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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 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Investigation of Advanced Processed Single-Crystal Turbine Blade Alloys

This investigation studied the influence of thermal processing and microstructure on the mechanical properties of the single-crystal, nickel-based superalloys PWA 1482 and PWA 1484. The objective of the program was to develop an improved single-crystal turbine blade alloy that is specifically tailored for use in hydrogen fueled rocket engine turbopumps. High-gradient casting, hot isostatic pressing (HIP), and alternate heat treatment (HT) processing parameters were developed to produce pore-free, eutectic-free microstructures with different (gamma)' precipitate morphologies. Test materials were cast in high thermal gradient solidification (greater than 30 C/cm (137 F/in.)) casting furnaces for reduced dendrite arm spacing, improved chemical homogeneity, and reduced interdendritic pore size. The HIP processing was conducted in 40 cm (15.7 in.) diameter production furnaces using a set of parameters selected from a trial matrix study. Metallography was conducted on test samples taken from each respective trial run to characterize the as-HIP microstructure. Post-HIP alternate HT processes were developed for each of the two alloys. The goal of the alternate HT processing was to fully solution the eutectic gamma/(gamma)' phase islands and to develop a series of modified (gamma)' morphologies for subsequent characterization testing. This was accomplished by slow cooling through the (gamma)' solvus at controlled rates to precipitate volume fractions of large (gamma)'. Post-solution alternate HT parameters were established for each alloy providing additional volume fractions of finer precipitates. Screening tests included tensile, high-cycle fatigue (HCF), smooth and notched low-cycle fatigue (LCF), creep, and fatigue crack growth evaluations performed in air and high pressure (34.5 MPa (5 ksi)) hydrogen at room and elevated temperature. Under the most severe embrittling conditions (HCF and smooth and notched LCF in 34.5 MPa (5 ksi) hydrogen at 20 C (68 F), screening test results showed increases in fatigue life typically on the order of 1OX, when compared to the current Space Shuttle Main Engine (SSME) Alternate Turbopump (AT) blade alloy (PWA 1480).

Peters, B. J.↗
NASA NTRS2000

A Study of Single Crystal Fatigue Failure Criteria

This paper presents the results of a study whose objective was to study the applicability of different failure equations in modeling low cycle fatigue (LCF) test data for single crystal test specimens. A total of four failure criteria were considered in this study. One of the failure equations was developed by Pratt & Whitney and is based on normal and shear strains on the primary crystallographic slip planes of the single crystal material. Other failure equations considered are based on isotropic criteria. Because these failure equations were originally developed for isotropic materials such as structural steel, they were modified to be applicable to the single crystal slip systems of the LCF specimen material. By observing how closely the various equations were able to reduce the scatter in the LCF test data, the applicability of those equations in modeling the LCF test data was assessed. It is desired to subsequently use the failure equation with the highest correlation in the development of a new single crystal failure criterion for the Alternative Turbopump Development (ATD) for the space shuttle main engine (SSME) High Pressure Fuel Turbopump (HPFTP).

Sayyah, Tarek↗
NASA NTRS2013

Development of a High Reliability Compact Air Independent PEMFC Power System

Autonomous Underwater Vehicles (AUV's) have received increasing attention in recent years as military and commercial users look for means to maintain a mobile and persistent presence in the undersea world. Compact, neutrally buoyant power systems are needed for both small and large vehicles. Historically, batteries have been employed in these applications, but the energy density and therefore mission duration are limited with current battery technologies. Vehicles with stored energy requirements greater than approximately 10 kWh have an alternate means to get long duration power. High efficiency Proton Exchange Membrane (PEM) fuel cell systems utilizing pure hydrogen and oxygen reactants show the potential for an order of magnitude energy density improvement over batteries as long as the subsystems are compact. One key aspect to achieving a compact and energy dense system is the design of the fuel cell balance of plant (BOP). Recent fuel cell work, initially focused on NASA applications requiring high reliability, has developed systems that can meet target power and energy densities. Passive flow through systems using ejector driven reactant (EDR) circulation have been developed to provide high reactant flow and water management within the stack, with minimal parasitic losses compared to blowers. The ejectors and recirculation loops, along with valves and other BOP instrumentation, have been incorporated within the stack end plate. In addition, components for water management and reactant conditioning have been incorporated within the stack to further minimize the BOP. These BOP systems are thermally and functionally integrated into the stack hardware and fit into the small volumes required for AUV and future NASA applications to maximize the volume available for reactants. These integrated systems provide a compact solution for the fuel cell BOP and maximize the efficiency and reliability of the system. Designs have been developed for multiple applications ranging from less than 1 kWe to 70 kWe. These systems occupy a very small portion of the overall energy system, allowing most of the system volume to be used for reactants. The fuel cell systems have been optimized to use reactants efficiently with high stack efficiency and low parasitic losses. The resulting compact, highly efficient fuel cell system provides exceptional reactant utilization and energy density. Key design variables and supporting test data are presented. Future development activities are described.

