleaning) these materials with respect to each of the contaminants are given in this paper, as well as recommendations for future tests.

Mollmann, Catherine↗
DOE OSTI2026

MODEL DEVELOPMENT AND VERIFICATION OF A 1,350°C AIR RECEIVER TEST SYSTEM

Open-loop volumetric receivers work with air at atmospheric pressure and are suitable for single-cycle or multicycle power plants. A novel additively manufactured (AM) silicon carbide (SiC), ceramic matrix composite (CMC) volumetric receiver was developed that consisted of a lattice structure, which absorbs solar radiation and converts it into heat energy. Heat energy from the porous receiver was transferred to heated ambient air. The receiver acted as a convective heat exchanger, transferring heat to the fluid through convection. Engineering was facilitated to develop a high-temperature air receiver test bed at Sandia national Laboratories (SNL) capable of demonstrating a 50kWth open-loop volumetric SiC air receiver module developed by General Electric Aerospace Research (GE Aerospace). This paper presents the development of the high temperature AM SiC-CMC air receiver, the test bed, and the first testing operations of this device, which was experimentally demonstrated to achieve 1,350°C for over 3.5 hours of operation, based on input flux levels of 67–91 W/cm2 0.5-2.5 kg/s flow rates. From the test campaign results, based on the measured convective heat transfer to the airflow and bounded radiative-loss assumptions, the solar-thermal efficiency of HOTSSTAR test module was estimated to be approximately as high as 74% for representative test conditions.

14 SOLAR ENERGY↗
DOE OSTI2018

Highly Sensitive Bulk Silicon Chemical Sensors with Sub-5 nm Thin Charge Inversion Layers

There is an increasing demand for mass-producible, low-power gas sensors in a wide variety of industrial and consumer applications. In this work, we report chemical-sensitive field-effect-transistors (CS-FETs) based on bulk silicon wafers, wherein an electrostatically confined sub-5 nm thin charge inversion layer is modulated by chemical exposure to achieve a high-sensitivity gas-sensing platform. Using hydrogen sensing as a "litmus" test, we demonstrate large sensor responses (>1000%) to 0.5% H 2 gas, with fast response (<60 s) and recovery times (<120 s) at room temperature and low power (<50 μW). On the basis of these performance metrics as well as standardized benchmarking, we show that bulk silicon CS-FETs offer similar or better sensing performance compared to emerging nanostructures semiconductors while providing a highly scalable and manufacturable platform.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Structure and enhanced thermochromic performance of low-temperature fabricated VO 2 /V 2 O 3 thin film

For VO 2 -based smart window manufacture, it is a long-standing demand for high-quality thin films deposited at low temperature. In this paper, the thermochromic films of VO 2 were deposited by a magnetron sputtering method at a fairly low temperature of 250 °C without subsequent annealing by embedding a V 2 O 3 interlayer. V 2 O 3 acts as a seed layer to lower the depositing temperature and buffer layer to epitaxial grow VO 2 film. The VO 2 /V 2 O 3 films display high solar modulating ability and narrow hysteresis loop. Finally, our data can serve as a promising point for industrial production with high degree of crystallinity at a low temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Performance of Different Water-Based Binder Formulations for Ni-Rich Cathodes Evaluated in LiNi 0.8 Mn 0.1 Co 0.1 O 2 //Graphite Pouch Cells

Water-based processing for lithium-ion battery electrodes is attractive due to its lower manufacturing cost and smaller environmental impact. However, multiple challenges associated with aqueous cathode processing have hindered commercial adoption. Polymer binders are an important component of the electrode, and thus the choice of binders can alter electrode cycling performance significantly. In this work, four different water-based binder combinations are investigated for Ni-rich LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811)-based cathodes, with a focus on the long-term electrochemical performance in practical-format full pouch cells. No additional pH-modulating additives were added to the aqueous cathode slurries, and no protective coatings were present on the cathode or aluminum current collector. Results are compared with the standard PVDF/NMP-based binder/solvent combination, used as a baseline. The influence of water-based binder type on slurry rheology and electrode microstructure are also discussed. All cells made by water-processing had worse rate performance compared to the baseline. However, the cell discharge capacity after 1000 U.S. Advanced Battery Consortium (USABC) cycles at C/3 charge/discharge rate was comparable to the baseline for two of the water-based cathode formulations (CMC & JSR, and LiPAA), demonstrating the potential viability of aqueous-processed Ni-rich cathodes at a commercial scale.

