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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 1,297 records · Page 72
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Corrosion Issues for Ceramics in Gas Turbines

The requirements for hot-gas-path materials in gas turbine engines are demanding. These materials must maintain high strength and creep resistance in a particularly aggressive environment. A typical gas turbine environment involves high temperatures, rapid gas flow rates, high pressures, and a complex mixture of aggressive gases. Figure 26.1 illustrates the requirements for components of an aircraft engine and critical issues [1]. Currently, heat engines are constructed of metal alloys, which meet these requirements within strict temperature limits. In order to extend these temperature limits, ceramic materials have been considered as potential engine materials, due to their high melting points and stability at high temperatures. These materials include oxides, carbides, borides, and nitrides. Interest in using these materials in engines appears to have begun in the 1940s with BeO-based porcelains [2]. During the 1950s, the efforts shifted to cermets. These were carbide-based materials intended to exploit the best properties of metals and ceramics. During the 1960s and 1970s, the silicon-based ceramics silicon carbide (SiC) and silicon nitride (Si3N4) were extensively developed. Although the desirable high-temperature properties of SiC and Si3N4 had long been known, consolidation of powders into component-sized bodies required the development of a series of specialized processing routes [3]. For SiC, the major consolidation routes are reaction bonding, hot-pressing, and sintering. The use of boron and carbon as additives which enable sintering was a particularly noteworthy advance [4]. For Si3N4 the major consolidation routes are reaction bonding and hot pressing [5]. Reaction-bonding involves nitridation of silicon powder. Hot pressing involves addition of various refractory oxides, such as magnesia (MgO), alumina (Al2O3), and yttria (y2O3). Variations on these processes include a number of routes including Hot Isostatic Pressing (HIP), gas-pressure sintering, sinter-HIPing, and Encapsulation-HIPing. It is important to note that each process involves the addition of secondary elements, which later were shown to dramatically influence oxidation and corrosion behavior. As dense bodies of silicon-based ceramics became more readily available, their desirable high temperature properties were confirmed. These materials retained strength to very high temperatures (i.e. 1300-1400 C). Further, they were lightweight and made from abundant materials. SiC and Si3N4 therefore emerged as leading ceramic candidates for components in heat engines, designed to operate at higher temperatures for better performance and fuel efficiency. The first US programs for ceramics in heat engines have been reviewed [6]. Selected programs on ceramic engine parts are summarized here in regard to their contributions to understanding the corrosion behavior of a heat engine environment.

Jacobson, Nathan S.↗
NASA NTRS1993

Space Engineering Projects in Design Methodology

NASA/USRA is an ongoing sponsor of space design projects in the senior design courses of the Mechanical Engineering Department at The University of Texas at Austin. This paper describes the UT senior design sequence, focusing on the first-semester design methodology course. The philosophical basis and pedagogical structure of this course is summarized. A history of the Department's activities in the Advanced Design Program is then presented. The paper includes a summary of the projects completed during the 1992-93 Academic Year in the methodology course, and concludes with an example of two projects completed by student design teams.

R Crawford↗
NASA NTRSDate not supplied

Numerical Investigation of Film Coefficient Engineering Methodology for Dissociated, Chemically Reacting Boundary Layers

Aerothermal analysis of spacecraft planetary entry is heavily dependent on heritage engineering models. The film coefficient heat transfer model examined in this paper estimates the convective heating to the vehicle for a laminar, dissociated, chemically reacting boundary layer for an Earth atmosphere. This model requires information about the vehicle and flow field for a given trajectory point and estimates a proportional relationship between enthalpy potential and convective heat flux. In practice it is the aerothermal engineer who must decide which assumptions are appropriate for their application. This work looks at numerous CFD simulations for an arbitrary, axisymmetric flight vehicle to analyze the relative importance of both the mass and energy constraints imposed at the wall boundary, as well as the effect of various diffusion models. The sensitivity of the engineering model is assessed based on the impact of the CFD assumptions as an effort to make it available to design engineers across industry.

