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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 NTRS2008

NEXT Ion Thruster Performance Dispersion Analyses

The NEXT ion thruster is a low specific mass, high performance thruster with a nominal throttling range of 0.5 to 7 kW. Numerous engineering model and one prototype model thrusters have been manufactured and tested. Of significant importance to propulsion system performance is thruster-to-thruster performance dispersions. This type of information can provide a bandwidth of expected performance variations both on a thruster and a component level. Knowledge of these dispersions can be used to more conservatively predict thruster service life capability and thruster performance for mission planning, facilitate future thruster performance comparisons, and verify power processor capabilities are compatible with the thruster design. This study compiles the test results of five engineering model thrusters and one flight-like thruster to determine unit-to-unit dispersions in thruster performance. Component level performance dispersion analyses will include discharge chamber voltages, currents, and losses; accelerator currents, electron backstreaming limits, and perveance limits; and neutralizer keeper and coupling voltages and the spot-to-plume mode transition flow rates. Thruster level performance dispersion analyses will include thrust efficiency.

Soulas, George C.↗
NASA NTRS2010

Design of a Facility to Test the Advanced Stirling Radioisotope Generator Engineering Unit

The Advanced Stirling Radioisotope Generator (ASRG), a high efficiency generator, is being considered for space missions. An engineering unit, the ASRG engineering unit (EU), was designed and fabricated by Lockheed Martin under contract to the Department of Energy. This unit is currently under extended operation test at the NASA Glenn Research Center (GRC) to generate performance data and validate the life and reliability predictions for the generator and the Stirling convertors. A special test facility was designed and built for the ASRG EU. This paper summarizes details of the test facility design, including the mechanical mounting, heat-rejection system, argon system, control systems, and maintenance. The effort proceeded from requirements definition through design, analysis, build, and test. Initial testing and facility performance results are discussed.

Lewandowski, Edward J.↗
NASA NTRS2010

Testing to Characterize the Advanced Stirling Radioisotope Generator Engineering Unit

The Advanced Stirling Radioisotope Generator (ASRG), a high efficiency generator, is being considered for space missions. Lockheed Martin designed and fabricated an engineering unit (EU), the ASRG EU, under contract to the Department of Energy. This unit is currently undergoing extended operation testing at the NASA Glenn Research Center to generate performance data and validate life and reliability predictions for the generator and the Stirling convertors. It has also undergone performance tests to characterize generator operation while varying control parameters and system inputs. This paper summarizes and explains test results in the context of designing operating strategies for the generator during a space mission and notes expected differences between the EU performance and future generators.

Lewandowski, Edward↗
NASA NTRS2011

Development of the ISS EMU SPEEDR

The Self Powered EVA EMU Data Recorder (SPEEDR) is an FPGA (Field-programmable gate array) based device designed to collect high-rate EMU (Extravehicular Mobility Unit) PLSS (Primary Life Support Subsystem) data for download at a later time. The existing EMU PLSS data down-link capability during EVA is one data packet every 2 minutes and is subject to bad packets or loss of signal. High-rate PLSS data is generated by the ECWS (Enhanced Caution and Warning System) but is not normally captured or distributed. Access to high-rate data will increase the capability of EMU anomaly resolution team to pinpoint issues remotely, saving crew time by reducing required call-down Q&A and on-orbit diagnostic activities. With no Shuttle flights post FY11, and potentially limited down-mass capability, the ISS crew and ground support personnel will have to be capable of on-orbit operations to maintain, diagnose, repair, and return to service EMU hardware, possibly through 2028. Collecting high-rate EMU PLSS data during both IVA (Intravehicular Activity) and EVA (Extravehicular Activity) operations will provide trending analysis for life extension and/or predictive performance. The SPEEDR concept has generated interest as a tool/technology that could be used for other ISS subsystems or future exploration-class space suits where hardware reliability/availability is critical and low/variable bandwidth may require "store then forward" methodology. Preliminary work in FY11 produced a functional prototype consisting of an FPGA evaluation board, custom memory/interface circuit board, and custom software. The SPEEDR concept includes a stand-alone battery that is recharged by a computer USB (Universal Serial Bus) port while data is being downloaded.

