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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Space nuclear power systems; Proceedings of the 8th Symposium, Albuquerque, NM, Jan. 6-10, 1991. Pts. 1-3

The present conference discusses NASA mission planning for space nuclear power, lunar mission design based on nuclear thermal rockets, inertial-electrostatic confinement fusion for space power, nuclear risk analysis of the Ulysses mission, the role of the interface in refractory metal alloy composites, an advanced thermionic reactor systems design code, and space high power nuclear-pumped lasers. Also discussed are exploration mission enhancements with power-beaming, power requirement estimates for a nuclear-powered manned Mars rover, SP-100 reactor design, safety, and testing, materials compatibility issues for fabric composite radiators, application of the enabler to nuclear electric propulsion, orbit-transfer with TOPAZ-type power sources, the thermoelectric properties of alloys, ruthenium silicide as a promising thermoelectric material, and innovative space-saving device for high-temperature piping systems. The second volume of this conference discusses engine concepts for nuclear electric propulsion, nuclear technologies for human exploration of the solar system, dynamic energy conversion, direct nuclear propulsion, thermionic conversion technology, reactor and power system control, thermal management, thermionic research, effects of radiation on electronics, heat-pipe technology, radioisotope power systems, and nuclear fuels for power reactors. The third volume discusses space power electronics, space nuclear fuels for propulsion reactors, power systems concepts, space power electronics systems, the use of artificial intelligence in space, flight qualifications and testing, microgravity two-phase flow, reactor manufacturing and processing, and space and environmental effects.

El-Genk, Mohamed S.↗
NASA NTRS1993

Design of a resistojet for Space Station Freedom

In the mid 1990's, NASA will begin assembly of Space Station Freedom, a permanent outpost in a low-earth orbit. For the station to remain in that orbit, an altitude control system must be developed to resist the effects of atmospheric drag. One system being considered by NASA is called a resistojet, and it uses highly pressurized waste gases heated by electrical resistance to provide thrust on the order of 1 Newton. An additional function of the resistojet is to vent waste gases used by the station and its inhabitants. This report focuses on resolving the issues of system performance, flow and heater control, and materials selection and designing test procedures to resolve, by experimentation, any remaining issues. The conceptual model of the resistojet consists of a shell wrapped by a resistive coil with gases flowing internally through the tube with additional components such as regulators, transducers, and thermocouples. For system performance, the major parameters were calculated from the desired thrust range, the pressure within the resistojet and the cold flow mode of operation; waste gases were analyzed at 100 percent capacity and between 58.95 kPa and 552 kPa. The design team found that any ventilation under all conditions would produce thrust, and therefore, it was decided to limit the design of the ventilation function. The design team proceeded with a simplified model to determine the nozzle throat diameter and chamber diameter.

Garza, Jose↗
NASA NTRS2001

Preliminary Component Integration Utilizing Rapid Prototyping Techniques

One of the most costly errors committed during the development of an element to be used in the space industry is the lack of communication between design and manufacturing engineers. A very important tool that should be utilized in the development stages by both design and manufacturing disciplines is rapid prototyping. Communication levels are intensified with the injection of functional models that are generated from a drawing. At the Marshall Space Flight Center, this discipline is utilized on a more frequent basis as a manner by which hardware may be tested for design and material compatibility.

Cooper, K.↗
NASA NTRS1986

A Mirror Transport Mechanism for Use at Cryogenic Temperatures

This report describes the Mirror Transport Mechanism (MTM), which supports a pair of dihedral mirrors and moves them in a very smooth and uniform scanning motion normal to a beamsplitter. Each scan is followed by a quick flyback and repeat. Included in the report will be material selection, design, and testing of all major components of the MTM in order to meet the stringent performance requirements under cryogenic conditions and survive the launch environment of the shuttle. Areas to be discussed in detail will be those in which failures or performance anomalies occurred and their solutions. Typically, this will include (but not to be limited to) flex pivot failures during vibration testing, excessive dihedral platform sag under one "g" operation, electronic and fiber optic characteristics, and tolerancing considerations. As of this writing, development of the mechanism has reached the final phase of thermal and vibration qualification. Environmental testing of the complete FIRAS (Far Infrared Absolute Spectrophotometer) experiment is just beginning.

