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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1981

The small community solar thermal power experiment. Parabolic dish technology for industrial process heat application

Aspects of incorporating a thermal energy transport system (ETS) into a field of parabolic dish collectors for industrial process heat (IPH) applications were investigated. Specific objectives are to: (1) verify the mathematical optimization of pipe diameters and insulation thicknesses calculated by a computer code; (2) verify the cost model for pipe network costs using conventional pipe network construction; (3) develop a design and the associated production costs for incorporating risers and downcomers on a low cost concentrator (LCC); (4) investigate the cost reduction of using unconventional pipe construction technology. The pipe network design and costs for a particular IPH application, specifically solar thermally enhanced oil recovery (STEOR) are analyzed. The application involves the hybrid operation of a solar powered steam generator in conjunction with a steam generator using fossil fuels to generate STEOR steam for wells. It is concluded that the STEOR application provides a baseline pipe network geometry used for optimization studies of pipe diameter and insulation thickness, and for development of comparative cost data, and operating parameters for the design of riser/downcomer modifications to the low cost concentrator.

Polzien, R. E.↗
NASA NTRS2011

From Paper to Production to Test: An Update on NASA's J-2X Engine for Exploration

The NASA/industry team responsible for developing the J-2X upper stage engine for the Space Launch System (SLS) Program has made significant progress toward moving beyond the design phase and into production, assembly, and test of development hardware. The J-2X engine exemplifies the SLS Program goal of using proven technology and experience from more than 50 years of United States spaceflight experience combined with modern manufacturing processes and approaches. It will power the second stage of the fully evolved SLS Program launch vehicle that will enable a return to human exploration of space beyond low earth orbit. Pratt & Whitney Rocketdyne (PWR) is under contract to develop and produce the engine, leveraging its flight-proven LH2/LOX, gas generator cycle J-2 and RS-68 engine capabilities, recent experience with the X-33 aerospike XRS-2200 engine, and development knowledge of the J-2S tap-off cycle engine. The J- 2X employs a gas generator operating cycle designed to produce 294,000 pounds of vacuum thrust in primary operating mode with its full nozzle extension. With a truncated nozzle extension suitable to support engine clustering on the stage, the nominal vacuum thrust level in primary mode is 285,000 pounds. It also has a secondary mode, during which it operates at 80 percent thrust by altering its mixture ratio. The J-2X development philosophy is based on proven hardware, an aggressive development schedule, and early risk reduction. NASA Marshall Space Flight Center (MSFC) and PWR began development of the J-2X in June 2006. The government/industry team of more than 600 people within NASA and PWR successfully completed the Critical Design Review (CDR) in November 2008, following extensive risk mitigation testing. Assembly of the first development engine was completed in May 2011 and the first engine test was conducted at the NASA Stennis Space Center (SSC), test stand A2, on 14 July 2011. Testing of the first development engine will continue through the autumn of 2011, be paused for test stand modifications to the passive diffuser, and then restart in the spring of 2012. This testing will be followed by specialized powerpack testing intended to examine the design and operating margins of the engine turbomachinery. The development plan beyond this point leads through more system-level, engine testing of several samples, analytical model validation activities, functional and performance verification, and then ultimate certification to support human spaceflight. This paper will discuss the J-2X development background, provide top-level information on design and development planning, and will explore some of the development challenges and mitigation activities pursued to date.

Kynard, Michael↗
DOE OSTI2025

Porous transport electrodes for oxygen evolution reaction in proton exchange membrane water electrolysis -cells: Materials, designs, and diagnoses

H 2 production using proton exchange membrane (PEM) water electrolysis (PEMWE) cells has received considerable attention because of the high efficiencies of these cells and no harmful emissions from the related process. In PEMWE cells, porous transport electrodes (PTEs) composed of a catalyst layer (CL) comprising O 2 evolution reaction (OER) catalysts, porous transport layer (PTL), and PEM play key roles in the stack performance and lifetime. Herein, Ir-based and non-precious-metal OER catalysts that are highly active and stable at low pH values and high anodic potentials are reviewed to understand their OER mechanisms. Various strategies are proposed for engineering CLs and PTLs to improve the interfacial properties and mass transfers of reactants and products to and from the active sites. Additionally, diagnoses of PTEs is significantly crucial for interpreting electrochemical processes and addressing their current challenges. Therefore, half-cell analyses, including diffusion electrode (DE), floating electrode (FE), and modified rotating disk electrode (MRDE) techniques, are explored, and membrane electrode assembly (MEA)-based analyses, such as the polarization technique, electrochemical impedance spectroscopy, and magnetic field analysis, are established. In conclusion, this study aims to provide an overview of recent technologies used for the engineering and diagnostic tools of PEMWE cells and insights into the advanced components and systems to be developed in this field.