Bernard. Craig↗
NASA NTRS2012

Development of the Self-Powered Extravehicular Mobility Unit Extravehicular Activity Data Recorder

The Self-Powered Extravehicular Mobility Unit (EMU) Extravehicular Activity (EVA) Data Recorder (SPEEDR) is a field-programmable gate array (FPGA)-based device designed to collect high-rate EMU Primary Life Support Subsystem (PLSS) data for download at a later time. During EVA, the existing EMU PLSS data downlink capability is one data packet every 2 minutes and is subject to bad packets or loss of signal. Higher-rate PLSS data is generated by the Enhanced Caution and Warning System but is not normally captured or distributed. Access to higher-rate data will increase the capability of EMU anomaly resolution team to pinpoint issues remotely, saving crew time by reducing required call-down Q&A and on-orbit diagnostic activities. With no Space Shuttle flights post Fiscal Year 2011 (FY11), and potentially limited down-mass capability, the ISS crew and ground support personnel will have to be capable of on-orbit operations to maintain, diagnose, repair, and return to service EMU hardware, possibly through 2028. Collecting high-rate EMU PLSS data during both intravehicular activity (IVA) and EVA operations will provide trending analysis for life extension and/or predictive performance. The SPEEDR concept has generated interest as a tool/technology that could be used for other International Space Station subsystems or future exploration-class space suits where hardware reliability/availability is critical and low/variable bandwidth may require store then forward methodology. Preliminary work in FY11 produced a functional prototype consisting of an FPGA evaluation board, custom memory/interface circuit board, and custom software. The SPEEDR concept includes a stand-alone battery that is recharged by a computer Universal Serial Bus (USB) port while data are being downloaded.

Bernard, Craig↗
NASA NTRS2009

Design of a Facility to Test the Advanced Stirling Radioisotope Generator Engineering Unit

The Advanced Stirling Radioisotope Generator (ASRG) is being considered to power deep space missions. An engineering unit, the ASRG-EU, was designed and fabricated by Lockheed Martin under contract to the Department of Energy. This unit is currently on an extended operation test at NASA Glenn Research Center to generate performance data and validate the life and reliability predictions for the generator and the Stirling convertors. A special test facility was designed and built for testing the ASRG-EU. Details of the test facility design are discussed. The facility can operate the convertors under AC bus control or with the ASRG-EU controller. It can regulate input thermal power in either a fixed temperature or fixed power mode. An enclosure circulates cooled air around the ASRG-EU to remove heat rejected from the ASRG-EU by convection. A custom monitoring and data acquisition system supports the test. Various safety features, which allow 2417 unattended operation, are discussed.

Lewandowski, Edward J.↗
NASA NTRS2012

A Distributed Approach to System-Level Prognostics

Prognostics, which deals with predicting remaining useful life of components, subsystems, and systems, is a key technology for systems health management that leads to improved safety and reliability with reduced costs. The prognostics problem is often approached from a component-centric view. However, in most cases, it is not specifically component lifetimes that are important, but, rather, the lifetimes of the systems in which these components reside. The system-level prognostics problem can be quite difficult due to the increased scale and scope of the prognostics problem and the relative Jack of scalability and efficiency of typical prognostics approaches. In order to address these is ues, we develop a distributed solution to the system-level prognostics problem, based on the concept of structural model decomposition. The system model is decomposed into independent submodels. Independent local prognostics subproblems are then formed based on these local submodels, resul ting in a scalable, efficient, and flexible distributed approach to the system-level prognostics problem. We provide a formulation of the system-level prognostics problem and demonstrate the approach on a four-wheeled rover simulation testbed. The results show that the system-level prognostics problem can be accurately and efficiently solved in a distributed fashion.

Daigle, Matthew J.↗
NASA NTRS2009

Creep-Fatigue Relationsihps in Electroactive Polymer Systems and Predicted Effects in an Actuator Design

The paper concerns the time-dependent behavior of electroactive polymers (EAP) and their use in advanced intelligent structures for space exploration. Innovative actuator design for low weight and low power valves required in small plants planned for use on the moon for chemical analysis is discussed. It is shown that in-depth understanding of cyclic loading effects observed through accelerated creep rates due to creep-fatigue interaction in polymers is critical in terms of proper functioning of EAP based actuator devices. In the paper, an overview of experimental results concerning the creep properties and cyclic creep response of a thin film piezoelectric polymer polyvinylidene fluoride (PVDF) is presented. The development of a constitutive creep-fatigue interaction model to predict the durability and service life of electroactive polymers is discussed. A novel method is proposed to predict damage accumulation and fatigue life of polymers under oyclic loading conditions in the presence of creep. The study provides a basis for ongoing research initiatives at the NASA Kennedy Space Center in the pursuit of new technologies using EAP as active elements for lunar exploration systems.