Stark, Kenneth W.↗
NASA NTRS2015

SAGE III on ISS Lessons Learned on Thermal Interface Design

The Stratospheric Aerosol and Gas Experiment III (SAGE III) instrument - the fifth in a series of instruments developed for monitoring vertical distribution of aerosols, ozone, and other trace gases in the Earth's stratosphere and troposphere - is currently scheduled for delivery to the International Space Station (ISS) via the SpaceX Dragon vehicle in 2016. The Instrument Adapter Module (IAM), one of many SAGE III subsystems, continuously dissipates a considerable amount of thermal energy during mission operations. Although a portion of this energy is transferred via its large radiator surface area, the majority must be conductively transferred to the ExPRESS Payload Adapter (ExPA) to satisfy thermal mitigation requirements. The baseline IAM-ExPA mechanical interface did not afford the thermal conductance necessary to prevent the IAM from overheating in hot on-orbit cases, and high interfacial conductance was difficult to achieve given the large span between mechanical fasteners, less than stringent flatness specifications, and material usage constraints due to strict contamination requirements. This paper will examine the evolution of the IAM-ExPA thermal interface over the course of three design iterations and will include discussion on design challenges, material selection, testing successes and failures, and lessons learned.

Davis, Warren↗
NASA NTRS2016

Composites for Exploration Upper Stage

The Composites for Exploration Upper Stage (CEUS) was a 3-year, level III project within the Technology Demonstration Missions program of the NASA Space Technology Mission Directorate. Studies have shown that composites provide important programmatic enhancements, including reduced weight to increase capability and accelerated expansion of exploration and science mission objectives. The CEUS project was focused on technologies that best advanced innovation, infusion, and broad applications for the inclusion of composites on future large human-rated launch vehicles and spacecraft. The benefits included near- and far-term opportunities for infusion (NASA, industry/commercial, Department of Defense), demonstrated critical technologies and technically implementable evolvable innovations, and sustained Agency experience. The initial scope of the project was to advance technologies for large composite structures applicable to the Space Launch System (SLS) Exploration Upper Stage (EUS) by focusing on the affordability and technical performance of the EUS forward and aft skirts. The project was tasked to develop and demonstrate critical composite technologies with a focus on full-scale materials, design, manufacturing, and test using NASA in-house capabilities. This would have demonstrated a major advancement in confidence and matured the large-scale composite technology to a Technology Readiness Level 6. This project would, therefore, have bridged the gap for providing composite application to SLS upgrades, enabling future exploration missions.

composites↗
NASA NTRS2016

Printed Circuit Board Quality Assurance

PCB Assurance Summary: PCB assurance actives are informed by risk in context of the Project. Lessons are being applied across Projects for continuous improvements. Newer component technologies, smaller/high pitch devices: tighter and more demanding PCB designs: Identifying new research areas. New materials, designs, structures and test methods.

Reliability↗
NASA NTRS2011

Low Cost Nuclear Thermal Rocket Cermet Fuel Element Environment Testing

Deep space missions with large payloads require high specific impulse and relatively high thrust to achieve mission goals in reasonable time frames.1,2 Conventional storable propellants produce average specific impulse. Nuclear thermal rockets capable of producing high specific impulse are proposed. Nuclear thermal rockets employ heat produced by fission reaction to heat and therefore accelerate hydrogen, which is then forced through a rocket nozzle providing thrust. Fuel element temperatures are very high (up to 3000 K), and hydrogen is highly reactive with most materials at high temperatures. Data covering the effects of high-temperature hydrogen exposure on fuel elements are limited.3 The primary concern is the mechanical failure of fuel elements that employ high-melting-point metals, ceramics, or a combination (cermet) as a structural matrix into which the nuclear fuel is distributed. The purpose of the testing is to obtain data to assess the properties of the non-nuclear support materials, as-fabricated, and determine their ability to survive and maintain thermal performance in a prototypical NTR reactor environment of exposure to hydrogen at very high temperatures. The fission process of the planned fissile material and the resulting heating performance is well known and does not therefore require that active fissile material be integrated in this testing. A small-scale test bed designed to heat fuel element samples via non-contact radio frequency heating and expose samples to hydrogen is being developed to assist in optimal material and manufacturing process selection without employing fissile material. This paper details the test bed design and results of testing conducted to date.

