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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 1,279 records · Page 71
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Environmentally Sound Processing Technology: JANNAF Safety and Environmental Protection Subcommittee and Propellant Development and Characterization Subcommittee Joint Workshop

Topics covered include: Risk assessment of hazardous materials, Automated systems for pollution prevention and hazardous materials elimination, Study design for the toxicity evaluation of ammonium perchlorate, Plasma sprayed bondable stainless surface coatings, Development of CFC-free cleaning processes, New fluorinated solvent alternatives to ozone depleting solvents, Cleaning with highly fluorinated liquids, Biotreatment of propyleneglycol nitrate by anoxic denitrification, Treatment of hazardous waste with white rot fungus, Hydrothermal oxidation as an environmentally benign treatment technology, Treatment of solid propellant manufacturing wastes by base hydrolysis, Design considerations for cleaning using supercritical fluid technology, and Centrifugal shear carbon dioxide cleaning.

Pickett, Lorri A.↗
NASA NTRS2005

Semiautomated, Reproducible Batch Processing of Soy

A computer-controlled apparatus processes batches of soybeans into one or more of a variety of food products, under conditions that can be chosen by the user and reproduced from batch to batch. Examples of products include soy milk, tofu, okara (an insoluble protein and fiber byproduct of soy milk), and whey. Most processing steps take place without intervention by the user. This apparatus was developed for use in research on processing of soy. It is also a prototype of other soy-processing apparatuses for research, industrial, and home use. Prior soy-processing equipment includes household devices that automatically produce soy milk but do not automatically produce tofu. The designs of prior soy-processing equipment require users to manually transfer intermediate solid soy products and to press them manually and, hence, under conditions that are not consistent from batch to batch. Prior designs do not afford choices of processing conditions: Users cannot use previously developed soy-processing equipment to investigate the effects of variations of techniques used to produce soy milk (e.g., cold grinding, hot grinding, and pre-cook blanching) and of such process parameters as cooking times and temperatures, grinding times, soaking times and temperatures, rinsing conditions, and sizes of particles generated by grinding. In contrast, the present apparatus is amenable to such investigations. The apparatus (see figure) includes a processing tank and a jacketed holding or coagulation tank. The processing tank can be capped by either of two different heads and can contain either of two different insertable mesh baskets. The first head includes a grinding blade and heating elements. The second head includes an automated press piston. One mesh basket, designated the okara basket, has oblong holes with a size equivalent to about 40 mesh [40 openings per inch (.16 openings per centimeter)]. The second mesh basket, designated the tofu basket, has holes of 70 mesh [70 openings per inch (.28 openings per centimeter)] and is used in conjunction with the press-piston head. Supporting equipment includes a soy-milk heat exchanger for maintaining selected coagulation temperatures, a filter system for separating okara from other particulate matter and from soy milk, two pumps, and various thermocouples, flowmeters, level indicators, pressure sensors, valves, tubes, and sample ports

Thoerne, Mary↗
DOE OSTI2020

Rapid Patterning and Advanced Device Structures for Low Cost Manufacturable Crystalline Si IBC Cells