Vasquez, Arturo↗
NASA NTRSDate not supplied

NASA’s Electric Propulsion Development Activities for Space Nuclear Propulsion Applications

Given increased worldwide support for advanced nuclear technology for terrestrial applications, there is a renewed interest in the possibility of nuclear-reactor-powered spacecraft. NASA continues investing in the technology areas necessary to support NASA’s future scientific and exploration goals. One of those technologies areas is electric propulsion, a highly efficient means for in-space propulsion that increases fuel economy by ionizing and accelerating an onboard propellant using spacecraft electrical power. The current NASA portfolio of electric propulsion investments in support of space nuclear applications focuses on a range of future applications with total system power levels of 50 kilowatts to multimegawatt. These investments support a fast-paced incremental rate for technology development advancement to support these applications. Systems at the 50-kilowatt power level can be accomplished today with existing technology and systems at the multimegawatt level will require further technology developments over the coming decade. Propulsion systems based an array of multiple Hall thrusters have been identified the most likely technology option for the near-term applications and systems utilizing lithium-fueled magneto-plasma-dynamic thrusters have been identified as the most promising alternative technology option for the far-term applications at very high-power levels.

Electric Propulsion↗
NASA NTRSDate not supplied

NASA’s Electric Propulsion Development Activities for Space Nuclear Propulsion Applications

Given increased worldwide support for advanced nuclear technology for terrestrial applications, there is a renewed interest in the possibility of nuclear-reactor-powered spacecraft. NASA continues investing in the technology areas necessary to support NASA’s future scientific and exploration goals. One of those technologies areas is electric propulsion, a highly efficient means for in-space propulsion that increases fuel economy by ionizing and accelerating an onboard propellant using spacecraft electrical power. The current NASA portfolio of electric propulsion investments in support of space nuclear applications focuses on a range of future applications with total system power levels of 50 kilowatts to multimegawatt. These investments support a fast-paced incremental rate for technology development advancement to support these applications. Systems at the 50-kilowatt power level can be accomplished today with existing technology and systems at the multimegawatt level will require further technology developments over the coming decade. Propulsion systems based an array of multiple Hall thrusters have been identified the most likely technology option for the near-term applications and systems utilizing lithium-fueled magneto-plasma-dynamic thrusters have been identified as the most promising alternative technology option for the far-term applications at very high-power levels.

Electric propulsion↗
DOE OSTI2022

Fluid mixing apparatus using liquid fuel and high- and low-pressure fluid streams

A fluid mixing apparatus includes mixing conduits that extend through a fluid plenum. The fluid plenum, which surrounds a first wall defining a main passage fluidly coupled to a low-pressure fluid source, is surrounded itself by a second wall defining a high-pressure plenum fluidly coupled to a high-pressure fluid source. An insulated tube disposed at the inlet of the first wall delivers a third fluid. The mixing conduits fluidly couple the high-pressure plenum to the main passage, where the high-pressure fluid is mixed with low-pressure fluid and the third fluid. Optionally, the fluid plenum may house a fourth fluid that is injected through injection holes in the mixing conduits. The fluid mixing apparatus may be used to mix one or more fuels with high- and low-pressure air in a gas turbine combustor. Alternately, the fluid mixing apparatus may mix a fluid with high- and low-pressure water streams.

Berry, Joseph Jonathan↗
DOE OSTI2023

Fluid mixing apparatus using high- and low-pressure fluid streams

A fluid mixing apparatus includes mixing conduits that extend through a fluid plenum and that define injection holes therethrough. The fluid plenum, which surrounds a first wall defining a main passage fluidly coupled to a low-pressure fluid source, is surrounded itself by a second wall defining a high-pressure plenum fluidly coupled to a high-pressure fluid source. The mixing conduits fluidly couple the high-pressure plenum to the main passage, and the fluid from the fluid plenum is delivered with the high-pressure fluid to the main passage, where the fluids mix before being discharged from an outlet of the main passage. The fluid mixing apparatus may be used to mix one or more fuels with high- and low-pressure air in a gas turbine combustor. Alternately, the fluid mixing apparatus may mix a fluid with high- and low-pressure water streams.