numerical boundary layer↗
NASA NTRS2024

PALMO: An OVERFLOW Machine Learning Airfoil Performance Database

The OVERFLOW Machine Learning Airfoil Performance (PALMO) database has been created to enable robust modeling of airfoil performance in a variety of applications. The database uses OVERFLOW simulation data second-order accurate in time and fourth-order accurate in space with Spalart-Allmaras turbulence closure. The foundation of the in-development PALMO database is the airfoil base cube. Each base cube includes simulation data parametrized over a range of Mach numbers, Reynolds numbers, and angles-of-attack. This first release of the database includes the NACA 4-series airfoils, with parametrization in airfoil thickness and camber from an NACA 0006 to an NACA 4424. In total, 52,480 NACA 4-series calculations were run on the NASA High-End Compute Capability (HECC) supercomputer and the corresponding airfoil performance coefficients are embedded in the Appendix of this document for public distribution. This provides high-order-accurate simulation data covering a wide range of aerospace design applications, which enables users to develop OVERFLOW-quality airfoil performance look-up tables without additional high-performance computing. In addition to engineering design and analysis of aerospace vehicles, PALMO is well suited to be a benchmark dataset for the development and testing of machine learning methods in aerospace engineering. Downstream surrogate models enable OVERFLOW- quality airfoil performance predictions for any arbitrary combination of camber, thickness, Mach number, Reynolds number, and angle-of-attack within the bounds of the database.

Database↗
DOE OSTI2012

Automated design synthesis of robotic/human workcells for improved manufacturing system design in hazardous environments [Slides]

The design of manufacturing systems in hazardous environments often requires knowledge from various fields. Some conceptual designs may be overlooked or unknowingly infeasible due to the design engineers’ lack of knowledge in a particular field. A computer can help alleviate this problem if given all relevant knowledge and the decision-making abilities of human designers. In this work, an expert system is utilized to store domain knowledge and automate the synthesis of conceptual manufacturing system designs in hazardous environments. Specific application is directed toward the design of systems for glovebox processes at LANL.

42 ENGINEERING↗
NASA NTRS1983

Opportunities for research in aerothermodynamics

"Aerothermodynamics' involves the disciplines of chemistry, thermodynamics, fluid mechanics and heat transfer which have collaborative importance in propulsion systems. There are growing opportunities for the further application of these disciplines to improve the methodology for the design of advanced gas turbines; particularly, the combustor and turbine. Design procedures follow empirical or cut and try guidelines. The tremendous advances in computational analysis and in instrumentation techniques hold promise for research answers to complex physical processes that are currently not well understood. The transfer of basic research understanding to engineering design should result in shorter, less expensive development commitments for engines. The status and anticipated opportunities in research topics relevant to combustors and turbines is reviewed.

Graham, R. W.↗
DOE OSTI2024

TRUST Contact Thermal Conductance (TRUST-CTC) Report: FY24

The objective of the Delivery Environments (DE) Testbeds to Reduce Uncertainties in Simulations and Tests (TRUST) project is to quantify and help increase confidence in specific areas of computational and experimental capabilities that are applicable to current and future delivery environments. More complete quantification of confidence in experimental and computational capabilities and the sufficient increase of confidence in those capabilities is critical to improving weapons engineering design, qualification, and assessment efforts that are critical to the current and future stockpile. Staff development will include cross-discipline collaboration to provide engineers with experience in both numerical simulations and experimental methods. This work uses and provides feedback on analysis tools and experimental results databases for efficient and responsive engineering which are currently under development. TRUST currently includes five testbeds and their associated engineering analysis baseline models (EABMs): 1. contact thermal conductivity, (CTC) 2. nonlinear dynamics, (ND) 3. sensors in environments for accelerometers, (SEA) 4. sensors in environments for fiber optic displacement gages, and (SEFOD) 5. sensors in environments for thermocouples (SETC). The TRUST project uses single-feature testbeds to quantify uncertainties in specific models and experiments and to identify capability development needs that can help to reduce these uncertainties. Each testbed is designed, configured, and tested in collaboration with groups with design and experimental capability: E-14 and MPA-CINT. The complementary simulations are conducted using W-13 analysis tools and stored in model repositories with plans for incremental progress toward EABM requirements. W-13 extends and exercises the testbed simulations in collaboration with experimentalists for uncertainty quantification of current and future materials, geometries, and environments. Additionally, TRUST is intended to provide engineers in W-13 and E-14 with experience in both numerical simulations and experimental methods through cross-discipline collaborations. Following the introduction to the TRUST project, the remainder of this report focuses on experimental and analytical efforts conducted in Fiscal Year (FY) 2024 relevant to the TRUST Contact Thermal Conductance (CTC) testbed.

