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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 1,477 records · Page 82

Sintered Cathodes for All-Solid-State Structural Lithium-Ion Batteries

All-solid-state structural lithium ion batteries serve as both structural load-bearing components and as electrical energy storage devices to achieve system level weight savings in aerospace and other transportation applications. This multifunctional design goal is critical for the realization of next generation hybrid or all-electric propulsion systems. Additionally, transitioning to solid state technology improves upon battery safety from previous volatile architectures. This research established baseline solid state processing conditions and performance benchmarks for intercalation-type layered oxide materials for multifunctional application. Under consideration were lithium cobalt oxide and lithium nickel manganese cobalt oxide. Pertinent characteristics such as electrical conductivity, strength, chemical stability, and microstructure were characterized for future application in all-solid-state structural battery cathodes. The study includes characterization by XRD, ICP, SEM, ring-on-ring mechanical testing, and electrical impedance spectroscopy to elucidate optimal processing parameters, material characteristics, and multifunctional performance benchmarks. These findings provide initial conditions for implementing existing cathode materials in load bearing applications.

Ceramics↗

Solar Sail Propulsion for Interplanetary Small Spacecraft

NASA is developing solar sail propulsion for use by small robotic interplanetary spacecraft. Solar sails use sunlight to derive useful thrust by reflecting solar photons from a large, mirror-like sail made of a lightweight, highly reflective material. Using reflected sunlight to obtain thrust instead of relying on the use of reaction mass has many advantages for exploring the inner solar system, including extremely large total delta V (velocity difference) and significant launch window flexibility.

Asteroid↗

Freeze Casting of LAGP for 3D Textured Solid-State Structural Electrolytes

In this study, all-solid-state structural lithium-ion batteries, a type of load bearing electrochemical energy storage that provides systems-level weight savings is being pursued for the realization of inherently safe next generation hybrid-electric and all-electric green aerospace propulsion systems. Currently investigated all-solid-state batteries do not meet the requirements for specific power and mechanical stability. To address these issues, freeze casting of lithium aluminum germanium phosphate (LAGP) electrolyte material has been explored for the creation of a textured 3D electrolyte scaffold with large interfacial surface area for high power discharge and hierarchical porosity for accommodation of active material volume changes during electrochemical cycling. We report the effects of freeze casting processing parameters on the microstructural development and mechanical performance of the scaffolds, characterized through scanning electron microscopy and ring-on-ring mechanical testing. Slurry composition and casting parameters such as solids loading, casting speed, tape angle, and temperature gradients have been modified to determine the impact on density, lamellar morphology, and final load-bearing performance.

ceramics↗

Plume-surface interaction testing for crewed lunar lander risk reduction

Spacecraft conducting propulsive near-surface operations such as landing or initial ascent must consider potential hazards caused by rocket exhaust interacting with planetary regolith. Gas-granular interactions can erode the surface and eject material, altering the landing site, obscuring views of the surface, and creating abrasion or impact risks. The next generation of lunar landers under development for NASA’s Human Landing System program will push us outside Apollo flight experience for plume-surface interaction. Strategic knowledge gaps and poorly constrained flight data inhibit our ability to accurately and precisely predict the plume-surface interaction environment for a given flight vehicle. We present an overview of a lunar relevant, supersonic plume-surface interaction test that will be conducted in 2024 to improve our understanding of lunar PSI and reduce associated risks to the HLS program.