Diagnosis of PEMWE Cells↗
DOE OSTI2021

Sorting for secreted molecule production using a biosensor-in-microdroplet approach

Significance The design–build–test cycle of metabolic engineering is swiftly becoming test limited owing to advances in DNA synthesis and library design. At the same time, improving extracellular production requires high-throughput studies to detect extracellular (not intracellular) content. Traditional approaches that utilize chromatography-based analysis or plate-based fluorescence assays are relatively throughput limited and require a high degree of liquid handling. These limitations are avoided here by creating a generalizable approach for small molecule production screening. Namely, this paradigm combines “off-the-shelf” biosensors with large library screening from producing cells in a cell-type agnostic manner.

Bowman, Emily K.↗
DOE OSTI2020

Multimodal Instrument Platform for High-Pressure MAS-NMR and IR Spectroscopic Interrogation

This project developed and tested a high-pressure (HP) flow-through instrument platform that combines HP- magic angle spinning nuclear magnetic resonance (MAS-NMR) spectroscopy for interrogating reactivity at interfaces between solid materials and HP fluids with HP- infrared (IR) spectroscopy for measuring fluid composition. Solid-fluid interfacial reactivity is usually dependent on concentrations of species within the fluid; thus, knowledge of the fluid composition measured by IR is critical to understanding solid-fluid interfacial reactivity probed by NMR. This new system adds to PNNL’s core capabilities in Chemical and Material Sciences to support fundamental programs in catalysis, interfacial molecular science, and geosciences, as well as in Earth and Biological Sciences to support energy production and storage, efforts to mitigate the impacts energy production systems, attenuation of contaminant plumes, and design of subsurface engineered systems for energy production and waste disposal.

36 MATERIALS SCIENCE↗
NASA NTRS2011

A Generalized Framework for Constrained Design Optimization of General Supersonic Configurations Using Adjoint Based Sensitivity Derivatives

The Aeronautics Research Mission Directorate (ARMD) sent out an NASA Research Announcement (NRA) for proposals soliciting research and technical development. The proposed research program was aimed at addressing the desired milestones and outcomes of ROA (ROA-2006) Subtopic A.4.1.1 Advanced Computational Methods. The second milestone, SUP.1.06.02 Robust, validated mesh adaptation and error quantification for near field Computational Fluid Dynamics (CFD), was addressed by the proposed research. Additional research utilizing the direct links to geometry through a CAD interface enabled by this work will allow for geometric constraints to be applied and address the final milestone, SUP2.07.06 Constrained low-drag supersonic aerodynamic design capability. The original product of the proposed research program was an integrated system of tools that can be used for the mesh mechanics required for rapid high fidelity analysis and for design of supersonic cruise vehicles. These Euler and Navier-Stokes volume grid manipulation tools were proposed to efficiently use parallel processing. The mesh adaptation provides a systematic approach for achieving demonstrated levels of accuracy in the solutions. NASA chose to fund only the mesh generation/adaptation portion of the proposal. So this report describes the completion of the proposed tasks for mesh creation, manipulation and adaptation as it pertains to sonic boom prediction of supersonic configurations.

Karman, Steve L., Jr.↗
NASA NTRSDate not supplied

Bionutrients: Microbial Production of on-Demand Nutrients on the International Space Station

Providing adequate nutrition to crew members is essential as deep-space missions cannot rely on consistent Earth-based resupply. The current NASA pre-packaged food system is designed for low-earth-orbit missions with a stated shelf-life of two years and notable vitamin degradation over time. One strategy to mitigate nutrient loss is to implement bioregenerative food sources to supplement the pre-packaged food system. The BioNutrients project is designed to provide targeted production of short shelf-life nutrients in a single-use production pack. BioNutrients-1 includes two strains of edible yeast that have been genetically engineered to produce carotenoids, β-carotene, and zeaxanthin. This five-year mission on the International Space Station (ISS), launched in 2019, tests the long-term storage and nutrient production of the microorganisms of interest. Additional microorganisms are also stored in stasis packs to determine the effects of long-duration storage on the ISS. These organisms may be useful for production of fermented foods, pharmaceuticals, or biomanufacturing processes. Improving on the BioNutrients-1 project, BioNutrients-2 has optimized the production pack hardware by reducing the overall mass and volume of the system. Furthermore, BioNutrients-2 has expanded the projects scope by investigating novel products and microbial food sources. BioNutrients-2 is a six-month mission, launched in 2022, which tests production of fresh foods such as yogurt and kefir. The BioNutrients missions seek to provide advances for in-space biomanufacturing by addressing safe and reliable production of high-value nutrients and on-demand foods for future exploration efforts.

