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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Thermal Testing of Planetary Probe TPS in Extreme Entry Environments

High temperature testing of thermal protection system (TPS) materials is a critical aspect of heat-shield materials development, as it determines the suitability and performance envelope of the materials. The present talk provides an overview of recent updates to NASAs IHF and AEDCs H3 high temperature arcjet test facilities that to enable higher heat flux (5000-8000 Wcm2) and high pressure (5-14 atm) testing of TPS. Some recent thermal tests of fully dense carbon phenolic will be discussed in this paper. These new facility upgrades will help improve the TRL level of novel TPS materials and will help qualifycertify heritage TPS material candidates for future missions that are expected to encounter extreme entry conditions, such as entry into Venus or Saturn.

Gasch, M.↗
NASA NTRS2014

Thermal Testing of Thermal Protection System (TPS) Materials

High temperature testing of thermal protection system (TPS) materials is a critical aspect of heat-shield materials development, as it determines the suitability and performance envelope of the materials. The present talk provides an overview of different high temperature test facilities that are available for conducting thermal tests for TPS materials. The facilities include arcjet testing, solar tower testing facilities and laser test facility. The facilities are selected based on the requirements and objectives of the tests and each have their benefits and limitations. The paper also describes the process of determining the test environments based on mission profiles and requirements. Some of the recent thermal tests of TPS materials are discussed in this paper. These tests have helped improve the TRL (Technology Readiness Level) level of novel TPS materials and make them viable TPS material candidates for future missions.

Thermal Protection Materials↗
NASA NTRS2019

Thermal Protection System Technology Maturation and Sustainment in Support of In-situ Science Missions: HEEET and PICA

Among the challenges faced by the Entry Descent and Landing (EDL) community have been: the lack of a matured forebody heatshield thermal protection system (TPS) capable of meeting the demanding entry environments for the high priority in-situ science missions identified in the decadal survey at Venus, Saturn and the Ice Giants, and the continued sustainment of thermal protection systems/materials. In response to the identified shortfall in TPS technologies capable of extreme entry environments NASA's Space Technology Mission Directorate (STMD) and Science Mission Directorate (SMD) initiated the Heatshield for Extreme Entry Environment Technology (HEEET) project which has matured a 3D-Woven TPS to Technology Readiness Level 6 and which is ready for infusion into these high priority missions. During the development of HEEET long term sustainability was a key consideration. However existing TPS also continue to face sustainability issues. Phenolic Impregnated Carbon Ablator (PICA) has been/is being utilized by many SMD Missions (Stardust, Mars Science Laboratory, OSIRIS-Rex, Mars 2020, Dragonfly) and is under consideration for others including Mars Sample Return, so maintaining PICA for the long term is a priority for NASA. This presentation will discuss raw material sustainability challenges faced by PICA and the efforts by NASA to work with Fiber Materials Inc (FMI) to resolve these challenges with a more sustainable supply chain. In addition, NASA is working with FMI to increase the manufacturing scale for single piece PICA heatshields and to expand the aerothermal performance envelop maturing PICA for larger sized heatshield and more aggressive entry environments. This presentation will also identify challenges and limitations with these systems, particularly around understanding failure modes in these materials and systems and how understanding these may allow use of these systems in environments that are difficult to achieve in ground based testing.

Heatshield for Extreme Entry Environment Technolog↗
NASA NTRS2019

Thermal Protection System Technology Maturation and Sustainment in Support of In Situ Science Missions: HEEET and PICA

