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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 1,459 records · Page 81
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Channel Wall Nozzle Manufacturing and Hot-Fire Testing using a Laser Wire Deposition Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. NASA has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA Marshall Space Flight Center (MSFC) completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Deposition Closeout (LWDC). This process has been developed to significantly reduce time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication and hot-fire testing performance is discussed in this paper.

Gradl, Paul R.↗
NASA NTRS2018

Channel Wall Nozzle Manufacturing and Hot-Fire Testing Using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. The National Aeronautics and Space Administration (NASA) has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements over traditional techniques. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA's Marshall Space Flight Center (MSFC) has completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Direct Closeout (LWDC). This process has been developed to significantly reduce the time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication, and hot-fire testing are discussed in this paper.

Gradl, Paul R.↗
NASA NTRS2019

Self-Healing Polymer Materials for Wire Insulation, Polyimides, Flat Surfaces, and Inflatable Structures

Materials based on low melt polyimide, polyurea, or polyurethane chemistry have been developed which exhibit self-healing properties. These high performance polymers can be utilized either by themselves or in combination with microcapsule technology to deliver self-healing properties to electrical wire insulation or in other high performance, thin wall technologies such as inflatable structures.

Jolley, Scott T.↗
NASA NTRS2019

Bimetallic Channel Wall Nozzle Development and Hot-Fire Testing Using Additively Manufactured Laser Wire Direct Closeout Technology

NASA has been developing and advancing regeneratively-cooled channel wall nozzle technology for liquid rocket engines to reduce cost and schedules associated with fabrication. One of the primary methods being advanced is Laser Wire Direct Closeout (LWDC). LWDC was developed to provide an additively manufactured laser deposited closeout of the coolant channels that also forms the structural jacket in-situ. This technique has been previously demonstrated through process development and hot-fire testing on a series of subscale nozzles at NASA Marshall Space Flight Center. The hot-fire test articles were fabricated using monolithic alloys to simplify the fabrication process. Ongoing research is being conducted to further expand use of this process for increased scale and bimetallic or multi-alloy options. The use of multi-alloys is desired to fully optimize the combination of materials in the radial and axial directions to reduce overall weight of the nozzle and allow for higher thermal and structural margins on the channel wall nozzle. NASA recently completed process development and hot-fire testing of a series of channel wall nozzles that incorporate a copper-alloy as the hotwall liner material and a superalloy and combination thereof for the structural jacket using the LWDC technique. The fabrication process was further advanced by using a multi-alloy axial joint using explosive bonding integrating a copper-alloy at the forward end of the nozzle hotwall and a stainless-alloy for the remaining length. A third alloy was then used for the channel closeout using the LWDC process. This paper will describe the process development using the LWDC process for channel closeout utilizing the multi-alloys, hardware design and results from hot-fire testing on subscale multi-alloy LWDC channel cooled nozzles.

Gradl, Paul↗
NASA NTRSDate not supplied

xEMU Wired Heart Rate Monitor

For the past several years, the Exploration Extra-Vehicular Mobility Unit (xEMU) team at NASA’s Johnson Space Center (JSC) has focused on development and testing of the xEMU to support missions to the International Space Station (ISS) and a moon landing in 2024. In that context, this paper examines the development and detailed design of the xEMU Wired Heart Rate Monitor (WHRM). This paper outlines the challenging technical requirements, significant architectural trades, technical solutions required to overcome these challenges, and a status of the detailed design. The preliminary results of Design Verification Testing (DVT) as it relates to WHRM are also provided, along with a forward strategy for final maturation into a flight-ready design.

NASA↗
NASA NTRSDate not supplied

DC Performance Testing of MgB2 Superconducting Straight Wire Samples

To enable turboelectric aircraft that utilize fully superconducting motors and generators, testing of high-current, low-AC-loss superconducting wires and coils must be performed. A preliminary investigation was conducted on the critical current capabilityof a magnesium diboride sample and on the complications that arise from testing the sample with a cryocooler. While a cryocooler provides the benefit of a wide and continuous operating temperature range, cooling a sample by conduction through solid media without a heat-exchange gas is difficult. This paper outlines the hardware and software used to conduct the first DC performance tests on magnesium diboride superconducting samples, along with several check-out tests and mitigation steps needed to produce quality superconducting data using a cryocooler rather than a cryogen

Superconductor↗
DOE OSTI2014

Low temperature junction growth using hot-wire chemical vapor deposition

A system and a process for forming a semi-conductor device, and solar cells (10) formed thereby. The process includes preparing a substrate (12) for deposition of a junction layer (14); forming the junction layer (14) on the substrate (12) using hot wire chemical vapor deposition; and, finishing the semi-conductor device.