Vinogradov, Aleksandra M.↗
NASA NTRS2012

Prognostics of Power Electronics, Methods and Validation Experiments

Abstract Failure of electronic devices is a concern for future electric aircrafts that will see an increase of electronics to drive and control safety-critical equipment throughout the aircraft. As a result, investigation of precursors to failure in electronics and prediction of remaining life of electronic components is of key importance. DC-DC power converters are power electronics systems employed typically as sourcing elements for avionics equipment. Current research efforts in prognostics for these power systems focuses on the identification of failure mechanisms and the development of accelerated aging methodologies and systems to accelerate the aging process of test devices, while continuously measuring key electrical and thermal parameters. Preliminary model-based prognostics algorithms have been developed making use of empirical degradation models and physics-inspired degradation model with focus on key components like electrolytic capacitors and power MOSFETs (metal-oxide-semiconductor-field-effect-transistor). This paper presents current results on the development of validation methods for prognostics algorithms of power electrolytic capacitors. Particularly, in the use of accelerated aging systems for algorithm validation. Validation of prognostics algorithms present difficulties in practice due to the lack of run-to-failure experiments in deployed systems. By using accelerated experiments, we circumvent this problem in order to define initial validation activities.

Kulkarni, Chetan S.↗
NASA NTRS2011

Prognostics of Power Mosfets Under Thermal Stress Accelerated Aging Using Data-Driven and Model-Based Methodologies

An approach for predicting remaining useful life of power MOSFETs (metal oxide field effect transistor) devices has been developed. Power MOSFETs are semiconductor switching devices that are instrumental in electronics equipment such as those used in operation and control of modern aircraft and spacecraft. The MOSFETs examined here were aged under thermal overstress in a controlled experiment and continuous performance degradation data were collected from the accelerated aging experiment. Dieattach degradation was determined to be the primary failure mode. The collected run-to-failure data were analyzed and it was revealed that ON-state resistance increased as die-attach degraded under high thermal stresses. Results from finite element simulation analysis support the observations from the experimental data. Data-driven and model based prognostics algorithms were investigated where ON-state resistance was used as the primary precursor of failure feature. A Gaussian process regression algorithm was explored as an example for a data-driven technique and an extended Kalman filter and a particle filter were used as examples for model-based techniques. Both methods were able to provide valid results. Prognostic performance metrics were employed to evaluate and compare the algorithms.

Electrolytic capacitors↗
NASA NTRS2015

ME8373 Spring 2015 ICME Proposal ICME Analysis of Fatigue Crack Growth Through a Weld in SA-516 Grade 70 Plate

This paper describes work accomplished to predict the service life of a flexure joint design which is a component of a diffuser duct in the A3 Test Stand, an altitude simulation rocket engine test facility at NASA's Stennis Space Center. The duct has two pressure shells separated by cooling water passages and connected by stiffening ribs and flexure joints. Rocket exhaust flows within the duct and heats the inner pressure shell while the outer pressure shell remains at ambient temperature. The flexure joints allow for differential thermal expansion of the inner and outer pressure shells and are subject to in-service loading by this thermal expansion along with water pressure in the cooling water passage, atmospheric pressure outside the duct, near vacuum conditions within the duct, and vibrational loads from operation of the facility and rocket engine. Figure 1 shows a schematic axisymmetric cross section of the diffuser pressure shells and flexure joints with a zoomed in view of the flexure joint. The flexure joints are expected to eventually fail by fatigue cracking leading to leaks from the cooling water passages to the outside. The zoomed in view in Figure 1 indicates where cracking is expected to occur, namely through a weld bead between two plates of SA-516 Grade 70 steel. This weld bead acts as the fulcrum of the flexure joint and it is clear from inspection of the geometry and loading represented in the zoomed in portion of Figure 1 that inherent in the design there is a severe notch formed between the flexure plate, weld bead, and stiffening ring that will be the site of crack initiation and location from which the crack grows to the outer surface of the weld bead.