Challenges faced by the Entry Descent and Landing (EDL) community include the lack of a matured forebody heatshield thermal protection system (TPS) capable of meeting the demanding entry environments for the high priority in-situ science missions identified in the decadal survey at Venus, Saturn and the Ice Giants, and the continued sustainment of thermal protection systems/materials. In response to the identified shortfall in TPS technologies capable of extreme entry environments NASA's Space Technology Mission Directorate (STMD) and Science Mission Directorate (SMD) initiated the Heatshield for Extreme Entry Environment Technology (HEEET) project which has matured a 3D-Woven TPS to Technology Readiness Level 6 and which is ready for infusion into these high priority missions. During the development of HEEET long term sustainability was a key consideration. However existing TPS also continue to face sustainability issues. Phenolic Impregnated Carbon Ablator (PICA) has been/is being utilized by many SMD Missions (Stardust, Mars Science Laboratory, OSIRIS-Rex, Mars 2020, Dragonfly) and is under consideration for others including Mars Sample Return, so maintaining PICA for the long term is a priority for NASA. This presentation will discuss raw material sustainability challenges faced by PICA and the efforts by NASA to work with Fiber Materials Inc (FMI) to resolve these challenges with a more sustainable supply chain. In addition, NASA is working with FMI to increase the manufacturing scale for single piece PICA heatshields and to expand the aerothermal performance envelop maturing PICA for larger sized heatshield and more aggressive entry environments. This presentation will also identify challenges and limitations with these systems, particularly around understanding failure modes in these materials and systems and how understanding these may allow use of these systems in environments that are difficult to achieve in ground based testing

Phenolic Impregnated Carbon Ablator (PICA)↗
NASA NTRS2020

Calibration Probe Uncertainty and Validation for the Hypersonic Material Environmental Test System

This paper presents an uncertainty analysis of the stagnation-point calibration probe surface predictions for conditions that span the performance envelope of the Hypersonic Materials Environmental Test System facility located at NASA Langley Research Center. A second-order stochastic expansion was constructed over 47 uncertain parameters to evaluate the sensitivities, identify the most significant uncertain variables, and quantify the uncertainty in the stagnation-point heat flux and pressure predictions of the calibration probe for a low- and high-enthalpy test condition. A sensitivity analysis showed that measurement bias uncertainty is the most significant contributor to the stagnation-point pressure and heat flux variance for the low-enthalpy condition. For the high-enthalpy condition, a paradigm shift in sensitivities revealed the computational fluid dynamics model input uncertainty as the main contributor. A comparison between the prediction and measurement of the stagnation-point conditions under uncertainty showed that there was evidence of statistical disagreement. A validation metric was proposed and applied to the prediction uncertainty to account for the statistical disagreement when compared to the possible stagnation-point heat flux and pressure measurements.

Brune, Andrew J.↗
NASA NTRSDate not supplied

High-Altitude ADS-B Flight Tests on a NASA ER-2 Research Airplane

Researchers at the National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (Edwards, California); the Federal Aviation Administration (FAA); and Regulus Group, LLC (Atlantic City, New Jersey) collaborated for the flight-test demonstration of an Automatic Dependent Surveillance-Broadcast (ADS-B) system equipped on a high-altitude Earth Resources-2 (ER-2) research airplane. The unique ER-2 airplane is a NASA-owned and operated airborne science version of the United States Air Force / Lockheed Martin Aeronautics (Bethesda, Maryland) U-2S airplane. The FAA has mandated that by the year 2020, aircraft operating within certain sections of the United States National Airspace system be equipped with ADS-B Out technology; the research presented in this paper is the first to show how the NASA ADS-B architecture satisfies the mandate for a unique high-altitude aircraft. An exceptional military aircraft design, security protocols, and the performance envelope of the ER-2 airplane made the avionics integration remarkably challenging. The design required the ADS-B avionics to survive the harsh flight environment of the ER-2 airplane. The most prominent challenge was the functional integration of modern civilian avionics into federated military legacy avionics. Flight-test objectives were to certify an ADS-B Out (1090ES) passive surveillance integrated with a Traffic Alert and Collision Avoidance System (TCAS) I active surveillance system on an ER-2 platform for high-altitude cruise operations. In April 2022, NASA conducted three flights at Edwards Air Force Base (Edwards, California) - each greater than one-hour flight reaching altitudes above 60,000 ft.