Berry, Jonathan Dwight↗
DOE OSTI2023

Mechanisms of adsorbing hydrogen gas on metal decorated graphene

Hydrogen is a key player in global strategies to reduce greenhouse gas emissions. In order to make hydrogen a widely used fuel, we require more efficient methods of storing it than the current standard of pressurized cylinders. An alternative method is to adsorb H 2 in a material and avoid the use of high pressures. Among many potential materials, layered materials such as graphene present a practical advantage as they are lightweight. However, graphene and other 2D materials typically bind H 2 too weakly to store it at the typical operating conditions of a hydrogen fuel cell, meaning that high pressure would still be required. Modifying the material, for example by decorating graphene with adatoms, can strengthen the adsorption energy of H 2 molecules, but the underlying mechanisms are still not well understood. In this work, we systematically screen alkali and alkaline-earth metal decorated graphene sheets for the static thermodynamic adsorption of hydrogen gas from first principles and focus on the mechanisms of binding. We show that there are three mechanisms of adsorption on metal decorated graphene and each leads to distinctly different hydrogen adsorption structures. The three mechanisms can be described as weak van der Waals physisorption, metal adatom facilitated polarization, and Kubas adsorption. Among these mechanisms, we find that Kubas adsorption is easily perturbed by an external electric field, providing a way to tune H 2 adsorption. In conclusion, this work is foundational and builds our understanding of H 2 adsorption under idealized conditions.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Cogeneration Technology Alternatives Study (CTAS). Volume 1: Summary

Various advanced energy conversion systems that can use coal or coal-derived fuels for industrial cogeneration applications were compared to provide information needed by DOE to establish research and development funding priorities for advanced-technology systems that could significantly advance the use of coal or coal-derived fuels in industrial cogeneration. Steam turbines, diesel engines, open-cycle gas turbines, combined cycles, closed-cycle gas turbines, Stirling engines, phosphoric acid fuel cells, molten carbonate fuel cells, and thermionics were studied with technology advancements appropriate for the 1985-2000 time period. The various advanced systems were compared and evaluated for wide diversity of representative industrial plants on the basis of fuel energy savings, annual energy cost savings, emissions savings, and rate of return on investment as compared with purchasing electricity from a utility and providing process heat with an on-site boiler. Also included in the comparisons and evaluations are results extrapolated to the national level.

Barna, G. J.↗
DOE OSTI2026

An analysis of alcohol compression ignition strategies on different engine platforms

Strategies that enable ignition of the low cetane alcohol fuels (methanol and ethanol) include intake heating (direct or via hot residual trapping), increased compression ratio (CR), multi-injection strategies, ignition enhancers, and active prechambers. The literature consistently shows alcohol compression ignition (CI) is more efficient than diesel at high loads irrespective of ignition strategy but shows contradictory results at low loads. To understand this, this work combines data from four different engine platforms ranging from a displaced volume of 0.4 to 2.1 L/cyl. using different alcohol CI ignition strategies. Using modeling to support experimental analysis, alcohol-specific efficiency penalties are highlighted to inform alcohol combustion system development. The alcohols’ lower energy density means more fuel must be injected near top dead center to achieve a given load, increasing the relative penalty of sensible/latent heating. Pilot injections help reduce this penalty. Intake heating incurs both a heat transfer penalty and a thermodynamic penalty due to a reduced ratio of specific heats during compression. A strategy that combines elevated CR, large pilot injections, and ignition enhancers can avoid this penalty. Alternatively, a prechamber strategy can achieve this without changing the CR, nor needing ignition enhancers in the fuel. At low loads, diesel burns in a partially premixed mode characterized by high burn rates and low heat losses, reducing alcohol-specific combustion benefits. Alcohol CI on the light-duty platform showed abnormally high heat transfer over diesel compared to other platforms, favoring a more premixed/partially premixed strategy despite a combustion efficiency tradeoff.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1992

Extravehicular activity self-rescue using a hand-held thruster

A study was performed in the virtual interactive environment workstation. Simulations were conducted to assess the feasibility and quantify the fuel and time requirements for a stranded crewperson to return to a space station after an accidental separation. A hand-held thruster, similar to the hand-held maneuvering unit from the Gemini program, was used for propulsion. Thirty different separation scenarios were composed of three separation rates, five initial spin rates, and an opportunity to use an attitude hold device in a repeated measures design. Statistically significant results were produced by separation velocity. Fuel, time maximum range, time to maximum range, maximum axial range, and final axial velocity increased with separation rate. A hand-held thruster is a viable alternative for accomplishing a self-rescue. Although one cannot prove a null effect, the fact that an attitude hold capability did not decrease solution time or fuel consumption is important for system designers. This fact, coupled with the success of a hand-held thruster in simulations, suggests that the added expense of more sophisticated solutions requiring a multitude of thrusters - and higher computation and power capabilities - may be unwarranted.