BioNutrients↗
NASA NTRSDate not supplied

Bionutrients: Microbial Production of on-Demand Nutrients on the International Space Station

Providing adequate nutrition to crew members is essential as deep-space missions cannot rely on consistent Earth-based resupply. The current NASA pre-packaged food system is designed for low-earth-orbit missions with a stated shelf-life of two years and notable vitamin degradation over time. One strategy to mitigate nutrient loss is to implement bioregenerative food sources to supplement the pre-packaged food system. The BioNutrients project is designed to provide targeted production of short shelf-life nutrients in a single-use production pack. BioNutrients-1 includes two strains of edible yeast that have been genetically engineered to produce carotenoids, β-carotene, and zeaxanthin. This five-year mission on the International Space Station (ISS), launched in 2019, tests the long-term storage and nutrient production of the microorganisms of interest. Additional microorganisms are also stored in stasis packs to determine the effects of long-duration storage on the ISS. These organisms may be useful for production of fermented foods, pharmaceuticals, or biomanufacturing processes. Improving on the BioNutrients-1 project, BioNutrients-2 has optimized the production pack hardware by reducing the overall mass and volume of the system. Furthermore, BioNutrients-2 has expanded the projects scope by investigating novel products and microbial food sources. BioNutrients-2 is a six-month mission, launched in 2022, which tests production of fresh foods such as yogurt and kefir. The BioNutrients missions seek to provide advances for in-space biomanufacturing by addressing safe and reliable production of high-value nutrients and on-demand foods for future exploration efforts.

BioNutrients↗
NASA NTRS2010

From Paper to Production: An Update on NASA's Upper Stage Engine for Exploration

The NASA/industry team responsible for developing the J-2X Upper Stage Engine for the Constellation Program's Ares I and Ares V launch vehicles has made significant progress toward moving the design from paper to production during the past year. The J-2X exemplifies the Constellation goal of using proven technology and experience from more than 50 years of United States spaceflight experience and seeking where possible to employ common hardware in the Ares I crew launch vehicle and the Ares V cargo launch vehicle. The J-2X will power the Ares I upper stage to place the Orion crew vehicle in orbit. For the Ares V, the J-2X will place the Earth departure stage (EDS) and lunar lander in orbit and later re-start to send the Orion and lander to the Moon. Pratt & Whitney Rocketdyne (PWR) is under contract to develop and produce the engine, leveraging its flight-proven LH2/LOX, gas generator cycle J-2 and RS-68 engine capabilities, recent experience with the X-33 aerospike XRS-2200 engine, and development knowledge of the J-2S tap-off cycle engine. The J-2X employs a gas generator operating cycle designed to produce 294,000 pounds of thrust in primary operating mode for the Ares I and Ares V ascent phases. It also has a secondary mode, during which it operates at 80 percent thrust by altering its mixture ratio to perform the TLI burn for the Ares V lunar sortie and lunar cargo missions. The J-2X development philosophy is based on proven hardware, an aggressive development schedule, and early risk reduction. NASA Marshall Space Flight Center (MSFC) and PWR began development of the J-2X in June 2006. The government/industry team of more than 600 people within NASA and PWR successfully completed the Critical Design Review (CDR) in November 2008, following extensive risk mitigation testing. The team is working toward a first flight of the J-2X on the Orion 1 mission in 2014. This paper will discuss the J-2X development background and provide top-level information on design and testing to date. Details will be provided on overcoming challenges such as gas generator instability, turbine blade life, and nozzle extension selection and materials.

Kynard, Mike↗
DOE OSTI2023

Design, Manufacturing, Assembly, and Lessons Learned of the Pre-production 325 MHz Couplers for the PIP-II Project at Fermilab

Five 325 MHz high-power couplers will be integrated into the pre-production Single Spoke Resonator Type-II (ppSSR2) cryomodule for the PIP-II project at Fermilab. Couplers were procured by both Fermilab and IJCLAB for this effort. The design of the coupler is described, including design optimizations from the previous generation. This paper then describes the coupler life cycle, including design, manufacturing, and assembly, along with the lessons learned at each stage.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Model-based quantification of margins and uncertainties in metal additive manufacturing for process design and qualification