25 ENERGY STORAGE↗
NASA NTRS2009

Thermal Test Verification of Emission Control through Directional Baffles for the James Webb Space Telescope

The thermal performance of NASA s planned James Webb Space Telescope is highly reliant on a collection of directional baffles that are part of the Integrated Science Instrument Module Electronics Compartment. In order to verify the performance of the baffle concept, two test assemblies were recently fabricated and tested at the Goddard Space Flight Center. The centerpiece of the testing was a fixture that used bolometers to measure the emission field through the baffles while the radiator panels and baffles ran a flight-like temperature. Although not all test goals were able to be met due to facility malfunctions, the test was able to prove the design viability enough to gain approval to begin manufacturing the flight article.

Garrison, Matthew↗
NASA NTRSDate not supplied

Towards Gbps Downlinks from Low-Cost Active Phased Arrays

Spacecraft performing science missions use high-directivity antennas to quickly downlink large amounts of collected data. Movement required to keep gimbaled reflector antennas trained on target receivers can impart blockages or vibrations which perturb precision science instruments. Recent manufacturing advances have made Ka-band electronically-steered antenna arrays a cost-effective option to mitigate these challenges, but only if these devices can be proven to deliver comparable quality of service. In this work we present a hardware and software architecture for high-rate links using an active phased array-based terminal in a 1U (10cm cube) form factor. Over-the-air tests in an antenna range characterize two key features of the architecture: high-order (32APSK and above) modulations and dual carriers. We calculate an optimal modulation-dependent input power backoff from array saturation and perform orbital simulations of the link at this operating point. We conclude that reliable links with rates in excess of 1Gbps are possible with current-generation hardware.

Adam Gannon↗
NASA NTRS1994

Technology Benefit Estimator (T/BEST): User's Manual

The Technology Benefit Estimator (T/BEST) system is a formal method to assess advanced technologies and quantify the benefit contributions for prioritization. T/BEST may be used to provide guidelines to identify and prioritize high payoff research areas, help manage research and limited resources, show the link between advanced concepts and the bottom line, i.e., accrued benefit and value, and to communicate credibly the benefits of research. The T/BEST software computer program is specifically designed to estimating benefits, and benefit sensitivities, of introducing new technologies into existing propulsion systems. Key engine cycle, structural, fluid, mission and cost analysis modules are used to provide a framework for interfacing with advanced technologies. An open-ended, modular approach is used to allow for modification and addition of both key and advanced technology modules. T/BEST has a hierarchical framework that yields varying levels of benefit estimation accuracy that are dependent on the degree of input detail available. This hierarchical feature permits rapid estimation of technology benefits even when the technology is at the conceptual stage. As knowledge of the technology details increases the accuracy of the benefit analysis increases. Included in T/BEST's framework are correlations developed from a statistical data base that is relied upon if there is insufficient information given in a particular area, e.g., fuel capacity or aircraft landing weight. Statistical predictions are not required if these data are specified in the mission requirements. The engine cycle, structural fluid, cost, noise, and emissions analyses interact with the default or user material and component libraries to yield estimates of specific global benefits: range, speed, thrust, capacity, component life, noise, emissions, specific fuel consumption, component and engine weights, pre-certification test, mission performance engine cost, direct operating cost, life cycle cost, manufacturing cost, development cost, risk, and development time. Currently, T/BEST operates on stand-alone or networked workstations, and uses a UNIX shell or script to control the operation of interfaced FORTRAN based analyses. T/BEST's interface structure works equally well with non-FORTRAN or mixed software analysis. This interface structure is designed to maintain the integrity of the expert's analyses by interfacing with expert's existing input and output files. Parameter input and output data (e.g., number of blades, hub diameters, etc.) are passed via T/BEST's neutral file, while copious data (e.g., finite element models, profiles, etc.) are passed via file pointers that point to the expert's analyses output files. In order to make the communications between the T/BEST's neutral file and attached analyses codes simple, only two software commands, PUT and GET, are required. This simplicity permits easy access to all input and output variables contained within the neutral file. Both public domain and proprietary analyses codes may be attached with a minimal amount of effort, while maintaining full data and analysis integrity, and security. T/BESt's sotware framework, status, beginner-to-expert operation, interface architecture, analysis module addition, and key analysis modules are discussed. Representative examples of T/BEST benefit analyses are shown.