ADS-B↗
NASA NTRS2023

Uncertainty Analysis of Slug Calorimeters in the HyMETS Arc-Jet Facility

The objective of this work is to perform an uncertainty analysis of the deduced stagnation heat flux environment on a slug calorimeter for conditions that span the performance envelope of the Hypersonic Materials Environmental Test System arc-jet facility located at NASA Langley Research Center. Analytical solutions are developed for boundary-value problems on the slug element accounting for non-ideal effects, including spatial variation in the slug heat flux, multi-dimensional thermal conduction, and back-face losses, which departs from the state-of-the-art method derived from the American Society of Testing and Materials. Boundary-value problem definitions are informed by preliminary finite element thermal analysis of the slug calorimeter assembly (including both slug and housing) and just the slug element. The analytical solutions are presented in a general sense and in a truncated form from error analysis. Results are shown in optimizing and validating the analytical models against available slug back-face thermal data. The optimization results indicate that the appropriate epistemic uncertainty of the deduced stagnation heat flux on the slug calorimeter is at most±2.5% for both a high-and low-enthalpy test condition. In addition, a numerical approach is used to determine the aleatory (probabilistic) uncertainty component in the slug stagnation heat flux by applying a marching least-squares slope routine through the steady-state portion of the slug back-face thermal response. Results indicate a compromise between the number of samples and the filter frequency of slug back-face thermal data points when evaluating the standard deviation of the deduced stagnation heat flux statistics. When combining the mixed uncertainty, both aleatory and epistemic, the interval of uncertainty in the deduced stagnation heat flux is determined to be up to ±4%, which is at least a 60% reduction from the standard uncertainty used in the state-of-the-art method.

uncertainty↗
NASA NTRSDate not supplied

Managing the Digital Thread for Structural Applications With Fit for Purpose Materials

With the increased emphasis on reducing the cost and time to market of new materials, the need for analytical tools that enable the virtual design and optimization of materials throughout their processing - internal structure - property - performance envelope, along with the capturing and storing of the associated material and model information across its lifecycle, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. Consequently, at NASA Glenn Research Center a robust information management system that manages the digital thread across the full material life (i.e., capture, analysis, maintenance, and dissemination of data) cycle directed at the design of ‘fit-for-purpose materials’ is under development. To this end the Application Table has been incorporated within NASA Glenn Research Center’s ICME Information Management framework within the ANSYS Granta MI tool. The Application Table provides a place where material and structural application information/requirements can be linked to marry the “design-the-material” (structural engineering) and the “design-with-material” (material science) paradigms and thereby enable application-driven design and optimization of materials and structures. In additional several associated toolsets, specifically: AIMAOS (Automated Information Management Across Organizations and Scales), Py MILab, and JARIMIS (Just A Rather Intelligent Material Interrogation System) are also under development to assist in the judicious automation of this process. AIMOAS offers users an interactive graphical user interface for connecting material information management systems with both commercial and in-house simulation tools at various length scales to enable such automation in the handoff across scales and maintenance of material digital twins and the digital thread. Py MILab, is an automatic framework for the capture, analysis, maintenance, and storage of material test data. Py MILab uses a modular approach for capturing raw data, analyzing the data, and storing the data in a database, interfaced by neutral file structures, to promote plug-and-play capabilities for various analysis types. Finally, JARIMIS is an expert system that integrates various materials informatics tools (e.g., MicroNet, Surrogate ML models, ANSYS Granta MI, etc.) to enable inverse design of materials and facilitate the application of machine learning (ML) and data science with human in the loop decision making to rapidly discover and optimize new materials.

Digital Transformation↗
DOE OSTI2024

Current TRISO Fuel Performance Capabilities and Considerations for Expanded Operational Envelopes

Current TRISO Fuel Performance Capabilities and Considerations for Expanded Operational Envelopes. US-DOE TRISO Fuel Development, AGR Fuel Design and Performance Requirements, AGR Program Fuel Irradiations, UCO Fuel Performance Evaluation Results, Performance Limiting Phenomena, Coated-Particle-Fueled Reactor Concepts and Fuel Designs, Expanded Fuel Performance Envelope, and Accelerated Fuel Qualification.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Evaluation of Directed Energy Deposition and Laser Powder Bed Fusion Nickel-Based Alloys Process Application Envelopes Based on Performance, Process Economics, Supply Chain Risks, and Reactor-Specific Targeted Components