Recent record efficiency Si cells have had an interdigitated back contact (IBC) design where both positive and negative contacts are fabricated on the back side of the Si wafer. Many industry groups have investigated IBC cells but used photolithography to pattern the rear contacts although it is considered impractical for low cost, high volume manufacturing. Alternative patterning methods using lasers and mechanical masking have been utilized in fabrication of patterned regions in IBC Si solar cells to replace photolithography. Another exciting advance in Si solar cell technology has been replacing the high temperature diffusion of doped regions inside the crystalline Si wafer with low temperature deposition of very thin layers of doped amorphous hydrogenated Si (a-Si:H) on the Si wafer. This is called a Si heterojunction (HJ) device. The a-Si:H provides excellent passivation of surface defects and has produced the highest open circuit voltages (VOC) of any Si solar cell device structure. The Institute of Energy Conversion (IEC) demonstrated the first IBC-HJ solar cell combining these two strategies in 2007 and has fabricated IBC-HJ cells with 20% efficiency using three photolithography steps. Despite the demonstrated efficiency potential of this device by industry groups (>26%) there is no commercial production because of the challenges of patterning and processing the structure in an industrial environment. Our work sought to address that challenge. The objective of this 3 year project was to develop the processing for the IBC-HJ Si solar cell using lasers for patterning and contact formation instead of photolithography. Laser patterning enables rapid, contactless manufacturing of patterned regions. We intensively studied laser fired contacts, laser patterning of the a-Si multi-layer stacks and metal layers and the use of plasma shadow masks. After an exhaustive focus in the first year on the laser fired emitter (LFE) and contact (LFC), we were unable to achieve VOC greater than 660 mV, compared to the 720 mV required to meet our milestones. We discovered that an additional issue with our original IBC structure was the presence of an inversion layer at the back surface connecting the p and n regions which reduced the VOC and fill factor (FF). We developed innovative methods for characterizing the inversion layer. These two limitations in the original design lead to development of a new IBC-HJ process sequence and device structure which we called Plasma Masked Laser Processed (PMLP). It retained the original high efficiency features including manufacturability. The LFC was replaced with a standard n-type a-Si HJ contact. The inversion layer was eliminated by replacing the previous p-type stack in the gap with an n-type or SiN stack. The PMLP used laser ablation of a multi-layer a-Si stack followed by chemical etching to open the n-contact. It required deposition of a patterned stack through a mask in the plasma deposition chamber. This turned out to be a source of significant problems due to inevitable unwanted deposition ‘leakage’ under the mask. This formed a blocking contact on the emitter which significantly reduced Voc and FF. Several iterations in PMLP device structure and chemical etching steps resulted in a large improvements, e.g. the efficiency increasing from 3 to 15% and Voc from 450 to 660 mV but they were unable to completely eliminate it. The best IBC-HJ device we fabricated had only 15% efficiency. For perspective, our standard FHJ devices had 20% efficiency.

14 SOLAR ENERGY↗
DOE OSTI2021

Ultra-low-density digitally architected carbon with a strutted tube-in-tube structure

Porous materials with engineered stretching-dominated lattice designs, which offer attractive mechanical properties with ultra-light weight and large surface area for wide-ranging applications, have recently achieved near-ideal linear scaling between stiffness and density. Here, rather than optimizing the microlattice topology, we explore a different approach to strengthen low-density structural materials by designing tube-in-tube beam structures. We develop a process to transform fully dense, three-dimensional printed polymeric beams into graphitic carbon hollow tube-in-tube sandwich morphologies, where, similar to grass stems, the inner and outer tubes are connected through a network of struts. Compression tests and computational modelling show that this change in beam morphology dramatically slows down the decrease in stiffness with decreasing density. In situ pillar compression experiments further demonstrate large deformation recovery after 30–50% compression and high specific damping merit index. Lastly, our strutted tube-in-tube design opens up the space and realizes highly desirable high modulus–low density and high modulus–high damping material structures.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Magneto-Mechanical Optimization of Cross-Sections for $ \text{cos}(\theta)$Accelerator Magnets

The cross-section design of cos (θ) superconducting magnets is historically developed in a two-step process: initially, the coil geometry is defined on the basis of magnetic optimizations; then, the structure is designed around the coil. The first step searches for the best coil cross-section maximizing the magnetic field, margin, field quality and conductor efficiency. The latter step aims at limiting the coil stresses and deformations. However, the coil design, defined with the initial magnetic optimization, can influence the mechanical behaviour of the magnet, altering, for example, the peak stress during operation. As the critical current is a function of the applied strain, the mechanical implications of the coil cross-section design can limit the achievable performance. In this paper we propose an integrated optimization process that targets the peak stress on the conductor in addition to the magnetic objectives. Here the results are presented for a sample high-field Nb 3 Sn dipole: a 4-layer design aiming at ultimate conductor performance.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Saturation Carrying Capacity for Group A Particles in a Circulating Fluidized Bed