Wesley A. Chambers↗

Reuse International Space Station (ISS) Modules as Lunar Habitat

NASA currently projects ending the ISS mission in approximately 2016, due primarily to the expense of re-boost and re-supply. Lunar outposts are expected to be in place in the same timeframe. In support of these mission goals, a scheme to reuse ISS modules on the moon has been identified. These modules could function as pressurized volumes for human habitation in a lunar vacuum as they have done in low-earth orbit. The ISS hull is structurally capable of withstanding a lunar landing because there is no atmospheric turbulence or friction. A compelling reason to send ISS modules to the moon is their large mass; a large portion of the ISS would survive re-entry if allowed to de-orbit to Earth. ISS debris could pose a serious risk to people or structures on Earth unless a controlled re-entry is performed. If a propulsive unit is devised to be attached to the ISS and control re-entry, a propulsion system could be used to propel the modules to the moon and land them there. ISS modules on the lunar surface would not require re-boost. Radiation protection can be attained by burying the module in lunar regolith. Power and a heat removal system would be required for the lunar modules which would need little support structure other than the lunar surface. With planetary mass surrounding the module, heat flux may be controlled by conductance. The remaining requirement is the re-supply of life-support expendables. There are raw materials on the moon to supplement these vital resources. The lunar maria is known to contain approximately 40% oxygen by mass in inorganic mineral compounds. Chemical conversion of moon rocks to release gaseous oxygen is known science. Recycling and cleaning of air and water are currently planned to be accomplished with ISS Environmental Control & Life Support Systems (ECLSS). By developing a Propulsion and Landing Module (PLM) to dock to the Common Berthing Mechanism (CBM), several identical PLMs could be produced to rescue and transfer the ISS modules to the lunar surface, one by one. The propulsion does not need to be as swift as Apollo, nor would the modules need to be manned during transportation to the moon. The trajectory from low-Earth to lunar orbit would avoid or quickly pass through the Van Allen belts to minimize radiation exposure to electronics onboard. A landing technology similar to Apollo's could be utilized to land an ISS module on the moon. Since the mission will be unmanned, system redundancy could be minimized to keep the cost down. If the mission failed and a module crashed landed on the moon, the risk of debris landing on Earth would be avoided and the raw materials could be used in future lunar missions.

Miernik, Janie↗

2020 Annual Merit Review, Vehicle Technologies Office

The 2020 U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy’s (EERE) Vehicle Technologies Office (VTO) Annual Merit Review (AMR) was held June 1-4, 2020, virtually, due to extenuating circumstances resulting from the global Coronavirus (COVID-19) pandemic. The review encompassed work done by VTO: 292 individual activities were reviewed by 334 reviewers. Exactly 1,133 individual review responses were received for the VTO technical reviews. The objective of the meeting was to review the accomplishments and plans for VTO over the previous 12 months, and provide an opportunity for industry, government, and academia to give inputs to DOE with a structured and formal methodology. The meeting also provided attendees with a virtual forum for interaction and technology information transfer.

25 ENERGY STORAGE↗

Stable White Coatings

In a previous research program for the Jet Propulsion- Laboratory, extensive studies led to the development and specifications of three zinc oxide-pigmented thermal-control coatings. The principal objectives of this program are: improvement of the three paints (as engineering materials), determination of the validity of our accelerated space-simulation testing, and continuation of the zinc oxide photolysis studies begun in the preceding program. Specific tasks that are discussed include: improvement of potassium silicate coatings as engineering materials and elucidation of their storage and handling problems; improvement of methyl silicone coatings as engineering materials; studies of zinc oxide photolysis to establish reasons for the observed stability of zinc oxide; and determination of space-simulation parameters such as long-term stability (to 8000 ESH), effect of coating surface temperature on the rate of degradation, and validity of accelerated testing (by reciprocity and wavelength dependency studies).

COATING↗

Rotating Fluidized Bed Reactor for Space Nuclear Propulsion: Design Studies and Experimental Results - Annual Report

The rotating fluidized bed reactor concept is being investigated for possible application in nuclear propulsion systems. Physics calculations show U-233 to be superior to U-235 as a fuel for a cavity reactor of this type. Preliminary estimates of the effect of hydrogen in the reactor, reflector material, and power peaking are given. A preliminary engineering analysis was made for U-235 and U-233 fueled systems. An evaluation of the parameters affecting the design of the system is given, along with the thrust-to-weight ratios. The experimental equipment is described, as are the special photographic techniques and procedures. Characteristics of the fluidized bed and experimental results are given, including photographic evidence of bed fluidization at high rotational velocities.

Source record↗

Monolithic solid oxide fuel cell development

The feasibility of the monolithic solid oxide fuel cell (MSOFC) concept has been proven, and the performance has been dramatically improved. The differences in thermal expansion coefficients and firing shrinkages among the fuel cell materials have been minimized, thus allowing successful fabrication of the MSOFC with few defects. The MSOFC shows excellent promise for development into a practical power source for many applications from stationary power, to automobile propulsion, to space pulsed power.

Myles, K. M.↗

High power bipolar lead-acid batteries

The Jet Propulsion Laboratory (JPL), with interest in advanced energy storage systems, is involved in the development of a unique lead acid battery design. This battery utilizes the same combination of lead and lead dioxide active materials present in the automobile starting battery. However, it can provide 2 to 10 times the power while minimizing volume and weight. The typical starting battery is described as a monopolar type using one current collector for both the positive and negative plate of adjacent cells. Specific power as high as 2.5 kW/kg was projected for 30 second periods with as many as 2000 recharge cycles.