Woods, Jody L.↗
NASA NTRS2008

Time-Dependent Erosion of Ion Optics

The accurate prediction of thruster life requires time-dependent erosion estimates for the ion optics assembly. Such information is critical to end-of-life mechanisms such as electron backstreaming. CEX2D was recently modified to handle time-dependent erosion, double ions, and multiple throttle conditions in a single run. The modified code is called "CEX2D-t". Comparisons of CEX2D-t results with LDT and ELT post-tests results show good agreement for both screen and accel grid erosion including important erosion features such as chamfering of the downstream end of the accel grid and reduced rate of accel grid aperture enlargement with time.

ion thrusters↗
NASA NTRSDate not supplied

Scalability of Cohesive Fatigue Analyses Using Explicit Solvers

A cohesive fatigue law has been integrated into a constitutive material model compatible with an explicit finite element solver. The cohesive fatigue model response is based on engineering approximations of the endurance limit and the Goodman diagram. This approach can predict stress-life diagrams for crack initiation, the Paris law regime, and transient effects of crack initiation and stable tearing. Simplified cyclic loading is utilized so that the applied load(or displacement) corresponds to the peak load of a fatigue cycle. Loads are held constant during fatigue while damage develops with increasing solution increments. An automatically-calculated ratio of fatigue cycles per solution increment controls the rate of damage growth, ensuring that damage growth is modeled with a sufficient minimum number of increments and damage growth advances to a minimum desired extent within the explicit analysis step time. The compatibility with an explicit finite element solver enables the analysis of structures that are computationally intractable for implicit finite element solvers. Scalability studies are conducted for geometrically nonlinear problems involving fiber-reinforced composite structures that exhibit fatigue damage growth of interacting matrix cracks and delaminations

Frank A Leone↗
NASA NTRSDate not supplied

Enabling in-time Prognostics with Surrogate Modeling through Physics-enhanced Dynamic Mode Decomposition Method

Computational models provide essential quantitative tools for assessing and predicting the health and performance of physical systems. However, high-fidelity models are rarely used in real-time operations or large optimization loops, due to their time-intensive nature. A common approach to improving computational efficiency of prognosis is to employ surrogate models. Such models can significantly decrease computation time for some accuracy loss. In this context, use of Dynamic Mode Decomposition (DMD) is proposed to generate surrogate models for lithium-ion (Li-ion) battery discharge. DMD has been suggested and used successfully in the area of fluid dynamics for over a decade, but it has not been applied to the PHM domain, where far-ahead prediction of nonlinear behavior is crucial to propagate faults or predict Remaining Useful Life (RUL). For Li-ion battery health management, the standard application of DMD using only the observable quantities of interest was unable to capture the nonlinear discharge of batteries exhibited in lab testing. The Koopman theory, however, provides a mechanism to tradeoff low dimensional nonlinear models with high-dimensional linear ones in a DMD framework, by augmenting nonlinear state variables into the system representation. In this way, DMD allows for configurable simulation accuracy dependent on the dimensionality of the Koopman operator. For battery health management, we augmented the observable variables with the hidden states of a higher-fidelity physics model to build the DMD surrogate. In comparison to a high-fidelity model, the surrogate improved computational efficiency with only a minimal loss of accuracy, and enabled long-term prognostics horizons. A generalized method for this was implemented in the prog models python package.

prognostics and health management↗
DOE OSTI2021

Monitoring Degradation of Nuclear Cable Insulation Subjected To Sequential and Simultaneous Thermal and Radiation Aging

Predicting useful remaining life of cables in nuclear power plants is a topic of growing interest as plant continue to age. A typical electrical cable consists of polymeric materials, such as the cable jacket and insulation, which are susceptible to degradation due to exposure to both elevated temperatures and gamma irradiation over decades of service. In this work two insulation materials, crosslinked polyethylene (XLPE) and ethylene propylene diene (EPDM) elastomer, were characterized to quantify aging using total color difference and indenter modulus. Since the effects of thermal and gamma radiation are not additive but coupled, the effects of different aging scenarios including sequential and simultaneous aging were also evaluated. In the case of sequential aging, two aging scenarios were explored where the order in which thermal and gamma radiation received were altered. Total color difference of XLPE showed that sequentially aged insulation specimens, which received radiation first, degraded slightly more at maximum exposure than specimens which received thermal first. Similarly, in the case of EPDM, the extent of degradation evaluated using total color difference was found to be most severe in the case of sequentially aged insulation specimens which received radiation first. Indenter modulus was found to be insensitive to aging for XLPE but trended for EPDM. The largest variations were observed for the sequentially aged insulation specimens which received radiation first, similar to what was observed for total color difference.

