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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 145 records · Page 8

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NASA NTRS1988

Catalytic ignition of hydrogen and oxygen propellants

An experimental program was conducted to evaluate the catalytic ignition of gaseous hydrogen and oxygen propellants. Shell 405 granular catalyst and a monolithic sponge catalyst were tested. Mixture ratio, mass flow rate, propellant temperature, and back pressure were varied parametrically in testing to determine the operational limits of the catalytic igniter. The test results show that the gaseous hydrogen and oxygen propellant combination can be ignited catalytically using Shell 405 catalyst over a wide range of mixture ratios, mass flow rates, and propellant injection temperatures. These operating conditions must be optimized to ensure reliable ignition for an extended period of time. A cyclic life of nearly 2000, 2 sec pulses at nominal operating conditions was demonstrated with the catalytic igniter. The results of the experimental program and the established operational limits for a catalytic igniter using the Shell 405 catalysts are presented.

Zurawski, Robert L.↗

NASA NTRS2020

Utilizing Modal Testing for Monitoring the Structural Health of Wind Tunnel Facility Hardware

The 10- by 10-Foot Abe Silverstein Supersonic Wind Tunnel (10×10) is the largest and fastest wind tunnel facility at NASA’s Glenn Research Center(GRC) and is specifically designed to test supersonic propulsion components from inlets and nozzles to full-scale jet and rocket engines[1]. Recently, a critical part of the wind tunnel failed and required a redesign before reintegrating into the facility. The design requirements of this new component required that clearances between large metallic components exist, which have the potential for undesirable nonlinear dynamics to occur, in particular rattling. Rattling is feared to occur when the wind tunnel is being operated in certain flow regimes that induce cyclic aero loads on the new component near its natural frequencies. This paper describes the approach taken to better understand and resolve this vibration problem using modal testing. A modal test was developed and executed by GRC’s Structural Dynamics Lab to quantify the modal parameters of the structure, namely which specific excitation frequencies caused the structure to rattle. These results were shared with facility operators as frequency ranges that should be avoided to ensure maximum lifespan of the new structure. Additional means of structural health monitoring (SHM) as well as Vortex shedding are briefly discussed in this paper.

Pederson, Kenneth↗

NASA NTRS1997

Performance Comparison Between NiH2 Dry Sinter and Slurry Electrode Cells

The electrical and thermal performance of dry sinter and slurry process electrode cells manufactured for the Hubble Space Telescope (HST) batteries have been characterized for a matrix of operating conditions over the temperature range from 14 to 86 F at various charge control levels. The dry sinter process electrode cells tested are similar to the onboard HST NiH2 cells. The slurry process electrode cells were developed to be less susceptible to electrode expansion and impedance changes with life. Both cell types were impregnated by the aqueous electrochemical process. Test conditions included standard capacity tests and electrical cycling using 96-minute cycling regimens incorporating gr depth-of-discharge (DOD) cycles. The dry sinter process electrodes have higher operating capacities to 1.20V/cell, but both electrode types have similar heat dissipation for the conditions tested. The results of the testing included cyclic heat generation during a typical 96-minute cycle, operating capacity data vs. cutoff voltage to generate a temperature-compensated voltage curve, and voltage characteristics suitable to develop a voltage prediction model. Analysis of data shows differences in the discharge voltage plateaus operating conditions evaluated. This is the basis for recommended changes in the battery charge control.

Armantrout, J. D.↗

NASA NTRS1985

Long-life high performance fuel cell program

A multihundred kilowatt Regenerative Fuel Cell for use in a space station is envisioned. Three 0.508 sq ft (471.9 cm) active area multicell stacks were assembled and endurance tested. The long term performance stability of the platinum on carbon catalyst configuration suitability of the lightweight graphite electrolyte reservoir plate, the stability of the free standing butyl bonded potassium titanate matrix structure, and the long life potential of a hybrid polysulfone cell edge frame construction were demonstrated. A 18,000 hour demonstration test of multicell stack to a continuous cyclical load profile was conducted. A total of 12,000 cycles was completed, confirming the ability of the alkaline fuel cell to operate to a load profile simulating Regenerative Fuel Cell operation. An orbiter production hydrogen recirculation pump employed in support of the cyclical load profile test completed 13,000 hours of maintenance free operation. Laboratory endurance tests demonstrated the suitability of the butyl bonded potassium matrix, perforated nickel foil electrode substrates, and carbon ribbed substrate anode for use in the alkaline fuel cell. Corrosion testing of materials at 250 F (121.1 C) in 42% wgt. potassium identified ceria, zirconia, strontium titanate, strontium zirconate and lithium cobaltate as candidate matrix materials.

