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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 NTRS2013

Are Soft Short Tests Good Indicators of Internal Li-ion Cell Defects?

The self discharge test at full state of charge, may not be a good one to detect subtle defects since the li-ion chemistry has the highest self discharge at full state of charge. One should characterize self discharge versus storage time for each cell manufacturer/design to differentiate between normal self discharge and that due to a subtle manufacturing defect. The various soft short test methods indicate that if this test is carried out at full discharge (0% SOC) with all capacity removed (by lowering the current load in a stepwise manner to the same end of discharge voltage), then the cells need to be placed in storage for more than 72 hours to get a good analysis on the presence of subtle defects since it takes more than 72 hours to achieve voltage stabilization. If the cells are to be charged up even to a small percentage (ex. 1%), 72 hours are sufficient to determine issues. However, the pass/fail criteria should be based on a valid OCV decline. Less than 10 mV voltage decline is not a good method to detect subtle defects. As mentioned in the first bullet, self discharge is a competing reaction when a charge is introduced and hence a characterization of the self discharge versus storage time is required to fully correlate voltage decline to a failure due to a subtle defect. Soft short test method cannot be relied on for defect detection because cells with and without voltage decline seemed to have similar defects and characteristics. Screening methods such as internal resistance and capacity as well as a 3-sigma range for OCV, mass and dimensions should be used to screen out outliers. A very critical aspect in the understanding of subtle defects is to carry out destructive analysis of cells from every lot to confirm the quality of production and screen all cells and batteries in a stringent manner to have a high quality set of flight cells. Self Discharge Test: Fully charged cells shall be placed in Open circuit stand for 72 hours (OCV measurement twice a day); continue for total of 14 days with 1 reading per day 2. Soft Short Test 1: Fully charge; cells discharged to manufacturer's end of disch. Voltage (EODV) cutoff at C/5 rate; stand for 30 minutes; discharge with C/500 to the same EODV. stand for another 30 minutes; discharge the cells again using C/1000 current to the same EODV. OCV measurements twice a day for 72 hours and then for total of 14 days (data collection same as in 1.) 3. Soft Short Test 2: Fully charge; cells discharged to the manuf. EODV with a C/13 constant current; provide a 10 hour rest, discharge again to the same EODV with a current of C/250, provide a 10 hour rest, discharge again using a C/250 rate, provide a 24 hour rest, charge using C/250 to 3.15 V (for ~12 hours). OCV measurements twice a day for at 72 hours. (data collection same as in 1.) 4. Soft Short Test 3: Fully charge; cells shall be discharged using C/10 current to manuf. EODV. Allow the cell to remain at Open circuit for 10 seconds. Discharge the cell at C/20 rate to the same EODV, hold open circuit for 24 hours. Discharge the cells at C/200 rate to the same end of voltage cutoff and hold open circuit for 24 hours. Discharge the cells one more time at C/200 rate to the same EODV and hold open circuit for 36 hours. Charge at C/200 rate to 3.15 V and hold for 3 days. Record OCV during the open circuit stand periods every 12 hours and at the beginning and end of the 3 day hold (include the 12 hour OCV recording during this time also). Capacity Cycling: Cells with declining voltages - one cell from each manufacturer chosen for cycling Destructive Physical Analysis (DPA): Cells with and without decline chosen from each lot for DPA.