42 ENGINEERING↗
NASA NTRS2006

NASA's J-2X Engine Builds on the Apollo Program for Lunar Return Missions

In January 2006, NASA streamlined its U.S. Vision for Space Exploration hardware development approach for replacing the Space Shuttle after it is retired in 2010. The revised CLV upper stage will use the J-2X engine, a derivative of NASA s Apollo Program Saturn V s S-II and S-IVB main propulsion, which will also serve as the Earth Departure Stage (EDS) engine. This paper gives details of how the J- 2X engine effort mitigates risk by building on the Apollo Program and other lessons learned to deliver a human-rated engine that is on an aggressive development schedule, with first demonstration flight in 2010 and human test flights in 2012. It is well documented that propulsion is historically a high-risk area. NASA s risk reduction strategy for the J-2X engine design, development, test, and evaluation is to build upon heritage hardware and apply valuable experience gained from past development efforts. In addition, NASA and its industry partner, Rocketdyne, which originally built the J-2, have tapped into their extensive databases and are applying lessons conveyed firsthand by Apollo-era veterans of America s first round of Moon missions in the 1960s and 1970s. NASA s development approach for the J-2X engine includes early requirements definition and management; designing-in lessons learned from the 5-2 heritage programs; initiating long-lead procurement items before Preliminary Desi& Review; incorporating design features for anticipated EDS requirements; identifying facilities for sea-level and altitude testing; and starting ground support equipment and logistics planning at an early stage. Other risk reduction strategies include utilizing a proven gas generator cycle with recent development experience; utilizing existing turbomachinery ; applying current and recent main combustion chamber (Integrated Powerhead Demonstrator) and channel wall nozzle (COBRA) advances; and performing rigorous development, qualification, and certification testing of the engine system, with a philosophy of "test what you fly, and fly what you test". These and other active risk management strategies are in place to deliver the J-2X engine for LEO and lunar return missions as outlined in the U.S. Vision for Space Exploration.

Snoddy, Jimmy R.↗
NASA NTRS2004

Conceptual Design of the Nuclear Electronic Xenon Ion System (NEXIS)

In support of the NEXIS program, Aerojet-Redmond Operations, with review and input from the JPL and Boeing, has completed the design for a development model (DM) discharge chamber assembly and main discharge cathode assembly. These efforts along with the work by JPL to develop the carbon-carbon-composite ion optics assembly have resulted in a complete ion engine design. The goal of the NEXIS program is to significantly advance the current state of the art by developing an ion engine capable of operating at an input power of 20kW, an Isp of 7500 sec and have a total xenon through put capability of 2000 kg. In this paper we will describe the methodology used to design the discharge chamber and cathode assemblies and describe the resulting final design. Specifics will include the concepts used for the mounting of the ion optics along with the concepts used for the gimbal mounts. In addition, we will present results of a vibrational analysis showing how the engine will respond to a typical Delta IV heavy vibration spectrum.

ion truster↗
DOE OSTI2020

W.A. Parish Post-Combustion CO 2 Capture and Sequestration Demonstration Project (Final Technical Report)