Martin, R. E.↗

NASA NTRS1980

Development of a preprototype sabatier CO2 reduction subsystem

A preoprototype Sabatier CO2 Reduction Subsystem was successfully designed, fabricated and tested. The lightweight, quick starting reactor utilizes a highly active and physically durable methanation catalyst composed of ruthenium on alumina. The use of this improved catalyst permits a single straight through plug flow design with an average lean component H2/CO2 conversion efficiency of over 99% over a range of H2/CO2 molar ratios of 1.8 to 5 while operating with flows equivalent to a crew size of one person steadystate to 3 persons cyclical (equivalent to 5 persons steady state). The reactor requires no heater operation after start-up even during simulated 55 minute lightside/39 minute darkside orbital operation over the above range of molar ratios and crew loadings. The subsystem's operation and performance is controlled by a microprocessor and displayed on a nineteen inch multi-colored cathode ray tube.

Kleiner, G. N.↗

DOE OSTI2026

Heavy-Duty Nonroad Material Handler Electrification Part 1: Real-World Drive Cycle Development

Knowing a detailed operating cycle is critical for developing and testing equipment. Operating cycles can be separated by two clear distinctions: (1) regulatory or non-regulatory and (2) application at the engine-only or full machine level. The Environmental Protection Agency’s (EPA) Nonroad Transient Cycle (NRTC) may be a good representation of engine use in many types of equipment, but there is a gap in standardized and validated drive cycles specifically for nonroad material handlers. Lacking a standardized drive cycle makes it difficult to accurately benchmark machine performance and validate new powertrain technologies. The objective of this investigation is to illustrate the development of a custom drive cycle augmented with real-world customer use data that serves multiple purposes: (1) understand the range of operation and utilization that formulated inputs for electrified architecture analysis and (2) develop a repetitive and consistent maneuver to establish baseline energy consumption enabling equivalent comparison to future electrified prototype builds. This article presents a solution specifically for a 23-ton nonroad material handler in which material handling, machine transport, and extended idle were homologated to form representative short cycles defined by machine velocity and hydraulic cylinder position. The most intensive material handling short cycles had a load factor of 40% and an average fuel rate of 16 L/h. Combined with a visual aid, the short cycles exhibited low variability, having less than 5% root mean square (RMS) error in lift and reach position with respect to the average. The machine’s performance on these short cycles at the Advanced Power Systems Research Center (APSRC) was compared to results from two real-world customer locations operating the instrumented test machine in a cyclical manner, and for similar ground conditions were found to be comparable in fuel consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1981

Development status of a preprototype water electrolysis subsystem

A preprototype water electrolysis subsystem was designed and fabricated for NASA's advanced regenerative life support program. A solid polymer is used for the cell electrolyte. The electrolysis module has 12 cells that can generate 5.5 kg/day of oxygen for the metabolic requirements of three crewmembers, for cabin leakage, and for the oxygen and hydrogen required for carbon dioxide collection and reduction processes. The subsystem can be operated at a pressure between 276 and 2760 kN/sq m and in a continuous constant-current, cyclic, or standby mode. A microprocessor is used to aid in operating the subsystem. Sensors and controls provide fault detection and automatic shutdown. The results of development, demonstration, and parametric testing are presented. Modifications to enhance operation in an integrated and manned test are described. Prospective improvements for the electrolysis subsystem are discussed.

Martin, R. B.↗

DOE OSTI2025

Specificity and tunability of efflux pumps: A new role for the proton gradient?