14 SOLAR ENERGY↗
DOE OSTI2015

Hot wire needle probe for thermal conductivity detection

An apparatus comprising a needle probe comprising a sheath, a heating element, a temperature sensor, and electrical insulation that allows thermal conductivity to be measured in extreme environments, such as in high-temperature irradiation testing. The heating element is contained within the sheath and is electrically conductive. In an embodiment, the heating element is a wire capable of being joule heated when an electrical current is applied. The temperature sensor is contained within the sheath, electrically insulated from the heating element and the sheath. The electrical insulation electrically insulates the sheath, heating element and temperature sensor. The electrical insulation fills the sheath having electrical resistance capable of preventing electrical conduction between the sheath, heating element, and temperature sensor. The control system is connected to the heating element and the temperature sensor.

42 ENGINEERING↗
DOE OSTI2016

Frame-mounted wire management device

A wire management device is disclosed. The device comprises a clip comprising an upper planar member and a lower planar member, each planar member having an inner and outer surface, wherein the inner surface of the upper planar member includes a post extending toward the inner surface of the lower planar member, a stem extending from the outer surface of the lower planar member, the stem including two outwardly-extending flanges, each of the first and second outwardly-extending flanges including an edge portion extending toward the outer surface of the lower planar member, and a transverse passage extending along the outer surface of the lower planar member, the transverse passage extending across the stem, wherein the stem has a recessed portion along the transverse passage.

42 ENGINEERING↗
DOE OSTI2017

Wire Chambers and Cherenkov Detectors at Fermilab Test Beam Facility

Fermilab Test Beam Facility (FTBF) is dedicated to helping scientists test their prototypes. For this, FTBF has instrumentation that is very useful for the users. However, before a user can test a detector, it is necessary to ensure the facility has the characteristics they need. During this summer, we studied beam properties by collecting Cherenkov and wire chamber data. Analyzed data will be used for updating the general information that FTBF posts on a web page.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Correlations of Interlayer Time with Distortion of Large Ti-6Al-4V Components in Laser Metal Deposition with Wire

Laser metal deposition with wire (LMD-w) is one of the emerging additive manufacturing (AM) technologies for large-scale aerospace components due to high deposition rates and material efficiency. However, it often results in undesired stresses and distortions due to non-uniform expansion and contraction of material during the printing. Controlling of inter-layer time, preheating and clamping is the effective method to mitigate the thermally induced stress and deformation. In this study, the effect of inter-layer time on the part distortion is investigated using finite element method (FEM). The model accounts for actual tool path, power and cooling conditions. The results show that the model effectively captures the fluctuation of the Ti-6Al-4V plate during printing. Also, it shows an asymmetric distortion on the plate edges. Ultimately, the sequentially coupled thermal-stress simulation provided a quantitative understanding of the inter-layer cooling time on the Ti plate distortion for the large-scale LMD-w process.

Lee, Yousub↗
DOE OSTI2019

Long length high temperature superconducting wires with uniform ion implanted pinning microstructures

A method for producing a long length high temperature superconductor wire, includes providing a substrate, having a surface with a length of at least 50 meters and a width. The surface supports a biaxially textured high temperature superconducting layer and the biaxially textured high temperature superconducting layer has a length and a width corresponding to the length and width of the surface of the substrate. The method includes irradiating the biaxially textured high temperature superconductor layer with an ion beam impinging uniformly along the length and across the width of the biaxially textured high temperature superconductor layer to produce a uniform distribution of pinning microstructures in the biaxially textured high temperature superconductor layer.

