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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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DOE OSTI2021

Modeling Nuclear Thermal Propulsion Startup Transients

A poster for the 2021 intern poster session. This poster details the RELAP-7/Griffin model developed for transient simulations to compare the effects of startup sequencing on the propellant efficiency, startup time, and maximum core temperature of a nuclear thermal propulsion (NTP) system. The sequencing parameters under consideration in this study are the ramping rates of both reactivity insertion and hydrogen propellant mass flow rate. Recommendations are made regarding startup sequencing based on the results produced by this model.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

FY2019 Materials Annual Progress Report

The Materials Technology Program supports the Vehicle Technologies Office’s (VTO’s) mission to help consumers and businesses reduce their transportation energy costs while meeting or exceeding vehicle performance expectations. The propulsion materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needed for a variety of high-efficiency powertrain types, sizes, fueling concepts, and combustion modes. The lightweight materials research portfolio enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast-iron and traditional steel components with lightweight materials such as advanced high-strength steels, magnesium (Mg) alloys, aluminum (Al) alloys, and fiber-reinforced polymer composites can directly reduce a vehicle’s fuel consumption. By 2025, Materials Technology research activities seek to enable a 25% weight reduction of the glider for light-duty (LD) vehicles including body, chassis, and interior as compared to a 2015 baseline at no more than a $5/lb-saved increase in cost.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

FY2020 Materials Annual Progress Report

The Materials Technology subprogram supports the Vehicle Technologies Office’s (VTO’s) mission to accelerate the deployment of clean energy technology toward achieving net-zero emissions in the transportation sector. The Propulsion Materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needed for a variety of high-efficiency powertrain types, sizes, fueling concepts, and combustion modes. The Lightweight Materials research portfolio enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast-iron (Fe) and traditional steel components with lightweight materials—such as advanced high-strength steels (AHSS), magnesium (Mg) alloys, aluminum (Al) alloys, and fiber-reinforced polymer composites—can directly reduce a vehicle’s fuel consumption. By 2025, the Materials Technology research activities seek to enable a 25% weight reduction of the glider for light-duty (LD) vehicles including body, chassis, and interior as compared to a 2015 baseline at no more than a $5/lb-saved increase in cost.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRSDate not supplied

Development Of 12 Kw Hall Thrusters for Nasa Lunar Gateway Power And Propulsion Element

NASA is embarking on a new and exciting era of human exploration to the Moon and its vicinity. As part of the Artemis program, NASA is developing the lunar Gateway, an orbiting platform in Near Rectilinear Halo Orbit (NRHO) about the Moon. The first two elements of the Gateway will be launched in 2024 and will be transferred from a high Earth orbit to the NRHO via the use of Solar Electric Propulsion (SEP). The SEP system is located on the Power and Propulsion Element (PPE) which will provide up to 60 kW of power. Aerojet Rocketdyne is developing the 12 kW flight Hall thrusters to be used for transferring the PPE and the Habitat and Logistics Outpost (HALO) module to NRHO. Work is continuing on the development testing, and these results will be described in the paper. The project has also recently completed its critical design review and is transitioning to the fabrication of the three flight thrusters. The 12 kW Hall thrusters are being developed under the NASA Advanced Electric Propulsion System (AEPS) program. As part of the AEPS program, AR built two Engineering Test Unit (ETU) Hall thrusters based on the NASA HERMeS engine and conducted a series of tests to validate the design. One series of tests focused on environments and functional testing, while the other series was mainly focused on long duration test blocks. Results from these tests were used to compare with NASA data from the HERMeS thruster. The comparison of the test results showed no change to the critical performance and lifetime parameters, which enabled the next phase of the program to proceed. Currently testing is continuing on the Engineering Development Units (EDU) as part of the flight qualification activities. The successful completion of the CDR serves as the starting point for the flight thruster fabrication, which is now underway to support the launch of the Gateway modules in 2024. The development and qualification of the AEPS 12 kW Hall thrusters is proceeding well. As the program completes CDR and transitions into flight builds of the three 12 kW Hall thrusters that will be used to transfer the combined PPE and HALO stack to the NRHO, the results of the development testing are reviewed in this presentation, and a status of the program and future plans is provided. The launch of the two Gateway modules and the transfer of this large payload to cislunar orbit will mark a significant milestone in electric propulsion, as it will demonstrate the ability of SEP to transfer very large payloads over great distances. This establishes the precedent that could lead to cargo transfers from the Earth to the Moon or even to Mars using SEP.