Efflux pumps that transport antibacterial drugs out of bacterial cells have broad specificity, commonly leading to broad spectrum resistance and limiting treatment strategies for infections. It remains unclear how efflux pumps can maintain this broad spectrum specificity to diverse drug molecules while limiting the efflux of other cytoplasmic content. We have investigated the origins of this broad specificity using theoretical models informed by the experimentally determined structural and kinetic properties of efflux pumps. We developed a set of mathematical models describing operation of efflux pumps as a discrete cyclic stochastic process across a network of states characterizing pump conformations and the presence/absence of bound ligands and protons. These include a minimal three-state model that lends itself to clear analytic calculations as well as a five-state model that relaxes some of the simpler model’s most strict assumptions. We found that the pump specificity is determined not solely by the drug affinity to the pump–as is commonly assumed–but it is also directly affected by the periplasmic pH and the transmembrane potential. Therefore, changes to the proton concentration gradient and voltage drop across the membrane can influence how effective the pump is at extruding a particular drug molecule. Furthermore, we found that while both the proton concentration gradient across the membrane and the transmembrane potential contribute to the thermodynamic force driving the pump, their effects on the efflux enter not strictly in a combined proton motive force. Rather, they have two distinguishable effects on the overall throughput. These results highlight the unexpected effects of thermodynamic driving forces out of equilibrium and illustrate how efflux pump structure and function are conducive to the emergence of multidrug resistance.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1979

Software design specification. Part 2: Orbital Flight Test (OFT) detailed design specification. Volume 3: Applications. Book 2: System management

The functions performed by the systems management (SM) application software are described along with the design employed to accomplish these functions. The operational sequences (OPS) control segments and the cyclic processes they control are defined. The SM specialist function control (SPEC) segments and the display controlled 'on-demand' processes that are invoked by either an OPS or SPEC control segment as a direct result of an item entry to a display are included. Each processing element in the SM application is described including an input/output table and a structured control flow diagram. The flow through the module and other information pertinent to that process and its interfaces to other processes are included.

Source record↗

NASA NTRS1983

SSME main combustion chamber life prediction

Typically, low cycle fatigue life is a function of the cyclic strain range, the material properties, and the operating temperature. The reusable life is normally defined by the number of strain cycles that can be accrued before severe material degradation occurs. Reusable life is normally signified by the initiation or propagation of surface cracks. Hot-fire testing of channel wall combustors has shown significant mid-channel wall thinning or deformation during accrued cyclic testing. This phenomenon is termed cyclic-creep and appears to be significantly accelerated at elevated surface temperatures. This failure mode was analytically modelled. The cyclic life of the baseline SSME-MCC based on measured calorimeter heat transfer data, and the life sensitivity of local hot spots caused by injector effects were determined. Four life enhanced designs were assessed.

Cook, R. T.↗

NASA NTRS1994

Brush seals for turbine engine fuel conservation

The program objective is to demonstrate brush seals for replacing labyrinth seals in turboprop engines. The approach taken was to design and procure brush seals with assistance from Sealol, modify and instrument an existing T407 low pressure turbine test rig, replace inner balance piston and outer balance piston labyrinth seals with brush seals, conduct cyclic tests to evaluate seal leakage at operating pressures and temperatures, and evaluate effect of seal pack width and rotor eccentricity. Results are presented in viewgraph format and show that brush seals offer performance advantages over labyrinth seals.

Sousa, Mike↗

DOE OSTI2025

Cyclic loading–unloading impacts on geomechanical stability of multiple salt caverns for underground hydrogen storage

Underground caverns in a salt dome are promising geologic features to store hydrogen because of salt’s extremely low permeability and self-healing behavior. The salt cavern storage community, however, has not fully understood the geomechanical behaviors of salt rock driven by quick operation cycles of injection–production, which may significantly impact the cost-effective storage-recovery performance of multiple caverns. Our field-scale generic model captures the impact of cyclic loading–unloading on the salt creep behavior and deformation under different cycle frequencies, operating pressure, and spatial order of operating cavern(s). This systematic simulation study indicates that the initial operation cycle and arrangement of multiple caverns play a significant role in the creep-driven loss of cavern volumes and cavern deformation. Finally, our future study will develop a new salt constitutive model based on geomechanical tests of site-specific salt rock to probe the cyclic behaviors of salt precisely both beneath and above the dilatancy boundary, including reverse (inverse transient) creep, the Bauschinger effect, and damage-healing mechanism.