The Petra Nova Project (Project) is a commercial scale post-combustion carbon capture project developed by a joint venture between NRG Energy, Inc. (NRG) and JX Nippon Oil Exploration (EOR) Limited (JX). The Project is designed to separate and capture carbon dioxide (CO2) from an existing coal-fired unit’s flue gas slipstream at NRG’s W.A. Parish Electric Generating Station (WAP) located southwest of Houston, Texas. The captured CO2 is dried, compressed, and transported via an 81-mile pipeline to the West Ranch oilfield (West Ranch) in Jackson County, Texas, where it is injected to boost oil production. The Project, which is partially funded by a grant (Grant) from the United States (U.S.) Department of Energy (DOE) under the Clean Coal Power Initiative (CCPI) Round 3, uses the Kansai Mitsubishi Carbon Dioxide Recovery advanced amine-based CO 2 absorption technology (KM-CDR Process®), which was jointly developed by Mitsubishi Heavy Industries, Ltd. (MHI) and the Kansai Electric Power Co. Inc., to treat and capture at least ninety percent (90%) of the CO 2 from a 240-megawatt equivalent (MWe) flue gas slipstream off of Unit 8 at WAP. When operating at full capacity, the Project captures approximately 5,200 short tons of CO 2 per day, which would otherwise be emitted into the atmosphere, representing the largest commercial scale deployment of post-combustion CO2 capture technology at a coal power plant to date. Under the Grant, the Project was managed in 3 phases: (1) Phase 1: Project Definition / Front End Engineering Design (FEED) (2) Phase 2: Detailed Engineering, Procurement & Construction (3) Phase 3: Demonstration and Monitoring. On December 29, 2016, commercial operation of the Project was achieved, ending Phase 2 and starting Phase 3, a 3-year demonstration period running from January 1, 2017 through December 31, 2019. The key objectives of Phase 3 were to (a) demonstrate the specific advanced technologies constructed during Phase 2 and (b) monitor the injected CO 2 at West Ranch to demonstrate technologies and protocols for monitoring, verification, and accounting (MVA). As of the end of Phase 3, Petra Nova captured 3,904,978 short tons of CO 2 (3,542,537 metric tons) that was transported to West Ranch. To support the DOE obligation to monitor, verify, and account for the sequestered CO 2 at West Ranch, Petra Nova contracted with the Bureau of Economic Geology (in the Jackson School of Geosciences at The University of Texas at Austin) to (a) design a monitoring program, (b) draft an MVA Plan for DOE review and approval, and (c) working with Petra Nova and the operator of West Ranch to manage and report on the MVA activity. This report discussed the technical aspects of the project during each of the 3 phases of the project as identified above.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1986

Cryogenic gear technology for an orbital transfer vehicle engine and tester design

Technology available for gears used in advanced Orbital Transfer Vehicle rocket engines and the design of a cryogenic adapted tester used for evaluating advanced gears are presented. The only high-speed, unlubricated gears currently in cryogenic service are used in the RL10 rocket engine turbomachinery. Advanced rocket engine gear systems experience operational load conditions and rotational speed that are beyond current experience levels. The work under this task consisted of a technology assessment and requirements definition followed by design of a self-contained portable cryogenic adapted gear test rig system.

Calandra, M.↗
DOE OSTI2025

Conceptual Design of a Water Tank Critical Facility for SPARC

Critical experiments, sometimes referred to zero-power reactors, are crucial tools in developing and validating nuclear physics predictions and thus an indispensable capability to ensure criticality safety during all parts of the nuclear fuel cycle and in reducing uncertainties in reactor physics predictions toward optimizing nuclear energy production. The System Physics Advanced Reactor Facility (SPARC) project was recently initiated to enable large-scale criticality experiments using a horizontal split table machine well suited toward solid core materials systems (fuel, moderator, reflector). The facility selected for this mission was a former pool-type research reactor building and thus also well suited toward a second critical experiment capability able to house full-size light-water reactor (LWR) fuel bundles. A conceptual design study was undertaken to review past water tank critical experiments used for LWR physics experiments and to develop an early engineering design for a new critical assembly tank (CAT). The work described here shows that a relatively simple CAT concept can be constructed and deployed in the SPARC facility to meet the urgent demands for new critical experiments on advanced LWR fuel bundles designs. The SPARC facility layout is conducive to the receipt and upending of LWR fuel bundles using existing containers and equipment from the LWR industry. The facility’s overhead crane can then be used to handle fuel bundles and place them in a vertical storage rack or in the CAT for critical experiments, both of which fit within the building’s “open basement” alongside other equipment planned for SPARC and the horizontal split table. A slightly lower area in the basement can serve as a large drain tank so that fail-safe valves drain the CAT reactor tank for safe shutdown. Neutronic configurations were determined where a 3 × 3 array of fuel bundles can be surrounded by full-length “loose rods” to adjust reactivity so that critical is achieved when the bundles are fully submerged. Viable configurations were determined for both pressurized- and boiling-water-reactor-type fuel bundles. This design concept was used to develop an early planning basis for establishing the CAT capability alongside the otherwise planned SPARC project in order to help streamline the process. Recent presidential executive orders have highlighted the need to achieve power uprates in LWR plants and the CAT capability will be a crucial element of these initiatives. Based on the work described herein, it is recommended that an earnest and timely project begin in order to establish this urgently needed capability.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1973