Empirical models continue to play a significant role in the design process of multiphase chemical reactors, particularly riser reactors in circulating fluidized bed (CFB) processes. It is imperative that accurate, industrial relevant correlations are developed to aid these design efforts. Using poor correlations could result in startup issues and significant redesign work. In this work, a new correlation is proposed to predict the saturation carrying capacity of Geldart Group A particles. This new correlation improves upon the currently available correlations for these materials and covers a broad range of Geldart Group A particles (particle diameters from 52 to 70 µm, and Archimedes numbers ranging from 5 to 20), superficial gas velocities (1 to 4 m/s), and riser diameters (0.066 to 0.3048 m). The new correlation has an Absolute Average Percent Deviation of only 17.6%, making it the most accurate correlation for Geldart Group A particles in the current literature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1977

Hybrid receiver study

The results are presented of a 4 month study to design a hybrid analog/digital receiver for outer planet mission probe communication links. The scope of this study includes functional design of the receiver; comparisons between analog and digital processing; hardware tradeoffs for key components including frequency generators, A/D converters, and digital processors; development and simulation of the processing algorithms for acquisition, tracking, and demodulation; and detailed design of the receiver in order to determine its size, weight, power, reliability, and radiation hardness. In addition, an evaluation was made of the receiver's capabilities to perform accurate measurement of signal strength and frequency for radio science missions.

Stone, M. S.↗
NASA NTRS1990

Design optimization for cost and quality: The robust design approach

Designing reliable, low cost, and operable space systems has become the key to future space operations. Designing high quality space systems at low cost is an economic and technological challenge to the designer. A systematic and efficient way to meet this challenge is a new method of design optimization for performance, quality, and cost, called Robust Design. Robust Design is an approach for design optimization. It consists of: making system performance insensitive to material and subsystem variation, thus allowing the use of less costly materials and components; making designs less sensitive to the variations in the operating environment, thus improving reliability and reducing operating costs; and using a new structured development process so that engineering time is used most productively. The objective in Robust Design is to select the best combination of controllable design parameters so that the system is most robust to uncontrollable noise factors. The robust design methodology uses a mathematical tool called an orthogonal array, from design of experiments theory, to study a large number of decision variables with a significantly small number of experiments. Robust design also uses a statistical measure of performance, called a signal-to-noise ratio, from electrical control theory, to evaluate the level of performance and the effect of noise factors. The purpose is to investigate the Robust Design methodology for improving quality and cost, demonstrate its application by the use of an example, and suggest its use as an integral part of space system design process.

Unal, Resit↗
NASA NTRS2005

Modern Radar Techniques for Geophysical Applications: Two Examples

The last decade of the evolution of radar was heavily influenced by the rapid increase in the information processing capabilities. Advances in solid state radio HF devices, digital technology, computing architectures and software offered the designers to develop very efficient radars. In designing modern radars the emphasis goes towards the simplification of the system hardware, reduction of overall power, which is compensated by coding and real time signal processing techniques. Radars are commonly employed in geophysical radio soundings like probing the ionosphere; stratosphere-mesosphere measurement, weather forecast, GPR and radio-glaciology etc. In the laboratorio di Geofisica Ambientale of the Istituto Nazionale di Geofisica e Vulcanologia (INGV), Rome, Italy, we developed two pulse compression radars. The first is a HF radar called AIS-INGV; Advanced Ionospheric Sounder designed both for the purpose of research and for routine service of the HF radio wave propagation forecast. The second is a VHF radar called GLACIORADAR, which will be substituting the high power envelope radar used by the Italian Glaciological group. This will be employed in studying the sub glacial structures of Antarctica, giving information about layering, the bed rock and sub glacial lakes if present. These are low power radars, which heavily rely on advanced hardware and powerful real time signal processing. Additional information is included in the original extended abstract.