Jeevarajan, J.↗
NASA NTRS1996

SSME Condition Monitoring Using Neural Networks and Plume Spectral Signatures

For a variety of reasons, condition monitoring of the Space Shuttle Main Engine (SSME) has become an important concern for both ground tests and in-flight operation. The complexities of the SSME suggest that active, real-time condition monitoring should be performed to avoid large-scale or catastrophic failure of the engine. In 1986, the SSME became the subject of a plume emission spectroscopy project at NASA's Marshall Space Flight Center (MSFC). Since then, plume emission spectroscopy has recorded many nominal tests and the qualitative spectral features of the SSME plume are now well established. Significant discoveries made with both wide-band and narrow-band plume emission spectroscopy systems led MSFC to develop the Optical Plume Anomaly Detection (OPAD) system. The OPAD system is designed to provide condition monitoring of the SSME during ground-level testing. The operational health of the engine is achieved through the acquisition of spectrally resolved plume emissions and the subsequent identification of abnormal emission levels in the plume indicative of engine erosion or component failure. Eventually, OPAD, or a derivative of the technology, could find its way on to an actual space vehicle and provide in-flight engine condition monitoring. This technology step, however, will require miniaturized hardware capable of processing plume spectral data in real-time. An objective of OPAD condition monitoring is to determine how much of an element is present in the SSME plume. The basic premise is that by knowing the element and its concentration, this could be related back to the health of components within the engine. For example, an abnormal amount of silver in the plume might signify increased wear or deterioration of a particular bearing in the engine. Once an anomaly is identified, the engine could be shut down before catastrophic failure occurs. Currently, element concentrations in the plume are determined iteratively with the help of a non-linear computer code called SPECTRA, developed at the USAF Arnold Engineering Development Center. Ostensibly, the code produces intensity versus wavelength plots (i.e., spectra) when inputs such as element concentrations, reaction temperature, and reaction pressure are provided. However, in order to provide a higher-level analysis, element concentration is not specified explicitly as an input. Instead, two quantum variables, number density and broadening parameter, are used. Past experience with OPAD data analysis has revealed that the region of primary interest in any SSME plume spectrum lies in the wavelength band of 3300 A to 4330 A. Experience has also revealed that some elements, such as iron, cobalt and nickel, cause multiple peaks over the chosen wavelength range whereas other elements (magnesium, for example) have a few, relatively isolated peaks in the chosen wavelength range. Iteration with SPECTRA as a part of OPAD data analysis is an incredibly labor intensive task and not one to be performed by hand. What is really needed is the "inverse" of the computer code but the mathematical model for the inverse mapping is tenuous at best. However, building generalized models based upon known input/output mappings while ignoring details of the governing physical model is possible using neural networks. Thus the objective of the research project described herein was to quickly and accurately predict combustion temperature and element concentrations (i.e., number density and broadening parameter) from a given spectrum using a neural network. In other words, a neural network had to be developed that would provide a generalized "inverse" of the computer code SPECTRA.

Hopkins, Randall↗
NASA NTRSDate not supplied

Sensor-based Prognostics for Safe Batteries for Electric Aircraft

With a new start awarded under CAS for Fiscal Year 2020, the Sensor-based Prognostics to Avoid Runaway Reactions and Catastrophic Ignition project, or SPARRCI, aims to eliminate safety risks of lithium-ion and next-generation lithium-based batteries. SPARRCI is taking a deeper dive into the inner workings of battery cells by introducing miniature multifunctional sensors within the cells to detect early signs of failure. Combined with nondestructive evaluation techniques to gather complementary battery health data, battery data will be monitored in real-time via prognostics which will ultimately be able to identify when the cell is exhibiting abnormal behavior bordering on failure, with the ability to provide early warning such that the battery may be taken offline prior to catastrophic failure events.

Brianne Demattia↗
NASA NTRS2012

Accelerated Aging Experiments for Capacitor Health Monitoring and Prognostics

This paper discusses experimental setups for health monitoring and prognostics of electrolytic capacitors under nominal operation and accelerated aging conditions. Electrolytic capacitors have higher failure rates than other components in electronic systems like power drives, power converters etc. Our current work focuses on developing first-principles-based degradation models for electrolytic capacitors under varying electrical and thermal stress conditions. Prognostics and health management for electronic systems aims to predict the onset of faults, study causes for system degradation, and accurately compute remaining useful life. Accelerated life test methods are often used in prognostics research as a way to model multiple causes and assess the effects of the degradation process through time. It also allows for the identification and study of different failure mechanisms and their relationships under different operating conditions. Experiments are designed for aging of the capacitors such that the degradation pattern induced by the aging can be monitored and analyzed. Experimental setups and data collection methods are presented to demonstrate this approach.