Hall thrusters↗

DOE OSTI2015

Center for Space Nuclear Research (CSNR) NTP Design Team Report

The CSNR NTR Design Team has developed a history of collaboration with NASA Marshall Spaceflight Center (MSFC). First assembled in the summer of 2013 to explore the concept of the Low-Enriched Uranium Nuclear Thermal Rocket (LEU-NTR), the team continued research to find solutions with guiding Nuclear Thermal Propulsion (NTP) technological development and provide design and analysis support for the Space Capable Cryogenic Thermal Engine (SCCTE) Project. The work presented in this report provides a background on the cermet LEU-NTR, summarizes work complete to explore a new design space for NTRs, and describes the SCCTE core that was developed.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Feasibility Study of Replacing the R/V Robert Gordon Sproul with a Hybrid Vessel Employing Zero-emission Propulsion Technology

This project is a natural "follow-on" to the 2017 MARAD-funded project establishing the technical, regulatory, and economic feasibilities of a zero-emission hydrogen fuel-cell coastal research vessel named the Zero-V. In this follow-on project, we examine the applicability of hydrogen fuel-cell propulsion technology for a different kind of vessel, namely a smaller coastal/local research vessel targeted as a replacement for the Scripps Institution of Oceanography (SIO) R/V Robert Gordon Sproul, which is approaching the end of its service life.

08 HYDROGEN↗

NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

DOE OSTI2020

Design and out-of-pile testing of a novel irradiation experiment vehicle to support qualification of nuclear thermal propulsion components

Fission power systems have demonstrated higher thermal energy density per unit mass than chemical systems. High mass specific energy density offers advantages in space thermal propulsion applications. In the 1960s, nuclear thermal propulsion (NTP) development included the ROVER/NERVA program, in which full-scale prototype reactors were tested on the ground using hydrogen as the reactor coolant and propellant. NTP systems are being revisited, with expectations of improved performance resulting from improved fuel materials, allowing propellant temperatures near 2,800 K and over 20 thermal propulsion cycles. An apparatus has been developed to test NTP fuel materials in a research reactor at temperature and in a radiation environment typical of the NTP application. Here, this paper presents the design constraints, preliminary scoping thermal analysis, and basic thermal qualification testing for the out-of-pile experiment set apparatus, or OUTSET.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1980

Model aerodynamic test results for two variable cycle engine coannular exhaust systems at simulated takeoff and cruise conditions

Wind tunnel tests were conducted to evaluate the aerodynamic performance of a coannular exhaust nozzle for a proposed variable stream control supersonic propulsion system. Tests were conducted with two simulated configurations differing primarily in the fan duct flowpaths: a short flap mechanism for fan stream control with an isentropic contoured flow splitter, and an iris fan nozzle with a conical flow splitter. Both designs feature a translating primary plug and an auxiliary inlet ejector. Tests were conducted at takeoff and simulated cruise conditions. Data were acquired at Mach numbers of 0, 0.36, 0.9, and 2.0 for a wide range of nozzle operating conditions. At simulated supersonic cruise, both configurations demonstrated good performance, comparable to levels assumed in earlier advanced supersonic propulsion studies. However, at subsonic cruise, both configurations exhibited performance that was 6 to 7.5 percent less than the study assumptions. At take off conditions, the iris configuration performance approached the assumed levels, while the short flap design was 4 to 6 percent less.