Rupich, Martin W.↗
DOE OSTI2019

Feasibility Analysis of Utilizing Maraging Steel in a Wire Arc Additive Process for High-Strength Tooling Applications

Traditional tool and die development require skilled labor, long lead time, and is highly expensive to produce. Metal Big Area Additive Manufacturing (mBAAM) is a wire-arc additive process that utilizes a metal inert gas (MIG) welding robot to print large-scale parts layer-by-layer. By using mBAAM, tooling can be manufactured rapidly with low costs. For cold work tooling applications, a high hardness level is desired to increase the life-time of the tool. A promising material that can achieve this is maraging steel. Maraging steel is known to have good weldability; however, further testing must be conducted to ensure it is feasible for printing using mBAAM. In this paper, initial process parameters were obtained by printing single bead welds. Multi-bead walls were then printed with some refinement of process parameters to construct homogenous outer features of the walls. Lastly, the walls were heat-treated, and hardness data was gathered through Rockwell Hardness tests.

Masuo, Chris↗
DOE OSTI2017

Why wait? Let's start computing while data is still on the wire

In this era of Big Data, computing useful information from data is becoming increasingly complicated, particularly due to the ever increasing volumes of data that need to travel over the network to data centers to be stored and processed, all highly expensive operations in the long haul. In this paper we suggest that we can do computing and analysis of data "on the wire," i.e., while data is still in transit. The nature of these computations include analysis, visualization, pattern recognition, and prediction, or forecasting, on the streaming data. We follow a service function chaining architecture to implement this, assuming that the data packets arrive within a single network administrative domain. As a demonstration of this new computing paradigm, we present three examples. Firstly, we demonstrate pattern recognition and data visualization on streaming forex data, which can be used for lucrative trading in the forex market. In our second example, we analyze and learn user buying patterns from clickstream data streaming from multiple websites. Finally, we monitor solar sensors for a zero reading while the packets are still on their way to the data center, to schedule any maintenance and requisite repairs with no time delay.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2019

Tank Test of an Active Power Rectification in Wave-to-Wire Energy Conversion

Maximum power control algorithms in wave energy converter (WEC) are mainly based on the fluid-structure dynamics with impedance matching from power take-off (PTO) damping or model predictive control through the buoy dynamics. However, the conventional buoy characteristics study cannot satisfy estimation of maximum output power in a practical wave-to-wire (W2W) system due to significant losses on mechanical and electrical components from PTO to power converter in comparison with the losses on the buoy. To analysis the non-ideal effects from mechanical transmission and energy conversion characteristics of WEC with a power converter output, a W2W simulation and tank testing is performed. The 1:20 scale WEC system with 1.17m buoy diameter includes a single body heaving buoy, mechanical-motion-rectifier based power-take-off, and power converter that store its output energy to a battery load. From the tank testing results, a circuit model is built and is used to estimate the system performance. The non-ideal effects such as viscous damping between buoy and power take-off, gearbox loss, generator loss, and power converter loss in the system are included in the circuit model with efficiencies from 60 - 80%. The maximum extracted power results under various wave conditions are dominated by these non-ideal effect.

16 TIDAL AND WAVE POWER↗
DOE OSTI2020

Optimizing branch re-wiring in a software instruction cache

A method includes a computer device receiving a branch instruction; the computer device managing two tables, where a first table relates to application blocks and a second table relates to available address slots; and the computer device calculating a target of the branch instruction using a branch-to-link register, the computer device optimizes re-wiring in a cache using the calculation and the managed two tables.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Cabling method of superconducting flat wires

A structure and method provide cables of high-temperature superconducting flat tape and/or filament wires, with a small bending diameter. A cable has a former having cross section that includes a rectangle having rounded ends (i.e. an obround), and the flat tape is wound around the surface of the former at an angle to minimize bending. The former surface may have raised helical ribs or lowered grooves to provide tape registration in multi-layer configurations. Tape may be wound from a spool onto the former under tension, and cut with a laser cutter to produce fine filaments immediately before winding. The former may be slit longitudinally to prevent loop eddy currents and reduce AC losses. The wound cable may be jacketed to provide a cable-in-conduit conductor (CICC), and coolant channels may be provided in the jacket or in the former.

Takayasu, Makoto↗