Prognostics of Electronics↗
DOE OSTI2023

Report on FY 2023 Research and Development on Specially Designed Creep-fatigue Experiments on Alloy 617 in Support of Improving Creep-fatigue Evaluation Approaches

Experimental and numerical studies in support of developing the integrated Elastic–Perfectly Plastic (EPP) plus Simplified Model Test (SMT) design methodology, referred to as the EPP+SMT method, continued in FY 2023. This report focuses on the methods for extrapolating the EPP+SMT creep-fatigue life curves at long hold times and low strain ranges at elevated temperatures. In this work, the available uniaxial creep-fatigue failure data on Alloy 617 at temperatures of 950°C and 850°C were analyzed to provide a guidance on the development of the extrapolation method and the creep-fatigue failure criteria. A viscoplastic constitutive model for Alloy 617 was adopted to extrapolate the mechanical responses to low strain ranges and long hold times. A set of design curves of Alloy 617 at temperatures of 950°C, 850°C, and 800°C with tensile hold times of 1 hr, 100 hr, and 1,000 hr are developed. Furthermore, creep-fatigue testing on two notch specimen geometries, shallow-notch and sharp V-notch, on Alloy 617 was performed 950°C to understand the multiaxial stress relaxation behavior. The experimental and numerical results on the notch specimens were compared with those on the standard uniaxial smooth bar specimens. The effect of multi-axial stress state combined with elastic follow-up on the stress relaxation behavior was investigated in this report.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Application of Weibull analysis to SSME hardware

Generally, it has been documented that the wearing of engine parts forms a failure distribution which can be approximated by a function developed by Weibull. The purpose here is to examine to what extent the Weibull distribution approximates failure data for designated engine parts of the Space Shuttle Main Engine (SSME). The current testing certification requirements will be examined in order to establish confidence levels. An examination of the failure history of SSME parts/assemblies (turbine blades, main combustion chamber, or high pressure fuel pump first stage impellers) which are limited in usage by time or starts will be done by using updated Weibull techniques. Efforts will be made by the investigator to predict failure trends by using Weibull techniques for SSME parts (turbine temperature sensors, chamber pressure transducers, actuators, and controllers) which are not severely limited by time or starts.

Gray, L. A. B.↗
NASA NTRS1992

User's guide to the Reliability Estimation System Testbed (REST)

The Reliability Estimation System Testbed is an X-window based reliability modeling tool that was created to explore the use of the Reliability Modeling Language (RML). RML was defined to support several reliability analysis techniques including modularization, graphical representation, Failure Mode Effects Simulation (FMES), and parallel processing. These techniques are most useful in modeling large systems. Using modularization, an analyst can create reliability models for individual system components. The modules can be tested separately and then combined to compute the total system reliability. Because a one-to-one relationship can be established between system components and the reliability modules, a graphical user interface may be used to describe the system model. RML was designed to permit message passing between modules. This feature enables reliability modeling based on a run time simulation of the system wide effects of a component's failure modes. The use of failure modes effects simulation enhances the analyst's ability to correctly express system behavior when using the modularization approach to reliability modeling. To alleviate the computation bottleneck often found in large reliability models, REST was designed to take advantage of parallel processing on hypercube processors.

Nicol, David M.↗
NASA NTRS2011

An Alternative Approach to Human Servicing of Manned Earth Orbiting Spacecraft

As manned spacecraft have grown larger and more complex, they have come to rely on spacewalks or Extravehicular Activities (EVA) for both mission success and crew safety. Typically these spacecraft maintain all of the hardware and trained personnel needed to perform an EVA on-board at all times. Maintaining this capability requires volume and up-mass for storage of EVA hardware, crew time for ground and on-orbit training, and on-orbit maintenance of EVA hardware . This paper proposes an alternative methodology to utilize launch-on-need hardware and crew to provide EVA capability for space stations in Earth orbit after assembly complete, in the same way that most people would call a repairman to fix something at their home. This approach would not only reduce ground training requirements and save Intravehicular Activity (IVA) crew time in the form of EVA hardware maintenance and on-orbit training, but would also lead to more efficient EVAs because they would be performed by specialists with detailed knowledge and training stemming from their direct involvement in the development of the EVA. The on-orbit crew would then be available to focus on the immediate response to the failure as well as the day-to-day operations of the spacecraft and payloads. This paper will look at how current ISS unplanned EVAs are conducted, including the time required for preparation, and offer alternatives for future spacecraft utilizing lessons learned from ISS. As this methodology relies entirely on the on-time and on-need launch of spacecraft, any space station that utilized this approach would need a robust transportation system including more than one launch vehicle capable of carrying crew. In addition the fault tolerance of the space station would be an important consideration in how much time was available for EVA preparation after the failure. Each future program would have to weigh the risk of on-time launch against the increase in available crew time for the main objective of the spacecraft.