Pallaka, Madhusudhan Reddy↗
DOE OSTI2022

Development Of Thermodynamic and Kinetic Simulation Tools and Testing Procedures for Enhanced Durability of Concrete Containing Industrial By-Products

This project developed screening tools that enable evaluation of alternative cementitious binders that create concretes to significantly reduce energy and emissions while remaining cost competitive on both initial and long-term costs. The team began with the viewpoint that acceptance of new cementitious binder products has a substantially greater chance of successful implementation when capital investment is not excessive and the end product has customers that have experience and resources to use this. As such, a binder system that is based on portland cement with blended using industrial by-products (alternative cementitious materials) has the potential for dramatic and meaningful impact. The team has focused on developing implementable solutions in specifications and current practice. This however requires three main factors: 1) ability to screen byproducts and alternative materials for success, 2) ability to ‘treat’ materials chemically to enhance kinetics, and 3) ability to provide predictions of performance of both binders and concrete from first principles. The project developed/refined a state of the art and scientifically based screening test for SCM called the pozzolanic reactivity test. The team developed kinetic models to simulate these materials as well as experimental approaches to alter selected reactions. Simulation tools were developed that enable the performance of concrete to be predicted based on the chemistry and reactivity of the cement and alternative SCM. Specifically, this project: • enhanced the kinetic reactivity models for use in multi-scale computational programs that use thermodynamics to predict reaction products. 2 • developed scaling models to extend thermodynamic modeling to link these models with pore structure. This enables strength, transport property, and coupled transport prediction. • developed tools to predict performance of cementitious materials using the pozzolanic reactivity test and chemical composition. The predicted properties are consistent with AASHTO R101 and the CEB-FIP model code and can be measured using associated test procedures. • demonstrated mechanical and fracture based modeling tools that thermodynamic predictions and inputs to predict concrete service life. These results have been used to demonstrate the value of enabling specifications to include ASTM C 595 cement as well ASTM C150 cement. In addition, these products are being used to expedite the evaluation of alternative SCM to aide in determining which materials have potential value and what ‘compositions’ of blended cements merit further investment.

42 ENGINEERING↗
DOE OSTI2025

Development of Surveillance Test Articles for Materials Degradation Management in MSR Environments

Materials in molten salt reactors (MSR) undergo accelerated degradation from corrosion, irradiation, and cyclic loads at elevated temperatures. Establishing a materials surveillance program to enable the assessment of material deterioration is critical to assure structural integrity of MSRs components. This presentation summarizes recent efforts towards the development of surveillance test articles for collecting various damages for monitoring materials degradation. Surveillance test articles with reduced dimensions were designed to capture creep-fatigue damage from cyclic loading at elevated temperatures. The strain evolution of test articles during thermal cycling was analyzed both numerically and experimentally. Out-of-reactor thermal cycling demonstrated successful capture of strain range for materials assessment. Moreover, test articles were subject to both mechanical loads and molten salt exposure, and the damage due to stress and corrosion was investigated. Additionally, damage inference models were developed to predict the remaining life of materials based on the accumulated damage in surveillance test articles.

36 - MATERIALS SCIENCE↗
NASA NTRS1987

A high temperature fatigue and structures testing facility

As man strives for higher levels of sophistication in air and space transportation, awareness of the need for accurate life and material behavior predictions for advanced propulsion system components is heightened. Such sophistication will require complex operating conditions and advanced materials to meet goals in performance, thrust-to-weight ratio, and fuel efficiency. To accomplish these goals will require that components be designed using a high percentage of the material's ultimate capabilities. This serves only to complicate matters dealing with life and material behavior predictions. An essential component of material behavior model development is the underlying experimentation which must occur to identify phenomena. To support experimentation, the NASA Lewis Research Center's High Temperature Fatigue and Structures Laboratory has been expanded significantly. Several new materials testing systems have been added, as well as an extensive computer system. The intent of this paper is to present an overview of the laboratory, and to discuss specific aspects of the test systems. A limited discussion of computer capabilities will also be presented.

Bartolotta, Paul A.↗