Brody, Adam R.↗
DOE OSTI2022

Quantifying the electrochemical active site density of precious metal-free catalysts in situ in fuel cells

We report advances in the development of precious-group metal-free (PGM-free) catalysts for the oxygen reduction reaction (ORR) in fuel cell cathodes have produced active catalysts that reduce the performance gap to the incumbent Pt-based materials. However, utilization of state-of-the-art PGM-free catalysts for commercial applications is currently impeded by their relatively low durability. Methods designed to study catalyst degradation in the operation of fuel cells are therefore critical for understanding durability issues and, ultimately, their solutions. Here we report the use of Fourier-transform alternating current voltammetry as an electrochemical method for accurate quantification of the electrochemically active site density of PGM-free cathode catalysts, and to follow their degradation in situ during the operation of polymer electrolyte fuel cells. Using this method, we were able to quantify the electrochemical active site density, which will enable the elucidation of degradation mechanisms of PGM-free ORR catalysts in situ in fuel cells.

25 ENERGY STORAGE↗
DOE OSTI2023

Butyric Acid Production from Delignified Corn Stover Using Thermophilic Bacterial Co-Cultures

Butyric acid (BA) is a valuable platform chemical in the food and pharmaceutical industries, and it is also a potential precursor for the production of biobutanol and sustainable aviation fuels (SAFs). BA is mainly synthesized from petroleum; thus, cost-effective, and sustainable alternatives for its production are attracting the interest of several sectors. The present work proposes a solids-to-acids bioprocess to produce BA from corn stover utilizing a co-culture that consists of two thermophilic bacteria, Clostridium thermocellum, a well-known efficient degrader of insoluble and oligomeric cellulosic substrates, and Clostridium thermobutyricum, a highly efficient BA producer from monomeric sugars. After initial proof of concept experiments, a series of optimization studies were carried out to evaluate the process limits of this co-culture. First, the co-cultivation of both microorganisms at different inoculum sizes in deacetylated and mechanically refined corn stover (DMR) was evaluated. No significant differences were found on the solids deconstruction and carbohydrates utilization among all the treatments. In addition, BA production was similar under all conditions, ranging between 2.1 and 2.4 g/L. Next, the deconstruction, and BA production capabilities of the co-culture at increased DMR solids contents (3, 4.5, and 6% (w/v)) were tested. Although no difference was observed in the solids deconstruction and carbohydrates utilization among treatments, BA production increased concomitantly to solids loading; the maximum values observed were 2.8, 3.6, and 6.2 g/L in the 3, 4.5, and 6% treatments, respectively. In fact, BA production did not reach its absolute maximum in the 6% treatment after 160 h of fermentation. Lastly, a fed-batch experiment was performed to investigate the co-culture capabilities and possible system constraints to achieve higher BA titers. Data on substrate modifications and product formation as well as on the growth of each microorganism will be shown. Results from this work demonstrate a promising bioprocess approach for the production of BA from lignocellulosic biomass using a thermophilic bacterial co-culture.

bacteria↗
DOE OSTI2021

$\mathrm{REX}$: An analytical tool for reactor operating envelope expansion through fuel-clad thermo-mechanics

Here REX, an analytical reactor design tool for the identification and expansion of reactor operating envelopes, is introduced and detailed. Written in MATLAB, REX takes core geometries and axially discretized detector and depletion output from the Serpent neutron transport code and performs full-core, pin-specific thermal-hydraulic and thermo-mechanical calculations. REX identifies the operating envelopes of advanced, solid-fuel nuclear reactors on the basis of their fuel-cladding, fuel-gas, and coolant-cladding interfacial thermo-mechanics. It iteratively pushes coolant inlet temperatures and modifies fuel pin geometries to induce mechanical failure in their original cladding materials at the fullest extent of their fuel cycle lengths and permissible coolant inlet temperatures. It then attempts to expand their operating envelopes by determining the mechanical responses of alternative cladding materials under the same geometric conditions. The result of the REX calculation sequence is a set of 5-D variables describing the temperatures, pressures, geometries, and mechanics of the core as functions of assembly, fuel pin, axial zone, depletion step, and coolant inlet temperature for each candidate cladding material with the limiting fuel pin geometry for the original material.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

FY2022 Progress Report for Advanced Re-fabrication/Re-instrumentation Capability Development