Mularski, John↗
NASA NTRS1995

A Probabilistic Tool that Aids Logistics Engineers in the Establishment of High Confidence Repair Need-Dates at the NASA Shuttle Logistics Depot

The NASA Shuttle Logistics Depot (NSLD) is tasked with the responsibility for repair and manufacture of Line Replaceable Unit (LRU) hardware and components to support the Space Shuttle Orbiter. Due to shrinking budgets, cost effective repair of LRU's becomes a primary objective. To achieve this objective, is imperative that resources be assigned to those LRU's which have the greatest expectation of being needed as a spare. Forecasting the times at which spares are needed requires consideration of many significant factors including: failure rate, flight rate, spares availability, and desired level of support, among others. This paper summarizes the results of the research and development work that has been accomplished in producing an automated tool that assists in the assignment of effective repair start-times for LRU's at the NSLD. This system, called the Repair Start-time Assessment System (RSAS), uses probabilistic modeling technology to calculate a need date for a repair that considers the current repair pipeline status, as well as, serviceable spares and projections of future demands. The output from the system is a date for beginning the repair that has significantly greater confidence (in the sense that a desired probability of support is ensured) than times produced using other techniques. Since an important output of RSAS is the longest repair turn-around time that will ensure a desired probability of support, RSAS has the potential for being applied to operations at any repair depot where spares are on-hand and repair start-times are of interest. In addition, RSAS incorporates tenants of Just-in-Time (JIT) techniques in that the latest repair start-time (i.e., the latest time at which repair resources must be committed) may be calculated for every failed unit This could reduce the spares inventory for certain items, without significantly increasing the risk of unsatisfied demand.

Bullington, J. V.↗
DOE OSTI2026

Towards the Ultimate Strength of Medium‐Entropy Alloys Through Pulsed Lasers

The tensile strength of metals at extreme strain rates is a key predictor of their performance in ballistic and structural impact applications. An important experimental method to reach these extreme strain rates is the use of high-amplitude, short-duration pulsed lasers. The Jupiter Laser Facility at the Lawrence Livermore National Laboratory enabled probing for the first time the mechanical response of several promising High Entropy Alloys at times on the order of nanoseconds (strain rates of ∼10 7 and ∼10 9 s −1 ). The measured strength is in the range of 6 to 10 GPa, ten times the quasistatic value. The mechanisms of plastic deformation and failure were identified and quantified through analysis and molecular dynamics simulation. The reflected wave amplitudes, obtained by VISAR, were used to determine the tensile (spall) stress. The high tensile strength obtained is due to two factors: the strain-rate dependence of plastic flow and the kinetics of void nucleation, growth, and coalescence. The experimental results are compared with an analytical prediction considering both grain-interior and grain-boundary void initiation. Molecular dynamics simulations, conducted at strain rates of 10 8 and 10 9 s −1 , rationalize the experimental results. In conclusion, they provide valuable information about the process of failure evolution, and reveal that grain boundary separation plays a pivotal role in spalling.