The goal of the Advanced Materials and Manufacturing Technologies (AMMT) program is to accelerate the deployment of new materials and manufacturing technologies into advanced nuclear-related systems. Although 316H stainless steel fabricated by laser powder bed fusion (LPBF) has already been identified as an alloy that could have a significant effect on various reactor technologies, many other materials and manufacturing techniques are being evaluated. Nickel-based alloys typically offer higher-temperature capabilities compared with advanced stainless steels, and previous reports looked at three Ni-based alloy categories: low-Co alloys with a potential use close to the reactor core; high-temperature, high-strength alloys; and molten salt–compatible alloys. Due to the increasing interest in the low Co 625 alloy for nuclear applications, the alloy was compared at the Oak Ridge National Laboratory (ORNL) with 617, 230, two high-temperature, high-strength solution-strengthened alloys. Hot cracking could not be suppressed for alloy 230, and it was shown that these cracks, which were elongated along the build direction (BD), had a drastic effect on the ductility of alloy 230 at room temperature when specimens were machined perpendicular to the BD. Cracking was not as significant for alloy 617, but still led to significant variation in ductility at room temperature along the build direction. On the contrary, LPBF printing of crack-free alloy 625 was achieved using similar printing parameters, and the alloy looks like a very promising candidate for various reactor technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Evaluation of DED and LPBF Fe-based Alloys Process Application Envelopes based on Performance, Process Economics, Supply Chain Risks, and Reactor-specific Targeted Components

The U.S. Department of Energy (DOE), Office of Nuclear Energy (NE), Advanced Materials and Manufacturing Technologies (AMMT) program aims to develop extreme-environment materials solutions for use in the deployment of advanced nuclear reactors and the sustainment of the current fleet. To achieve this objective, a combination of experiment, a computational tool, and machine learning (ML) for the design of materials is adopted for the maturation of materials for nuclear technology. Through advanced manufacturing techniques such as laser powder bed fusion (LPBF) and laser powder direct energy deposition (LP-DED), components with complex geometries can be fabricated with reduced time and effort. Such advanced manufacturing methods can also provide the opportunity to improve materials performance through optimized microstructures and mechanical properties. However, existing engineering alloys are not always well suited for fabrication with additive manufacturing (AM), as their compositions have been tuned to optimize fabrication via conventional methods. Thus, similar alloys with modified compositions that are better suited for AM can be studied for improved performance. Over the past three years, the AMMT teams from Argonne National Laboratory (ANL) and Pacific Northwest National Laboratory (PNNL) studied various known Fe-based alloys by evaluating their initial printability using LPBF, and an AMMT-developed down-selection and decision matrix reduced the number of alloys to be studied from six to three in fiscal year (FY) 2024. Additionally, in FY 2024, for parallel evaluation, these three alloys were studied using LPDED. While LPBF is better for small- to medium-sized components with high detail and internal features, LP-DED combines a material feed system to place the powder onto the exact spot where the laser will melt the material. This AM method can be easily scaled to extremely large components and provides high build rate speeds compared to those of conventional LPBF systems. Additionally, DED is a better choice for complex geometries and compositional gradients.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1987

Performance and operating envelope of imaging and scattering particle sizing instruments

Scattering and imaging type particle sizing instruments are analyzed in terms of their ability to make accurate determinations of particle size distributions, number density, and total mass. Sources of counting and sizing errors are explained. Ways are described of identifying these errors and how these errors can effect the measurements.

Hovenac, Edward A.↗
NASA NTRS2014

Full-Envelope Launch Abort System Performance Analysis Methodology

The implementation of a new dispersion methodology is described, which dis-perses abort initiation altitude or time along with all other Launch Abort System (LAS) parameters during Monte Carlo simulations. In contrast, the standard methodology assumes that an abort initiation condition is held constant (e.g., aborts initiated at altitude for Mach 1, altitude for maximum dynamic pressure, etc.) while dispersing other LAS parameters. The standard method results in large gaps in performance information due to the discrete nature of initiation conditions, while the full-envelope dispersion method provides a significantly more comprehensive assessment of LAS abort performance for the full launch vehicle ascent flight envelope and identifies performance "pinch-points" that may occur at flight conditions outside of those contained in the discrete set. The new method has significantly increased the fidelity of LAS abort simulations and confidence in the results.