Arokiasamy, B. J.↗
DOE OSTI2023

Hybrid Solar System (Final Scientific/Technical Report)

GTI Energy (GTI) teamed with the University of California at Merced (UCM) to scaleup the hybrid solar system (HSS) technology for demonstrating its performance at the US Gypsum (USG) plant in Plaster City, California. The technology integrates two-stage concentrating solar collector with matching particle thermal transport and storage (TSS) system to deliver cost-effective, and on-demand distributed high temperature industrial process heat up to 600°C with solar thermal, in this case to a gypsum kettle, to reduce its fuel use and carbon footprint. Current solar technologies, which reach these temperatures, are not distributable (towers) or cost-effective (dish). The research team developed a conceptual system design for host site retrofit, including preliminary heat balance, process flow diagram, particle to process heat exchanger and equipment placements at the site. Subsequently, parallel efforts were carried out at UCM to design, build and test a 12 m long commercial scale prototype concentrating thermal-only collector system and at GTI to design, build and test a matching 650°C capable particle TTS system. The nominal 50 kWth collector consists of a parabolic trough and three 4 m long two-stage receivers in series. Prior to on-sun testing, a 4 m long receiver was fabricated and successfully tested at 650 °C in a laboratory setting for 100 hrs of continuous operation showing less than 15% radiation loss. A 7 m wide x 17 m long parabolic trough was then installed at UCM for on-sun testing of the 12 m long receiver, and concurrently several 4 m long receivers were built. The optics of the parabolic trough were calibrated, and on-sun test were carried out on 12 m long receivers. During tests, the intense solar radiation (53x) caused the absorber tubes in the receivers to bend, reducing the overall optical efficiency. To address the bending issue, a self-consistent algorithm that includes ray tracing, thermal and deformation models was developed to perform thermal stress analysis on absorbers for parabolic solar collectors. Results obtained with this algorithm showed a dramatic rise in deformation as absorber tube length increases. A combined efficiency parameter that includes the occluded area for the mounts was developed to obtain an optimized tube length obtained. Based on the results, a length of 2.7 m for the absorber + 0.2 m for the coupler was chosen to minimize any bending and optimize optical efficiency while maintaining ease of mounting. The associated particle TTS system was designed, built and successfully tested at GTI. It includes storage, receiving and lock hoppers and piping that simulates the transfer of captured solar energy to an actual industrial furnace. Tests over 77 charge-discharge cycles demonstrated <2% particle degradation, with no problematic particle accumulations and no flow interruptions. The piping pressure drop was about 5 psi. The team also worked with Stanley Consultants (Stanley) to prepare conceptual and preliminary engineering packages to facilitate follow-on development and commercialization efforts. These include process and instrumentation diagram’s (P&ID’s), general arrangements, electrical one-line, project definitions document, equipment data sheets, schedule, and construction cost estimate for 2 MWth system. Updated HSS technology commercialization and customer engagement plans and detailed costs and evaluated market trade-offs and manufacturing.