Materials science↗
DOE OSTI2020

Mechanical properties and microstructure of 316L stainless steel produced by hybrid manufacturing

Hybrid manufacturing is a combination of additive (deposition) and subtractive (machining) manufacturing in a single machine tool. Such a system can be used for near net shape manufacturing and component repair using either similar or dissimilar materials. Integrated into a single system, transition between additive and subtractive manufacturing can occur immediately and be leveraged to generate large components by alternating between the processes. In this investigation, we show how the interleaved capabilities can reduce overall cycle time by up to 68 %, improve average relative elongation to failure by 71 %, and reduce the average relative porosity fraction by 83 % when compared to traditional additive manufactured components. Results from this investigation builds the foundation needed for hybrid manufacturing to be applicable towards the manufacture of large complex components such as nosecones and marine propulsors.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Thermal Assessment and In-Situ Monitoring of Insulated Gate Bipolar Transistors in Power Electronic Modules: Preprint

Insulated gate bipolar transistor (IGBT) power modules are devices commonly used for switching of high voltages and currents. Usage and environmental conditions can cause these power modules to degrade over time, and this gradual process may eventually lead to catastrophic failure of the device. This degradation process may cause some early performance symptoms related to the state of health of the power module, making it possible to detect reliability degradation of the IGBT module. Testing can be used to accelerate this process, permitting a rapid determination of whether specific declines in device reliability can be characterized. In this study, thermal cycling was conducted on multiple power modules simultaneously in order to assess the effect of thermal cycling on the degradation of the power module. In-situ monitoring of temperature was performed from inside each power module using high temperature thermocouples. Device imaging and characterization was performed along with temperature data analysis, to assess failure modes and mechanisms within the power modules. While the experiment was aimed to assess the potential damage effects of thermal cycling on die attach, results indicated that wirebond degradation was the life limiting failure mechanism.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Virtual Metering for Monitoring Building Energy Consumption

The United States Department of Energy (DOE) has standard metering requirements of commercial buildings for optimizing energy performance. The guiding principles are to continuously track and optimize energy performance and install building-level meters for electricity, natural gas, and steam. Some buildings at Los Alamos National Laboratory (LANL) have physical submeters monitoring their energy consumption, but these meters have proven to be unreliable. And, in most cases, replacing them has proven to be a slow process. Installing new submeters also requires a temporary lockout of the circuit on which they are being installed. Many buildings at LANL contain laboratories with ongoing experiments or data centers, which makes an equipment power outage nearly impossible to plan. This inability to plan power outages results in long-term submeter failures. Although most submeters are eventually replaced, failures lead to missing consumption data for some unpredictable, extended time. A building automation system (BAS) is a system that provides control and monitoring on a building to maintain the operational performance of the building and occupancy comfort. Many buildings at LANL currently have a BAS, and all new renovations and installs will include installing a BAS if one does not already exist. The intended purpose for a BAS is primarily to monitor the health and efficiency of a building; however, it is also possible to calculate equipment power and energy consumption using BAS information. This project aims to use virtual meters to monitor building energy consumption as a cost-effective and minimally labor-intensive alternative to installing physical submeters. The fault detection and diagnostics tool, SkySpark, provides a centralized database for all the data from the various BAS that are active at LANL. This data includes the information that is needed to create virtual meters for heating, ventilating, and air conditioning (HVAC) systems in most buildings, including heating and cooling loads. 9 This report begins with a detailed summary of the project, including the reasoning, procedure, and results. The specific processes of creating the various virtual meters are then identified. Then the limitations are discussed. And, lastly, the results and future potential are presented.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Oregon Roadway CSZ Liquefaction and Landslide Impact Screening Analysis

The roadway transportation routes and the surrounding environments in Oregon will be subject to ground acceleration and potential associated deformation due to the propagation of waves of energy during a Cascadia Subduction Zone (CSZ) earthquake. Linear features such as highways may be subject to partial or complete disruption of their function resulting from ground deformations at and along the roadway. A potential source of these disruptions associated with a CSZ event are landslides and liquefaction in the soils along and beneath the highways and local roadways. The construction of the Oregon roadway system and urban development have occurred largely along the banks of the rivers—those along the Pacific coast, and along the valleys throughout the Oregon Coast Range and Cascade Mountains. These locations also represent areas where landslides and liquefaction have occurred historically, or may potentially occur in the future, presenting a significant vulnerability for the roadway system and dependent post-CSZ earthquake emergency response and recovery effort. Many of the Oregon areas with landslide- and liquefaction-prone soils have the potential to impact roadway transportation routes after a major earthquake causing delays in establishing routes to transport emergency response personnel and resources to impacted areas and communities. This report presents methods used to project the impacts that CSZ earthquake-induced landslides and liquefaction may have on roadways across Oregon. First, this report presents an approach for estimating the risk of landslides to Oregon roadways, and determining approximate reopening times. Second, this report presents a similar approach for estimating the risk of liquefaction-induced ground displacements to roadway pavements, also resulting in approximate reopening times for roadway segments. The outcomes of these two ground failure analyses serve as inputs to a broader analysis of CSZ earthquake impacts to Oregon’s surface transportation system and its ability to support post-disaster response and recovery activities, as part of the Oregon Transportation Systems Regional Resiliency Assessment Program project (CISA 2021).