Halpert, Gerald↗

Autonomous NanoTechnology Swarm (ANTS) Prospecting Asteroid Mission (PAM), Asteroid Proximity Operations

The Autonomous NanoTechnology Swarm (ANTS) is a generic mission architecture based on spatially distributed spacecraft, autonomous and redundant components, and hierarchical organization. The ANTS Prospecting Asteroid Mission (PAM) is an ANTS application which will nominally use a swarm of 1000 spacecraft. There would be 10 types of "specialists" with common spacecraft buses. There would be 10 subswarms of approximately 100 spacecraft each or approximately 10 of each specialist in each swarm. The ANTS PAM primary objective is the exploration of the asteroid belt in search of resources and material with astrobiologically relevant origins and signatures. The ANTS PAM spacecraft will nominally be released from a station in an Earth-Moon L1 libration point orbit, and they will use Solar sails for propulsion. The sail structure would be highly flexible, capable of changing morphology to change cross-section for capture of sunlight or to form effective "tip vanes" for attitude control. ANTS PAM sails would be capable of full to partial deployment, to change effective sail area and center of pressure, and thus allow attitude control. Results of analysis of a transfer trajectory from Earth to a sample target asteroid will be presented. ANTS PAM will require continuous coverage of different asteroid locations as close as one to two asteroid "diameters" from the surface of the asteroid for periods of science data collection during asteroid proximity operations. Hovering spacecraft could meet the science data collection objectives. The results of hovering analysis will be presented. There are locations for which hovering is not possible, for example on the illuminated side of the asteroid. For cases where hovering is not possible, the results of utilizing asteroid formations to orbit the asteroid and achieve the desired asteroid viewing will be presented for sample asteroids. The ability of ANTS PAM to reduce the area of the solar sail during asteroid proximity operations is critical to the maintenance of orbiting formations for a period of time. Results of analysis of potential "traffic" problems during asteroid proximity operations will be presented.

Marr, Greg↗

Thermal Mechanical Stability of Single-Crystal-Oxide Refractive Concentrators Evaluated for High-Temperature Solar-Thermal Propulsion

Recently, refractive secondary solar concentrator systems were developed for solar thermal power and propulsion (ref. 1). Single-crystal oxides-such as yttria-stabilized zirconia (Y2O3-ZrO2), yttrium aluminum garnet (Y3Al5O12, or YAG), magnesium oxide (MgO), and sapphire (Al2O3)-are candidate refractive secondary concentrator materials. However, the refractive concentrator system will experience high-temperature thermal cycling in the solar thermal engine during the sun/shade transition of a space mission. The thermal mechanical reliability of these components in severe thermal environments is of great concern. Simulated mission tests are important for evaluating these candidate oxide materials under a variety of transient and steady-state heat flux conditions. In this research at the NASA Lewis Research Center, a controlled heat flux test approach was developed for investigating the thermal mechanical stability of the candidate oxide. This approach used a 3.0-kW continuous-wave (wavelength, 10.6 mm) carbon dioxide (CO2) laser (ref. 2). The CO2 laser is especially well-suited for single-crystal thermal shock tests because it can directly deliver well-characterized heat energy to the oxide surfaces. Since the oxides are opaque at the 10.6-mm wavelength of the laser beam, the light energy is absorbed at the surfaces rather than transmitting into the crystals, and thus generates the required temperature gradients within the specimens. The following figure is a schematic diagram of the test rig.

Jacobson, Nathan S.↗

Testing of Flexible Ballutes in Hypersonic Wind Tunnels for Planetary Aerocapture

Studies were conducted for the In-Space Propulsion (ISP) Ultralightweight Ballute Technology Development Program to increase the technical readiness level of inflatable decelerator systems for planetary aerocapture. The present experimental study was conducted to develop the capability for testing lightweight, flexible materials in hypersonic facilities. The primary objectives were to evaluate advanced polymer film materials in a high-temperature, high-speed flow environment and provide experimental data for comparisons with fluid-structure interaction modeling tools. Experimental testing was conducted in the Langley Aerothermodynamics Laboratory 20-Inch Hypersonic CF4 and 31-Inch Mach 10 Air blowdown wind tunnels. Quantitative flexure measurements were made for 60 degree half angle afterbody-attached ballutes, in which polyimide films (1-mil and 3-mil thick) were clamped between a 1/2-inch diameter disk and a base ring (4-inch and 6-inch diameters). Deflection measurements were made using a parallel light silhouette of the film surface through an existing schlieren optical system. The purpose of this paper is to discuss these results as well as free-flying testing techniques being developed for both an afterbody-attached and trailing toroidal ballute configuration to determine dynamic fluid-structural stability. Methods for measuring polymer film temperature were also explored using both temperature sensitive paints (for up to 370 C) and laser-etched thin-film gages.