03 NATURAL GAS↗
NASA NTRSDate not supplied

Selection of Alternator Voltage for Dynamic Radioisotope Power Systems

In this paper, we present a study to select an appropriate alternator voltage of the free-piston Stirling convertors (FPSC) for efficient and light Dynamic Radioisotope Power Systems (DRPS). With a system thermal-to-electrical efficiency 3-4 times greater than radioisotope thermoelectric generator (RTG) systems and a higher power density than Brayton systems in the power range of interest for radioisotope-powered systems, Stirling-based DRPS is uniquely suited to benefit upcoming NASA missions. Much effort has been invested in the design and optimization of the thermal, mechanical, and materials aspects of FPSCs, but the electrical aspect has been more nebulous. Therefore, in this paper, a preliminary study will be presented to select the appropriate Stirling alternator voltage to develop a light and efficient system using available flight components. Power conversion systems face a trade between efficiency and system volume/mass with the optimal trade being determined by the application. Neglecting non-idealities related to insulation thickness and winding packing factor and assuming a constant winding area, alternator efficiency is independent of alternator voltage. Because wire size and alternator current can be traded against turn count and alternator voltage without impacting efficiency, the guidance on the optimal design comes from analysis of the controller power electronics and the remainder of the system. Properties of available flight-qualified electrical components, such as rated voltage/current and on-resistance, typically come in discrete values instead of a continuous range of values. With multiple components being required to form the power conversion stage of the controller, each limited to incremental values, a continuous optimization is of little benefit. Instead of a continuous optimization, a random process using properties of the available components can be used to develop a Pareto design front indicating the optimized trade space. The most advantageous trade between system efficiency and mass for the system at hand can then be selected from the range of feasible designs. In the final paper, the design process, assumptions, and preliminary results will be presented.

Free-Piston Stirling Convertor Controller, Dynamic↗
NASA NTRS1939

Flight Tests of N.A.C.A. Nose-slot Cowlings on the BFC-1 Airplane

The results of flight tests of four nose-slot cowling designs with several variations in each design are presented. The tests were made in the process of developing the nose-slot cowling. The results demonstrate that a nose-slot cowling may be successfully applied to an airplane and that it utilizes the increased slipstream velocity of low-speed operation to produce increased cooling pressure across the engine. A sample design calculation using results from wind-tunnel, flight, and ground tests is given in an appendix to illustrate the design procedure.

Stickle, George W↗
NASA NTRS1994

Process and methodology of developing Cassini G and C Telemetry Dictionary

While the Cassini spacecraft telemetry design had taken on the new approach of 'packetized telemetry', the AACS (Attitude and Articulation Subsystem) had further extended into the design of 'mini-packets' in its telemetry system. Such telemetry packet and mini-packet design produced the AACS Telemetry Dictionary; iterations of the latter in turn provided changes to the former. The ultimate goals were to achieve maximum telemetry packing density, optimize the 'freshness' of more time-critical data, and to effect flexibility, i.e., multiple AACS data collection schemes, without needing to change the overall spacecraft telemetry mode. This paper describes such a systematic process and methodology, evidenced by various design products related to, or as part of, the AACS Telemetry Dictionary.

Kan, Edwin P.↗
NASA NTRS2017

Laser Processed Condensing Heat Exchanger Technology Development

The reliance on non-permanent coatings in Condensing Heat Exchanger (CHX) designs is a significant technical issue to be solved before long-duration spaceflight can occur. Therefore, high reliability CHXs have been identified by the Evolvable Mars Campaign (EMC) as critical technologies needed to move beyond low earth orbit. The Laser Processed Condensing Heat Exchanger project aims to solve these problems through the use of femtosecond laser processed surfaces, which have unique wetting properties and potentially exhibit anti-microbial growth properties. These surfaces were investigated to identify if they would be suitable candidates for a replacement CHX surface. Among the areas researched in this project include microbial growth testing, siloxane flow testing in which laser processed surfaces were exposed to siloxanes in an air stream, and manufacturability.

Hansen, Scott↗
NASA NTRS2012

System Engineering Processes at Kennedy Space Center for Development of the SLS and Orion Launch Systems

There are over 40 subsystems being developed for the future SLS and Orion Launch Systems at Kennedy Space Center. These subsystems developed at the Kennedy Space Center Engineering Directorate follow a comprehensive design process which requires several different product deliverables during each phase of each of the subsystems. This Paper describes this process and gives an example of where the process has been applied.