Laser powder bed fusion (LPBF) Additive Manufacturing (AM) has the potential to enable the production of components with novel designs and material properties unachievable otherwise. However, process repeatability is a challenge, making qualification ill-defined and greatly reducing the utility of what could be an important manufacturing technology. In this work, a combination of modeling, uncertainty quantification (UQ), and experimentation are used in an effort to predict and bound the range of possible outcomes of the LPBF process. Quantities of interest predicted are melt pool dimensions, microstructure features, and mechanical distortions. A combination of high fidelity thermal-fluid models, microstructure growth models, and reduced fidelity, rapid thermal and mechanical models are used. Uncertainty propagation techniques are used to predict probability distributions of quantities of interest from estimates of process uncertainties. Repeated experiments are done to quantify observed probability distributions and compared to predicted distributions to determine if predictions are precise and accurate. Novel modeling methods are microstrucutre characterization techniques are also discussed. It is found that high fidelity models do a generally good job bounding experimentally observed melt pool morphologies for both bead-on-plate and powder bed cases. Microstructure models are able to bound a number of experimentally observed microstructure statistics, but with low precision due to challenges with calibrating the microstructure growth model parameters. A developed modified inherent strain distortion model does not accurately predict observed distortions. A lumped laser distortion model shows promise in being both accurately and precisely bounding observed outcomes from the deflection comb build, but requires further evaluation on more builds and geometries.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Insights into Long-Term Global Precipitation from IMERG and GPCP

Multiple satellite-based datasets provide estimates of the long-term record of global precipitation. Each necessarily includes both the real atmospheric behavior and a collection of artifacts driven by the input data sources and design choices in the retrievals and dataset construction. For this presentation, the Integrated Multi-satellitE Retrievals for GPM (IMERG) products from the Global Precipitation Measurement (GPM) mission’s U.S. Science Team are designed as a modern High-Resolution Precipitation Product (HRPP), while the Global Precipitation Climatology Project’s (GPCP) products are designed as a modern Climate Data Record (CDR). Although they share some common input data sources, the computational process for each is rather different. Comparing the precipitation estimates from each algorithm gives us insights into likely artifacts and the natural variations that are common to both. The goal of an HRPP is to give the best estimate of precipitation at each time step in the dataset, generally meaning that “all possible available” data are used. In contrast, the CDR is intended to provide a precipitation record that has relatively homogeneous statistics, necessary for climate analysis. Each analysis strives for both goals, of course, but this means that the HRPP uses the disparate collection of satellites whose statistics don’t quite match the ideal record, while the CDR is computed from fewer satellites that provide a relatively homogeneous set of precipitation statistics. This presentation employs the current versions of the IMERG and GPCP products, V07B and V3.2, respectively. A variety of analyses have demonstrated that IMERG has more artifacts, as expected, which tend to result from changes in the source of intercalibration for the various input satellites, namely the Combined Radar-Radiometer Algorithm using TMI and PR during the TRMM era and using GMI and DPR-Ku during the GPM era. As well, a shift occurs when the altitudes of the TRMM and GPM satellites change as a result of orbit boosts. For the most part the mean precipitation shows good continuity across these boundaries, but there are noticeable changes in the respective histograms. The latter has taken on more importance in recent years due to increased scrutiny on extremes which implicitly focus on the upper end of the precipitation histograms. The GPCP product is more homogeneous, with only one major change in calibrator, transitioning from the SSMI series of satellites to the SSMIS series of satellites in 2009. The GPCP analysis does a good job of minimizing artifacts in the means at this boundary, while the histograms show a smaller, but still noticeable shift in the histograms, a result that is similar to data boundaries in IMERG. The GPCP Daily, which is a month-by-month rescaling of the daily accumulated IMERG Final product, shows more consistency than the equivalent daily IMERG, but inherits the histogram shifts from IMERG. Given this overlay of artifacts, there is enough consistency between the products to illustrate some important long-term variations, including interannual variations, not all of which are easily attributable to ENSO events, and trends that are large regionally, but comparatively small when averaged across the globe.

precipitation↗
NASA NTRS1983

Interactive computer graphics - Why's, wherefore's and examples

The benefits of using computer graphics in design are briefly reviewed. It is shown that computer graphics substantially aids productivity by permitting errors in design to be found immediately and by greatly reducing the cost of fixing the errors and the cost of redoing the process. The possibilities offered by computer-generated displays in terms of information content are emphasized, along with the form in which the information is transferred. The human being is ideally and naturally suited to dealing with information in picture format, and the content rate in communication with pictures is several orders of magnitude greater than with words or even graphs. Since science and engineering involve communicating ideas, concepts, and information, the benefits of computer graphics cannot be overestimated.