58 GEOSCIENCES↗
DOE OSTI2024

Multiphysics Simulations of Nanofibrous High Power Targets for the Inference of Failure Modes

Fermilab s High Power Targetry Research and Development (HPT R&D) group have been developing and studying an electrospun nanofiber target concept to support the need for robust targets in future fixed target facilities. These nanofiber mats have demonstrated resistance to radiation damage, and the free motion of the individual fibers is expected to mitigate the cyclic stresses induced by a pulsed, high-power beam. To evaluate the efficacy of this concept, nanofiber mat samples have been sent by the HPT R&D group to the HiRadMat facility at CERN for prototypic thermal shock testing; the outcomes of these experiments show that the survivability of a nanofiber target depends on its construction parameters, in particular the packing density of the fibers. Samples with higher packing densities have consistently been destroyed by exposure to the HiRadMat beam, with a hole at the beam center visible, and layers of nanofibers peeled away from the center hole, whereas samples with lower densities have survived with limited damage. The exact reason for the failure of the higher density targets was unclear at the time of the original experiments, but the results of our recent multiphysics simulations which recreate the experiments support the hypothesis that the expansion and pressurization of the air inside the target after being heated by the pulsed beam is the cause; in a high density nanofiber mat, the motion of air through the pores of the mat is much more restricted, and induces a larger pressure on the fibers, blowing the mat apart. In this talk, we ll share the results of these simulations and discuss how they support this hypothesis.

Asztalos, Will↗
DOE OSTI2025

Feasibility of an Accelerometer-Based Structural Health Monitoring System for the LANL Blast Tube

A modeling- and simulation-based study was conducted on the feasibility of implementing an accelerometer-based SHM system on the Los Alamos National Laboratory blast tube. A blast tube experiment was modeled using the Abaqus explicit finite element solver. A custom user subroutine was written to apply test-like pressure loading to the inside surface of the blast tube. The subroutine applies analytically defined pressure loads derived from tracer output taken from a Compressible Flow Computational Fluid Dynamics Solver model of the blast tube. Five unique versions of the model were created: an undamaged reference model at 65°F was used as the baseline and compared to equivalent models at 10°F and 100°F. These three models were compared to models with small damage at the reference temperature. The two types of damage considered were a radial (circumferential) crack in the main tube body and a longitudinal crack in the supports. Acceleration outputs were extracted from accelerometer bodies included in the model and were post processed using a variety of standard SHM techniques. Different potential features signaling failure were extracted and compared using statistical methods in the time and frequency domains. A method was identified that clearly shows that differences in structural response resulting from the modeled damage can be differentiated from the structural response resulting from changing environmental conditions. However, the amount of damage applied to create observable differences in the accelerometer data was so large that simpler methods of damage detection would be more cost effective in locating damage.

42 ENGINEERING↗
NASA NTRS1972

Breakdown phenomena in reverse biased silicon solar cells.

Solar cell reverse current-voltage characteristics have been found to vary widely and to be generally unstable. At reverse voltages greater than approximately 20 V and at cell power dissipations of more than 4 W, the probability of permanent breakdown, resulting in cell short-circuit failure, was found to increase with increasing voltage and exposure time. Shorted cells showed evidence of cell contact material and silicon melting in very localized areas with lava-like flow patterns and channels bridging the p and n contacts.

Rauschenbach, H. S.↗