Schafer, Eric J.↗
DOE OSTI2020

Mind the Gap: Building Simulation in the Architectural Design Studio

Building modelling and simulation approaches are increasingly being utilized in architectural design studios to guide and inform the design process and offer evidence-based feedback on proposed building performance. The development of intuitive and simplified simulation interfaces has greatly contributed to achieving this integration. One aspect that is often overlooked is the workflow that governs and regulates integrated design, which can have significant impacts on final design outcomes. Currently there are numerous software packages available for building performance simulations. This makes it challenging to select an appropriate tool that provides accurate results yet allows a designer to make informed architectural decisions with a designer-friendly interface. Furthermore, workflows to incorporate simulations into the design process proved to highly impact student’s project design integration. Yet, it is not clear what type of workflows are successful to achieve this goal, under what conditions, and/or for which building and site typologies. This paper addresses these issues by first reviewing three different workflows for integrating building performance simulation processes and highlighting their strengths and weaknesses. Second, a comparative case study approach was employed to test three of the most common workflows in three different integrated design architectural studios at the senior and vertical studio levels as well as in two courses that run parallel and complementary to the design studios. The workflows, processes, and the resultant student projects were further analyzed based on criteria for better integrated design and architectural excellence as outlined in the American Institute of Architects Committee on the Environment (AIA COTE) Top 10 Student’s Competition. Third, to situate the pedagogical case studies’ results within a larger context, a survey of the AIA COTE Top 10 student competition award recipients over the last five years was conducted. The results are summarized in a pedagogical framework that outlines best strategies of the type of workflows, software, design process used, methods to achieve desired interaction between design process and analytical feedback, and metrics for educators to evaluate the success of this integration and their learning outcomes in the design studio. The goal is to help bridge the gap between the building design and simulation within the design studio’s creative process for more integrated design outcomes.

Elzeyadi, Ihab↗
NASA NTRS1995

Textile technology development

The objectives of this report were to evaluate and select resin systems for Resin Transfer Molding (RTM) and Powder Towpreg Material, to develop and evaluate advanced textile processes by comparing 2-D and 3-D braiding for fuselage frame applications and develop window belt and side panel structural design concepts, to evaluate textile material properties, and to develop low cost manufacturing and tooling processes for the automated manufacturing of fuselage primary structures. This research was in support of the NASA and Langley Research Center (LaRc) Advanced Composite Structural Concepts and Materials Technologies for Primary Aircraft Structures program.

Shah, Bharat M.↗
NASA NTRS2000

Flight Control System Development for the BURRO Autonomous UAV

Developing autonomous flying vehicles has been a growing field in aeronautical research within the last decade and will continue into the next century. With concerns about safety, size, and cost of manned aircraft, several autonomous vehicle projects are currently being developed; uninhabited rotorcraft offer solutions to requirements for hover, vertical take-off and landing, as well as slung load transportation capabilities. The newness of the technology requires flight control engineers to question what design approaches, control law architectures, and performance criteria apply to control law development and handling quality evaluation. To help answer these questions, this paper documents the control law design process for Kaman Aerospace BURRO project. This paper will describe the approach taken to design control laws and develop math models which will be used to convert the manned K-MAX into the BURRO autonomous rotorcraft. With the ability of the K-MAX to lift its own weight (6000 lb) the load significantly affects the dynamics of the system; the paper addresses the additional design requirements for slung load autonomous flight. The approach taken in this design was to: 1) generate accurate math models of the K-MAX helicopter with and without slung loads, 2) select design specifications that would deliver good performance as well as satisfy mission criteria, and 3) develop and tune the control system architecture to meet the design specs and mission criteria. An accurate math model was desired for control system development. The Comprehensive Identification from Frequency Responses (CIFER(R)) software package was used to identify a linear math model for unloaded and loaded flight at hover, 50 kts, and 100 kts. The results of an eight degree-of-freedom CIFER(R)-identified linear model for the unloaded hover flight condition are presented herein, and the identification of the two-body slung-load configuration is in progress.

Colbourne, Jason D.↗