Generazio, Edward R.↗
DOE OSTI2022

3.5 kW/in3 Planar Coupled Inductor Design and Optimization for a 50 kW 3-level Four-Switch Buck-Boost (3L-FSBB) Converter

Planar magnetics design has been widely used in power electronics field because of the low profile, ease of manufacturability, and high power density. This paper first proposes a 3-level four-switch buck-boost (3L-FSBB) converter for the dc-dc applications where the zero common-mode (CM) voltage emissions, step-up and step-down are all required. With the consideration of power density, efficiency, and cost, a 15oz heavy copper coupled inductor for 3-level FSBB converter was designed and optimized with the low-cost commercial core and planar windings. According to the soft-switching quadrangle modulation for 3-L FSBB, the turns number and stacked core number are optimized first. And then, a two-board design is proposed to reduce the fringing effect and improve the thermal performance. Finally, a 75 kVA two-stage ac-dc-dc converter including a 3-level FSBB converter was built to verify the electrical design.

Cao, Yuliang↗
DOE OSTI2013

Development of Production PVD-AIN Buffer Layer System and Processes to Reduce Epitaxy Costs and Increase LED Efficiency (Final Scientific/Technical Report)

The DOE has set aggressive goals for solid state lighting (SSL) adoption, which require manufacturing and quality improvements for virtually all process steps leading to an LED luminaire product. The goals pertinent to this proposed project are to reduce the cost and improve the quality of the epitaxial growth processes used to build LED structures. The objectives outlined in this proposal focus on achieving cost reduction and performance improvements over state-of-the-art, using technologies that are low in cost and amenable to high efficiency manufacturing. The objectives of the outlined proposal focus on cost reductions in epitaxial growth by reducing epitaxy layer thickness and hetero-epitaxial strain, and by enabling the use of larger, less expensive silicon substrates and would be accomplished through the introduction of a high productivity reactive sputtering system and an effective sputtered aluminum-nitride (AlN) buffer/nucleation layer process. Success of the proposed project could enable efficient adoption of GaN on-silicon (GaN/Si) epitaxial technology on 150mm silicon substrates. The reduction in epitaxy cost per cm 2 using 150mm GaN-on-Si technology derives from (1) a reduction in cost of ownership and increase in throughput for the buffer deposition process via the elimination of MOCVD buffer layers and other throughput and CoO enhancements, (2) improvement in brightness through reductions in defect density, (3) reduction in substrate cost through the replacement of sapphire with silicon, and (4) reduction in non-ESD yield loss through reductions in wafer bow and temperature variation. The adoption of 150mm GaN/Si processing will also facilitate significant cost reductions in subsequent wafer fabrication manufacturing costs. There were three phases to this project. These three phases overlap in order to aggressively facilitate a commercially available production GaN/Si capability. In Phase I of the project, the repeatability of the performance was analyzed and improvements implemented to the Veeco PVD-AlN prototype system to establish a specification and baseline PVD-AlN films on sapphire and in parallel the evaluation of PVD AlN on silicon substrates began. In Phase II of the project a Beta tool based on a scaled-up process module capable of depositing uniform films on batches of 4” or 6” diameter substrates in a production worthy operation was developed and qualified. In Phase III, the means to increase the throughput of the PVD-AlN sy0stem was evaluated and focused primarily on minimizing the impact of the substrate heating and cooling times that dominated the overall cycle time.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