Gregory, T. J.↗
NASA NTRS1997

Data Management System

CENTRA 2000 Inc., a wholly owned subsidiary of Auto-trol technology, obtained permission to use software originally developed at Johnson Space Center for the Space Shuttle and early Space Station projects. To support their enormous information-handling needs, a product data management, electronic document management and work-flow system was designed. Initially, just 33 database tables comprised the original software, which was later expanded to about 100 tables. This system, now called CENTRA 2000, is designed for quick implementation and supports the engineering process from preliminary design through release-to-production. CENTRA 2000 can also handle audit histories and provides a means to ensure new information is distributed. The product has 30 production sites worldwide.

Source record↗
NASA NTRS2021

Development of an Additive Manufacturing Ecosystem for Qualification of Additive Manufacturing Processes and Materials in Aviation

The major challenges associated with additive manufacturing (AM) are an ability to qualify parts and the costs associated with the technology. Our team will study and mature technologies as detailed below to develop an ecosystem for the qualification of AM machines, which in turn supports the certification of part production. Additive manufacturing offers unique opportunities for the aviation industry in the fabrication of original components and replacement parts. Aggressive use of metals AM has, for example, allowed the rapid development and production of new launch vehicle designs, at substantially reduced costs. Aviation has unique challenges, such as higher production volumes, but the potential value of integrating AM into aviation manufacturing is clear. To implement the ecosystem for AM qualification, the team will run a set of six multi-disciplinary projects. Each of these projects will address a current barrier to AM process qualification, and efficient production.

Koushik Datta↗
DOE OSTI2024

Elevated Temperature Graphite Mechanical Testing

High purity graphite will be used for core components within most High Temperature Reactor (HTR) designs. Several "high tech” industries currently utilize synthetic, high-purity, commercially available graphite components to fabricate photovoltaic cells, semi-conductors, optical fibers, and other high value electronic industry products. New advanced HTR designs are also interested in using these graphite grades for long-term, internal core component applications. Consequently, the US Department of Energy, Advanced Reactor Technologies (DOE-ART) program has spent several years testing different high purity graphite grades for potential use within these new nuclear reactor designs. A significant part of that effort has been in the development and improvement of American Society for Testing and Materials (ASTM) test standards specifically for nuclear graphite grades. Nearly all ASTM test standards have either been developed or improved by the DOE-ART program over the past 25 years. The ART program continues to assist in the development of new ASTM test standards in support of the future commercial HTR fleet currently being designed and built in the USA. The newest effort undertaken by ART is the development of high temperature mechanical testing practices that may be acceptable for a future ASTM test standard (or guide) for this critical material property measurement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRSDate not supplied

BioNutrients-2: Improvements to the BioNutrients-1 Nutrient Production System

The BioNutrients (BN) project aims to develop an on-demand nutrient production system capable of rapid and safe delivery of multiple nutrients in a single-use production pack for long-duration missions. The general concept of this system will be to develop an edible engineered microorganism capable of surviving during long-term storage, revival and growth of that microorganism for product production, and delivery of precise quantities of nutrients for human consumption. BN-1 is a five-year flight project currently on the International Space Station (ISS). It is testing the long-term storage of various microorganisms for the biomanufacturing of space relevant compounds and to validate the performance of the first generation (Gen-1) of production packs. The BN-2 project is a continuation of the BN-1 flight project and intends to expand the projects overall scope by introducing novel products, broadening the range of microbial food sources, and improving previously designed hardware from the BN-1 project. We are in the process of optimizing our platform biomanufacturing technology for in situ production of yogurt and kefir on the ISS. BN-2 will test the efficacy of this technology for future delivery of probiotic organisms which can be engineered to produce additional nutritional supplements (consumption by the crew is not planned in this project). Furthermore, to improve the feasibility of this technology for mission use we have transitioned from a hard-shell pack to a Gen-2, fluorinated ethylene propylene (FEP) bag. The single-use FEP bioreactor will facilitate growth of known organisms and ensure a contaminant free environment, while reducing mass and volume. These bioreactors will be employed for production of additional space relevant products in the BN-2 project. On-orbit testing of Gen-2 production packs will be necessary for future iterations, in order to optimize bag design and product production for eventual flight use by the crew.

BioNutrients↗
DOE OSTI2020

Uranium nitride tristructural-isotropic fuel particle

A summary of activities around concept development, design, manufacturing, and early irradiation testing of a novel coated fuel particle, uranium nitride tristructural-isotropic fuel is provided. This fuel particle offers significantly higher uranium density over historic manifestations of coated fuel particles and may be more optimal for a range of advanced reactor applications. After reviewing the design process, steps involving production of this fuel form are discussed. Low burnup irradiation data on this fuel particle are now available, indicating that performance metrics have been met to date based on the original design expectations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