Aubuchon, Vanessa V.↗
NASA NTRS1998

Initial Flight Test Evaluation of the F-15 ACTIVE Axisymmetric Vectoring Nozzle Performance

A full envelope database of a thrust-vectoring axisymmetric nozzle performance for the Pratt & Whitney Pitch/Yaw Balance Beam Nozzle (P/YBBN) is being developed using the F-15 Advanced Control Technology for Integrated Vehicles (ACTIVE) aircraft. At this time, flight research has been completed for steady-state pitch vector angles up to 20' at an altitude of 30,000 ft from low power settings to maximum afterburner power. The nozzle performance database includes vector forces, internal nozzle pressures, and temperatures all of which can be used for regression analysis modeling. The database was used to substantiate a set of nozzle performance data from wind tunnel testing and computational fluid dynamic analyses. Findings from initial flight research at Mach 0.9 and 1.2 are presented in this paper. The results show that vector efficiency is strongly influenced by power setting. A significant discrepancy in nozzle performance has been discovered between predicted and measured results during vectoring.

Orme, John S.↗
DOE OSTI2025

Refining seasonal performance metrics for room air-conditioning in emerging markets: Integrating building simulations with real-world equipment performance data

Buildings significantly impact worldwide energy consumption, emphasizing the need to reduce the cooling energy demand, especially in warm climates. Minimum energy performance standards (MEPS) and seasonal performance metrics such as the Cooling Seasonal Performance Factor (CSPF) are crucial for improving room air conditioning (RAC) efficiency. However, challenges remain, particularly in emerging markets like Brazil, where seasonal performance metrics have recently been introduced. This study assesses the factors influencing country-level seasonal efficiency metrics and proposes a framework to refine these calculations by considering local climates and expected RAC usage in real-world households via building simulations. Key considerations include outdoor air temperature binning for different climates, RAC usage patterns (i.e., daytime and nighttime usages), envelope thermal performance of households, and urban heat island (UHI) effects. The results reveal that CSPF values can vary significantly based on climate conditions, with observed CSPF ranging from 4.10 to 11.59 Wh/Wh across 577 Brazilian climates. The inclusion of UHI effects led to a reduction in CSPF values by up to 29% during nighttime operations in hot urban areas. Additionally, building envelope efficiency showed contrasting impacts on RAC performance, with CSPFs reaching up to 15.35 Wh/Wh under specific optimized conditions. These findings highlight the need for transparent policymaking in RAC performance databases, facilitating the application of approaches like those proposed in this study and supporting diverse stakeholders in decision-making.

Bavaresco, Mateus↗
NASA NTRS1977

Advanced high pressure engine study for mixed-mode vehicle applications

High pressure liquid rocket engine design, performance, weight, envelope, and operational characteristics were evaluated for a variety of candidate engines for use in mixed-mode, single-stage-to-orbit applications. Propellant property and performance data were obtained for candidate Mode 1 fuels which included: RP-1, RJ-5, hydrazine, monomethyl-hydrazine, and methane. The common oxidizer was liquid oxygen. Oxygen, the candidate Mode 1 fuels, and hydrogen were evaluated as thrust chamber coolants. Oxygen, methane, and hydrogen were found to be the most viable cooling candidates. Water, lithium, and sodium-potassium were also evaluated as auxiliary coolant systems. Water proved to be the best of these, but the system was heavier than those systems which cooled with the engine propellants. Engine weight and envelope parametric data were established for candidate Mode 1, Mode 2, and dual-fuel engines. Delivered engine performance data were also calculated for all candidate Mode 1 and dual-fuel engines.

Luscher, W. P.↗
NASA NTRS1979

Unconventional nozzle tradeoff study

Plug cluster engine design, performance, weight, envelope, operational characteristics, development cost, and payload capability, were evaluated and comparisons were made with other space tug engine candidates using oxygen/hydrogen propellants. Parametric performance data were generated for existing developed or high technology thrust chambers clustered around a plug nozzle of very large diameter. The uncertainties in the performance prediction of plug cluster engines with large gaps between the modules (thrust chambers) were evaluated. The major uncertainty involves, the aerodynamics of the flow from discrete nozzles, and the lack of this flow to achieve the pressure ratio corresponding to the defined area ratio for a plug cluster. This uncertainty was reduced through a cluster design that consists of a plug contour that is formed from the cluster of high area ratio bell nozzles that have been scarfed. Light-weight, high area ratio, bell nozzles were achieved through the use of AGCarb (carbon-carbon cloth) nozzle extensions.

Obrien, C. J.↗