Propulsion system design for the ATT.

The NASA funded Advanced Transport Technology (ATT) systems studies are directed at identifying the optimum propulsion system characteristics required for a low noise, low emissions level engine designed for an advanced commercial transport that employs the supercritical wing technology. This transport could be in service in the late 70s or early 80s and would be designed for transcontinental and international ranges with cruise speeds up to Mach 0.98. This paper reviews the significant results of the propulsion system study, the implications in the propulsion design concept, and the acoustically treated nacelle.

Brines, G. L.↗
NASA NTRS1978

Plug cluster module demonstration

The low pressure, film cooled rocket engine design concept developed during two previous ALRC programs was re-evaluated for application as a module for a plug cluster engine capable of performing space shuttle OTV missions. The nominal engine mixture ratio was 5.5 and the engine life requirements were 1200 thermal cycles and 10 hours total operating life. The program consisted of pretest analysis; engine tests, performed using residual components; and posttest analysis. The pretest analysis indicated that operation of the operation of the film cooled engine at O/F = 5.5 was feasible. During the engine tests, steady state wall temperature and performance measurement were obtained over a range of film cooling flow rates, and the durability of the engine was demonstrated by firing the test engine 1220 times at a nominal performance ranging from 430 - 432 seconds. The performance of the test engine was limited by film coolant sleeve damage which had occurred during previous testing. The post-test analyses indicated that the nominal performance level can be increased to 436 seconds.

Rousar, D. C.↗
NASA NTRS1978

Orbit Transfer Vehicle (OTV) engine phase A study

Requirements for the orbit transfer vehicle engine were examined. Engine performance/weight sensitivities, the effect of a service life of 300 start/shutdown cycles between overalls on the maximum engine operating pressure, and the sensitivity of the engine design point (i.e., thrust chamber pressure and nozzle area ratio) to the performance requirements specified are among the factors studied. Preliminary engine systems analyses were conducted on the stage combustion, expander, and gas generator engine cycles. Hydrogen and oxygen pump discharge pressure requirements are shown for various engine cycles. Performance of the engine cycles is compared.

Mellish, J. A.↗
NASA NTRS1979

Propellant mass usage and flow measurement

Practices are outlined for the design, installation, checkout, calibration, and operation of a system to be used for measuring propellant flow in a liquid monopropellant rocket engine. Design guidelines rather than detailed specifications are provided for the critical components of each portion of the system. System elemental uncertainties are presented in an appendix.

Source record↗
NASA NTRS1986

Concepts for space maintenance of OTV engines

Concepts for space maintainability of OTV engines are examined. The advanced efforts are based on work recently completed for NASA Lewis Research Center Space Propulsion Technology Division. An engine design is developed which is driven by space maintenance requirements and by a failure modes and effects analysis. Modularity within the engine is shown to offer cost benefits and improved space maintenance capabilities. Space-operable disconnects are conceptualized for both engine change-out and for module replacement. Through FME mitigation the modules are conceptualized to contain the most often replaced engine components. A preliminary space maintenance plan is developed around a controls and condition monitoring system using advanced sensors, controls, and conditioning monitoring concepts.

Martinez, A.↗