In support of performing follow-on irradiation experiments with previously irradiated materials, the Halden Reactor Project developed unique and state of the art capabilities to refabricate and re-instrument previously irradiated materials. Such materials were used in in-pile tests at the Halden reactor, and out-of-pile tests for example using furnaces as a heat source. The decision to close the Halden Reactor Project results in the loss of this refabrication and re-instrumentation capability. As a result, the United States (U.S.) Department of Energy (DOE) has determined to develop refabrication and re-instrumentation capability at the unique shielded facilities at Idaho National Laboratory (INL). The development of refabrication capability has been completed and demonstrated. This report focuses on the complementary aspects of reinstrumentation and the progress to-date. Halden spent nearly 30 years developing both refabrication and re-instrumentation. Collaboration with Halden is allowing Idaho National Laboratory (INL) to develop this capability much more rapidly. In FY-21 the results include development of the capability to drill annular center holes in ceramic UO2 fuel pellets, development of fuel rod end caps with feedthroughs for centerline instrumentation inside the rodlet, The procurement of both fuel drilling and welding demonstration equipment from Halden, evaluation of surface thermocouple attachments to support better understanding of temperature measurement uncertainties, and finally, the conceptual design of a new shielded enclosure where advanced refabrication and re-instrumentation equipment can be housed. In FY-22, the results include; Completing set up of the drilling and welding modules procured from Halden, and early experimental trials using that equipment.; Completing set up of an out-of-cell circumferential weld system to allow for further weld development to take place and support fabrication of fuel for fresh fuel experiments.; Evaluation of the Hot Fuel Examination Facility (HFEF) infrastructure to support future installation of advanced re-fabrication/re-instrumentation equipment, specifically related to necessary infrastructure for cryo-drilling.; Developments in dry-drilling alternative. Including experimental studies showing cordierite is the most suitable surrogate for UO 2 for performing drilling studies. That drilling performance is enhanced when a fuel-clad bonding condition is simulated.; Conceptual design completed for attaching surface thermocouples to irradiated fuel in support of TWIST capsule experiments. The authors would like to thank the numerous colleagues at INL and Halden who provided support in accomplishing this work. Their support both material and intellectual is invaluable in advancing the state of the art and establishing the capabilities for refabrication and re-instrumentation at INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Techno-economic and environmental assessment of solar-based electrical vehicles charging stations integrated with hydrogen production

With the growing interest in adopting both commercial and residential electric vehicles (EVs) utilizing green renewable energy, the techno-economic assessment of EV charging stations with solar energy is a critical aspect of the transition to sustainable transportation. However, battery storage capacity for variable solar energy production is becoming increasingly less cost-effective due to the higher Lithium price. Complementing solar energy production and battery storage, the potential of combining green hydrogen fuel energy integration with solar energy for EV charging stations can provide a sustainable alternative to reach carbon-free transportation. This research aims to assess the technical and economic viability of grid-connected Photovoltaic (PV)-based EV charging stations across Kentucky based on existing EV load profiles. The study considers different PV system sizes, locations, orientations, and the impact of net metering policies and electricity tariffs on the profitability of the PV systems. Further, using excess PV energy, Lithium-Ion batteries will be charged, which will be assessed considering the techno-economic and environmental impacts of green EV charging stations. To further enhance green renewable energy production, we also investigated the feasibility of on-grid PV-based EV charging stations with Lithium-Ion batteries charged during low tariff periods. In comparison with these scenarios, we studied the potential benefits of integrating green hydrogen energy production using excess solar energy with and without governmental incentives. Furthermore, we assess the environmental impact of these green EV charging stations across Kentucky. Our study indicates that EV stations across Kentucky have similar techno-economic feasibility with insignificant deviation in the levelized cost of electricity, payback period, and PV energy fraction with/without Li-Ion batteries. However, with green hydrogen production, the marginal H 2 production cost indicates the first scenario (on-grid PV energy charging) is the most significant, roughly 10 USD/Kg, which is similar to 1.5 times higher than the second (charging during low-tariff periods) and the third scenarios (power grid to satisfy the demand deficit - approximately 6.5 USD/Kg). From the environmental perspective, the second scenario would be a good option for either hybrid EV/H 2 or EV charging stations in Kentucky, factoring in the hydrogen production cost and the carbon footprint.

08 HYDROGEN↗
DOE OSTI2025

Robust engineered catalyst for the conversion of brown grease to renewable diesel via decarboxylation/decarbonylation

A novel engineered Ni–Cu/Al 2 O 3 decarboxylation/decarbonylation catalyst achieved quantitative conversion of brown grease, excellent yield of diesel-like hydrocarbons, effective heteroatom removal, and remarkable resistance to deactivation for hundreds of hours on stream. This offers an industrial alternative to hydrotreating for transforming waste oleaginous feedstocks into renewable diesel and sustainable aviation fuel.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