08 HYDROGEN↗

DOE OSTI2024

Report on DIC Cyclic Dryout Testing of ATF Cladding Materials

Boiling water reactors can experience anticipated operational occurrences, where an expected deviation from normal operating conditions is witnessed for short time scales. One example of such transients arises from cladding dryout, where stable boiling becomes unstable, resulting in cladding heat up before re-wetting occurs. To understand the impact of such transients on fuel cladding lifetime and performance, cyclic dryout conditions were imposed upon fresh fuel cladding in the absence of irradiation. Pressurized cladding tube segments were exposed to rapid temperature increases to intermediate temperatures below a cladding rupture threshold and deformation was monitored in situ via 3-D digital image correlation. The impact of cycle frequency on cladding deformation was assessed. A clear understanding of elastic and plastic strain responses were developed for Zr alloy deformation under temperature transients, and these results can be used to support material model development and validate fuel performance codes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1985

Thrust chamber life prediction

The reusable life of the Space Shuttle main engine (SSME) is influenced by the cyclic life of the regeneratively liquid cooled main combustion chamber (MCC). During an operational duty cycle the MCC liner is subjected to a large transient thermal gradient that imparts a high thermal cyclic strain to the liner hot gas wall. Life predictions of such chambers have usually been based on low cycle fatigue (LCF) evaluations. Hot-fire testing, however, has shown significant mid-channel wall deformation and thinning during accrued cyclic testing. This phenomenon is termed cyclic creep and appears to be significantly accelerated at elevated temperatures. An analytical method that models the cyclic creep phenomenon and its application to thrust chamber life prediction is presented. The chamber finite element geometry is updated periodically to account for accrued wall thinning and distortion. Failure is based on the tensile instability failure criterion. Cyclic life results for several chamber life enhancing coolant channel designs are compared to the typically used LCF analysis that neglects cyclic creep. The results show that the usable cyclic creep life is approximately 30 to 50% of the commonly used LCF life.

Kasper, H. J.↗

NASA NTRS2003

Universal Responses of Cyclic-Oxidation Models Studied

Oxidation is an important degradation process for materials operating in the high-temperature air or oxygen environments typical of jet turbine or rocket engines. Reaction of the combustion gases with the component material forms surface layer scales during these oxidative exposures. Typically, the instantaneous rate of reaction is inversely proportional to the existing scale thickness, giving rise to parabolic kinetics. However, more realistic applications entail periodic startup and shutdown. Some scale spallation may occur upon cooling, resulting in loss of the protective diffusion barrier provided by a fully intact scale. Upon reheating, the component will experience accelerated oxidation due to this spallation. Cyclic-oxidation testing has, therefore, been a mainstay of characterization and performance ranking for high-temperature materials. Models simulate this process by calculating how a scale spalls upon cooling and regrows upon heating (refs. 1 to 3). Recently released NASA software (COSP for Windows) allows researchers to specify a uniform layer or discrete segments of spallation (ref. 4). Families of model curves exhibit consistent regularity and trends with input parameters, and characteristic features have been empirically described in terms of these parameters. Although much insight has been gained from experimental and model curves, no equation has been derived that can describe this behavior explicitly as functions of the key oxidation parameters.