Bradley, D. E.↗
NASA NTRS2003

The Application of Metal Matrix Composite Materials in Propulsion System Valves

Metal Matrix Composite (MMC) materials have been developed and used in many applications to reduce the weight of components where weight and deflection are the driving design requirement. MMC materials are being developed for use in some propulsion system components, such as turbo-pumps and thrust chambers. However, to date, no propulsion system valves have been developed that take advantage of the materials unique properties. The stiffness of MMC's could help keep valves light or improve life where deflection is the design constraint (such as seal and bearing locations). The low CTE of the materials might allow the designer to reduce tolerances and clearances producing better performance and lighter weight valves. Using unique manufacturing processes allow parts to be plated/coated for longer life and allow joining either by welding or threading/bolting. Additionally, casting of multi part pre-forms to form a single part can lead to designs that would be hard or impossible to manufacture with other methods. Therefore, NASA's Marshall Space Flight Center (MSFC) has developed and tested a prototype propulsion system valve that utilizes these materials to demonstrate these advantages. Through design and testing, this effort will determine the best use of these materials in valves designed to achieve the goal of a highly reliable and lightweight propulsion system. This paper is a continuation of the paper, The Application of Metal Matrix Composite Materials In Propulsion System Valves, presented at the JANNAF Conference held in April, 2002. Fabrication techniques employed, valve development, and valve test results will be discussed in this paper.

Laszar, John↗
NASA NTRS1971

Effects of cyclical environments on high-performance multi-layer insulation materials.

Results of a test program designed to determine the effects of 100 temperature and compressive loading cycles on several multilayer insulation materials and composites. A total of four reflector materials, four separator materials, eight face-sheet systems, and one fastener material were subjected to 100 temperature cycles from -320 to 400 or 650 F. Generic types of materials studied included Mylar, Kapton, Dacron, Nomex, and Beta Glass. The temperature cycling was followed by visual inspection, metal adhesion tests on the reflectors, and tensile tests of the face sheets, fastener, and separators. A total of six composites were subjected to compressive cycles between zero and 0.15 psi, and density changes were measured. Application of the experimental results to the shuttle orbiter is discussed.

Krause, D. R.↗
DOE OSTI2022

BISON Validation to In-Situ Cladding Burst Test and High Burnup LOCA Experiments

The process to develop and qualify nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and post irradiation examinations (PIEs); and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes approximately 20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long and drawn-out process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in-situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In general, the in-situ measurements provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the United States nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the Nuclear Regulatory Commission, through their research information letter, outlined a number of technical issues for the industry to address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heatup phase. Leveraging these advanced in-situ capabilities, this work intends to use insitu data generated from a simulated LOCA in the Severe Accident Test Station at Oak Ridge National Laboratory to better understand high-temperature creep and its impact on Zircaloy balloon and rupture performance. This work used the BISON fuel performance code to compare BISON’s high-temperature creep model predictions to in-situ data and identify limitations and gaps within the model. Additionally, BISON will subsequently be used to simulate relevant high-burnup LOCA tests. The results will be analyzed and compared to the available post-test data in a manner consistent with the approach outlined in the Nuclear Regulatory Commission research information letter.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

I.6.C Battery Safety Testing

Abuse tests are designed to determine the safe operating limits of HEV\PHEV energy storage devices. Testing is intended to achieve certain worst-case scenarios to yield quantitative data on cell\module\pack response, allowing for failure mode determination and guiding developers toward improved materials and designs. Standard abuse tests with defined start and end conditions are performed on all devices to provide comparison between technologies. New tests and protocols are developed and evaluated to more closely simulate real world failure conditions. While robust mechanical models for vehicles and vehicle components exist, there is a gap for mechanical modeling of EV batteries. The challenge with developing a mechanical model for a battery is the heterogeneous nature of the materials and components (polymers, metals, metal oxides, liquids).

25 ENERGY STORAGE↗
DOE OSTI2020

Battery Abuse Testing

Abuse tests are designed to determine the safe operating limits of HEV\PHEV energy storage devices. Testing is intended to achieve certain worst-case scenarios to yield quantitative data on cell\module\pack response, allowing for failure mode determination and guiding developers toward improved materials and designs. Standard abuse tests with defined start and end conditions are performed on all devices to provide comparison between technologies. New tests and protocols are developed and evaluated to more closely simulate real-world failure conditions. While robust mechanical models for vehicles and vehicle components exist, there is a gap for mechanical modeling of EV batteries. The challenge with developing a mechanical model for a battery is the heterogeneous nature of the materials and components (polymers, metals, metal oxides, liquids). This year saw the stand up of a new drop tower tester capable of providing dynamic mechanical test results.