Nelson, D. P.↗

DOE OSTI2024

Self-Propulsion by Directed Explosive Emulsification

An active droplet system, programmed to repeatedly move autonomously at a specific velocity in a well-defined direction, is demonstrated. Coulombic energy is stored in oversaturated interfacial assemblies of charged nanoparticle-surfactants by an applied DC electric field and can be released on demand. Spontaneous emulsification is suppressed by an increase in the stiffness of the oversaturated assemblies. Rapidly removing the field releases the stored energy in an explosive event that propels the droplet, where thousands of charged microdroplets are ballistically ejected from the surface of the parent droplet. The ejection is made directional by a symmetry breaking of the interfacial assembly, and the combined interaction force of the microdroplet plume on one side of the droplet propels the droplet distances tens of times its size, making the droplet active. The propulsion is autonomous, repeatable, and agnostic to the chemical composition of the nanoparticles. The symmetry-breaking in the nanoparticle assembly controls the microdroplet velocity and direction of propulsion. Finally, this mechanism of droplet propulsion will advance soft micro-robotics, establishes a new type of active matter, and introduces new vehicles for compartmentalized delivery.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Sunbeam: Near-sun statites as beam platforms for beam-driven rockets

Here, we outline a method of beamed power for propulsion that utilizes relativistic electron beams. The physics of charged particle beam propagation in the space plasma environment is discussed and the long-range (> 100 AU) advantage of relativistic electron beams is emphasized. A preliminary statite-based beam emitter for powering probes to 0.1c is proposed and the challenges in beamed-power uses are explored.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Detailed chemistry modeling of rotating detonations with dilute n -heptane sprays and preheated air

Utilization of liquid fuels is crucial to enabling commercialization of rotating detonation engines (RDE) in the near future. In this study, Eulerian-Lagrangian simulations are conducted for rotating detonative combustion with dilute n-heptane sprays and preheated air. Two-dimensional flattened configuration is used and a skeletal chemical mechanism with 44 species and 112 elementary reactions for n-heptane combustion is adopted. The flow structure, droplet distribution, and thermochemical parameters in the refill zone are first analyzed. It is shown that the mixture in the refill zone is heterogeneous, including evaporating droplets, vapor, and air. When the total temperature is below 950 K, the average equivalence ratio increases with the total temperature. When it is higher than 950 K, the average equivalence ratio is almost constant. Subsequently, the chemical explosive mode analysis is applied to identify the controlling reactions and dominant combustion modes in the fuel refill zone and reaction fronts. Results demonstrate that the initiation reaction (R104: n-C 7 H 16 + O 2 2-C 7 H 15 + HO 2 ) and low-temperature reaction (R107: RO 2 R'O 2 H) are dominant in the upstream and downstream of the refill zone, respectively. The intermediate species from low-temperature chemistry, R'O 2 H, is found to be important for the chemical explosive mode in the undetonated mixture. The influence of species diffusion and dispersed droplets is further analyzed. Results show that vapor autoignition facilitated by droplet evaporation occurs in the refill zone. Finally, the effects of the air total temperature on the detonation propagation speed and RDE propulsion performance are investigated. Further, it is found that the detonation propagation speed and specific impulse increase with air total temperature. The total pressure ratio first increases and then decreases as the air total temperature increases. Moreover, when the total temperature of the preheated air is above 1,300 K, the effects of low-temperature chemistry are negligible.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Materials (FY 2022 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2022. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Hybrid Temperature-Reactivity PID Controllers for Nuclear Thermal Propulsion Startup

In this work, a novel temperature-reactivity controller is introduced to rotate control drums based on a chamber temperature signal. It consists of two components: (1) a reactivity-driven proportional controller converting the temperature demand into a reactivity signal, and (2) a temperature-driven proportional-derivative controller which relies on a derivative term to anticipate sudden changes in demand and limit temperature overshoot. A weighting function is proposed to continuously transition from one component to the other.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Hybrid Temperature-Reactivity PID Controllers for Nuclear Thermal Propulsion Startup

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

NASA CERCER Development TDM Presentation

In NASA's Space Nuclear Propulsion program there is a development effort of for a composite fuel containing zirconium carbide (ZrC) and uranium mononitride (UN), this fuel form is referred to as a CERCER (ceramic-ceramic). These series of slides were put together to showcase the primary achievements in our research over the past year to our program sponsors. This is a yearly meeting to evaluate progress.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Materials (FR 2023 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2023. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