Smialek, James L.↗

NASA NTRS2008

Reliability and Confidence Interval Analysis of a CMC Turbine Stator Vane

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight, enable higher operating temperatures requiring less cooling and thus leading to increased engine efficiencies. However, these materials are brittle and show degradation with time at high operating temperatures due to creep as well as cyclic mechanical and thermal loads. In addition, these materials are heterogeneous in their make-up and various factors affect their properties in a specific design environment. Most of these advanced composites involve two- and three-dimensional fiber architectures and require a complex multi-step high temperature processing. Since there are uncertainties associated with each of these in addition to the variability in the constituent material properties, the observed behavior of composite materials exhibits scatter. Traditional material failure analyses employing a deterministic approach, where failure is assumed to occur when some allowable stress level or equivalent stress is exceeded, are not adequate for brittle material component design. Such phenomenological failure theories are reasonably successful when applied to ductile materials such as metals. Analysis of failure in structural components is governed by the observed scatter in strength, stiffness and loading conditions. In such situations, statistical design approaches must be used. Accounting for these phenomena requires a change in philosophy on the design engineer s part that leads to a reduced focus on the use of safety factors in favor of reliability analyses. The reliability approach demands that the design engineer must tolerate a finite risk of unacceptable performance. This risk of unacceptable performance is identified as a component's probability of failure (or alternatively, component reliability). The primary concern of the engineer is minimizing this risk in an economical manner. The methods to accurately determine the service life of an engine component with associated variability have become increasingly difficult. This results, in part, from the complex missions which are now routinely considered during the design process. These missions include large variations of multi-axial stresses and temperatures experienced by critical engine parts. There is a need for a convenient design tool that can accommodate various loading conditions induced by engine operating environments, and material data with their associated uncertainties to estimate the minimum predicted life of a structural component. A probabilistic composite micromechanics technique in combination with woven composite micromechanics, structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Since the measured data for the ceramic matrix composite properties is very limited, obtaining a probabilistic distribution with their corresponding parameters is difficult. In case of limited data, confidence bounds are essential to quantify the uncertainty associated with the distribution. Usually 90 and 95% confidence intervals are computed for material properties. Failure properties are then computed with the confidence bounds. Best estimates and the confidence bounds on the best estimate of the cumulative probability function for R-S (strength - stress) are plotted. The methodologies and the results from these analyses will be discussed in the presentation.

Murthy, Pappu L. N.↗

DOE OSTI2025

Strain-Based Assessment of Shale Caprock during Cyclic Underground Hydrogen Storage

Successful large-scale underground hydrogen storage (UHS) in depleted gas reservoirs depends on the integrity of the overlying caprock to prevent hydrogen loss during cyclic injection and depletion. Prior studies on crushed Marcellus shale, a potential caprock, indicate that cyclic hydrogen injection and depletion induces microstructural changes, increasing porosity and permeability. However, the extent of these changes in intact shale remains unclear. This study presents a strain-based experimental approach to quantify volumetric strain evolution in intact Marcellus shale matrix under unconstrained stress conditions. A quadrant-shaped shale sample without visible fractures underwent eight hydrostatic pore-pressure cycles (injection to 1500 psi and depletion to 500 psi in 250 psi steps). Linear strain gauges measured strain in three orthogonal directions. Results indicate progressive plastic strain accumulation, leading to an ∼12% increase in matrix porosity after eight cycles, with an estimated 19% increase after 30 cycles. This porosity increase follows a logarithmic trend, suggesting a diminishing effect in later cycles. Additionally, permeability and diffusive mass flux are projected to rise by ∼70% over 30 cycles, enhancing hydrogen migration risk. The shale matrix also exhibited mechanical stiffening over successive cycles, limiting large-scale deformation but not preventing porosity enhancement. A new parameter, α, was introduced to characterize shale sensitivity to cyclic loading, aiding UHS caprock assessments. These findings underscore the necessity of incorporating cyclic loading effects in UHS site selection and operational strategies to ensure long-term storage integrity.

08 HYDROGEN↗

NASA NTRS1984

Bending fatigue of electron-beam-welded foils. Application to a hydrodynamic air bearing in the Chrysler/DOE upgraded automotive gas tubine engine

A hydrodynamic air bearing with a compliment surface is used in the gas generator of an upgraded automotive gas turbine engine. In the prototype design, the compliant surface is a thin foil spot welded at one end to the bearing cartridge. During operation, the foil failed along the line of spot welds which acted as a series of stress concentrators. Because of its higher degree of geometric uniformity, electron beam welding of the foil was selected as an alternative to spot welding. Room temperature bending fatigue tests were conducted to determine the fatigue resistance of the electron beam welded foils. Equations were determined relating cycles to crack initiation and cycles to failure to nominal total strain range. A scaling procedure is presented for estimating the reduction in cyclic life when the foil is at its normal operating temperature of 260 C (500 F).

Saltsman, J. F.↗