25 ENERGY STORAGE↗
NASA NTRS1993

Advanced Turbine Technology Applications Project (ATTAP)

The Advanced Turbine Technologies Application Project (ATTAP) is in the fifth year of a multiyear development program to bring the automotive gas turbine engine to a state at which industry can make commercialization decisions. Activities during the past year included reference powertrain design updates, test-bed engine design and development, ceramic component design, materials and component characterization, ceramic component process development and fabrication, ceramic component rig testing, and test-bed engine fabrication and testing. Engine design and development included mechanical design, combustion system development, alternate aerodynamic flow testing, and controls development. Design activities included development of the ceramic gasifier turbine static structure, the ceramic gasifier rotor, and the ceramic power turbine rotor. Material characterization efforts included the testing and evaluation of five candidate high temperature ceramic materials. Ceramic component process development and fabrication, with the objective of approaching automotive volumes and costs, continued for the gasifier turbine rotor, gasifier turbine scroll, extruded regenerator disks, and thermal insulation. Engine and rig fabrication, testing, and development supported improvements in ceramic component technology. Total test time in 1992 amounted to 599 hours, of which 147 hours were engine testing and 452 were hot rig testing.

Source record↗
DOE OSTI2023

BISON validation to in situ cladding burst test and high-burnup LOCA experiments

The process for developing and qualifying nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and postirradiation examinations; and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes ~20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In situ measurements generally provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the US nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the US Nuclear Regulatory Commission (NRC) outlined in its research information letter several technical issues that the industry must address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heat-up phase. By leveraging these advanced in situ capabilities, this work used in situ data generated from a simulated LOCA to better understand high-temperature creep and its effect on Zircaloy balloon and rupture performance. Here, this work used the BISON fuel performance code to assess the high-temperature creep model predictions with in situ data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Report on Thermal Cycling Testing and Bimaterial Weld Development for a Passively Actuated Materials Surveillance Test Article

This report describes the continuation and conclusion of a thermal cycling test program designed to evaluate a family of passively actuated material surveillance test articles. Additionally, the report details a preliminary study of bimetallic welding between 316 stainless steel and TZM (tungsten-zirconium-molybdenum) alloy. The test program was ultimately successful in demonstrating the basic viability of the passively actuated test article concept as well as specifically validating the procedures developed to size specimens to mimic the mechanical response of operating components. The report discusses and summarizes the results of the complete test program which tested samples for more than 1,000 controlled thermal cycles. The weld development program included both stir friction and electron beam joining. The stir friction welding was ultimately successful, while the electron beam welding would require additional development. Ultimately, these test programs pave the way for implementing a materials surveillance program in future molten salt reactors (MSRs). The report conclusions outline a plan for transforming the research and developed described here into a definite set of practices and procedures for a surveillance program at a future operating reactor.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1985

Development and testing of advanced fire-resistant photovoltaic modules

The evaluation of back-surface materials flammability in order to identify fire resistant module designs is examined. The fire test apparatus, burning-brand test sequence, and spread-of-flame test sequence are described. Video recordings and time-temperature profiles of module back surfaces are utilized to study the flammability failure mechanism and identify high-temperature materials. A table of flammability test results for various module designs is provided. The data reveals that 2-mil kapton, fiberglass cloth coated or impregnated with a material to plug pores, and metal foil back-surface materials achieve class A and B fire-resistance levels, and are applicable for photovoltaic module designs.

Sugimura, R. S.↗
NASA NTRS2026

Improvement of Odor Control for the UWMS Hard-Sided Fecal Canister and the Alternate Fecal Canister

On longer range exploration missions, the mass and volume of critical hardware and consumables required to support crew will pose a big stowage challenge. This includes the hardware for the collection and storage of human metabolic solid waste. The amount of stowage needed for this hardware both before (empty) and after (full) use will be a significant burden on the overall spacecraft habitable volume, layout, and design. To help with this challenge, the National Aeronautics and Space Administration (NASA) Mars Campaign Office (MCO) Logistics Reduction (LR) Portfolio has developed a collapsible canister for the collection and containment of fecal deposits. The Alternate Fecal Canister (AFC) is a collapsible alternative to the exploration toilet Hard-sided Fecal Canister (HFC). The AFC in its empty state has a volumetric benefit to smaller vehicles on longer missions. The current designs for HFC and AFC were tested with human fecal material for odor containment at White Sands Test Facility (WSTF) where the tests on both were unsuccessful. The source of the lack of containment was isolated to a gasket used on both HFC and AFC. The gasket used was found to be open cell in design. This paper provides a summary of the materials selection and testing process to identify a replacement gasket material with the intention to replace the gaskets on both existing units as well as incorporate it into the designs going forward for future builds for exploration. Details will be provided on the design of the canisters interface with the odor bacteria lid which led to the selection of the thickness of the desired replacement. Finally, the paper will provide an update on the testing in advance of a return to WSTF for final testing and detail plans to complete testing and perform a demonstration on ISS with UWMS.

ECLSS↗