Buck, Gregory M.↗

Testing of Flexible Ballutes in Hypersonic Wind Tunnels for Planetary Aerocapture

Studies were conducted for the In-Space Propulsion (ISP) Ultralightweight Ballute Technology Development Program to increase the technical readiness level of inflatable decelerator systems for planetary aerocapture. The present experimental study was conducted to develop the capability for testing lightweight, flexible materials in hypersonic facilities. The primary objectives were to evaluate advanced polymer film materials in a high-temperature, high-speed flow environment and provide experimental data for comparisons with fluid-structure interaction modeling tools. Experimental testing was conducted in the Langley Aerothermodynamics Laboratory 20-Inch Hypersonic CF4 and 31-Inch Mach 10 Air blowdown wind tunnels. Quantitative flexure measurements were made for 60 degree half angle afterbody-attached ballutes, in which polyimide films (1-mil and 3- mil thick) were clamped between a 1/2-inch diameter disk and a base ring (4-inch and 6-inch diameters). Deflection measurements were made using a parallel light silhouette of the film surface through an existing schlieren optical system. The purpose of this paper is to discuss these results as well as free-flying testing techniques being developed for both an afterbody-attached and trailing toroidal ballute configuration to determine dynamic fluid-structural stability. Methods for measuring polymer film temperature were also explored using both temperature sensitive paints (for up to 370 C) and laser-etched thin-film gages.

Buck, Gregory M.↗

Demonstration of Subscale Cermet Fuel Specimen Fabrication Approach Using Spark Plasma Sintering and Diffusion Bonding

Nuclear thermal propulsion (NTP) has the potential to expand the limits of human space exploration by enabling crewed missions to Mars and beyond. The viability of NTP hinges on the development of a robust nuclear fuel material that can perform in the harsh operating environment (> or = 2500K, reactive hydrogen) of a nuclear thermal rocket (NTR) engine. Efforts are ongoing to develop fuel material and to assemble fuel elements that will be stable during the service life of an NTR. Ceramic-metal (cermet) fuels are being actively pursued by NASA Marshall Space Flight Center (MSFC) due to their demonstrated high-temperature stability and hydrogen compatibility. Building on past cermet fuel development research, experiments were conducted to investigate a modern fabrication approach for cermet fuel elements. The experiments used consolidated tungsten (W)-60vol%zirconia (ZrO2) compacts that were formed via spark plasma sintering (SPS). The consolidated compacts were stacked and diffusion bonded to assess the integrity of the bond lines and internal cooling channel cladding. The assessment included hot hydrogen testing of the manufactured surrogate fuel and pure W for 45 minutes at 2500 K in the compact fuel element environmental test (CFEET) system. Performance of bonded W-ZrO2 rods was compared to bonded pure W rods to access bond line integrity and composite stability. Bonded surrogate fuels retained structural integrity throughout testing and incurred minimal mass loss.

Barnes, Marvin W.↗

Solar Power System and Radioisotope Thermoelectric Generation Technologies at Jupiter-Saturn-Uranus Environments: New Insights and Paradigms

Power system selection for outer planet destinations, such as Jupiter, Saturn, and Uranus and beyond, is complex, involving and dependent on many interdisciplinary factors such as power system mass, specific power, cost, mechanical and electrical integration, and natural radiation environment. Low solar irradiance at Jupiter, Saturn, and Uranus systems (i.e., 50, 15, and 4 W/m2 , respectively) makes solar power systems challenging in mechanical / electrical integration and accommodating radiation environments. More costly radioisotope thermoelectric generator (RTG) systems can help proposed missions overcome radiation environment and spacecraft control challenges at Jupiter, Saturn, and Uranus. NASA’s Jet Propulsion Laboratory (JPL) has recently made significant strides in demonstrating high-efficiency, radiation-hard solar cell technologies for low-irradiance, low-temperature (LILT) applications, and high-efficiency thermoelectric (TE) materials and modules for higher-specific-power RTGs. Stateof-art multi-junction solar cells now routinely demonstrate high efficiencies of 30-34% at LILT (9.5AU and -165°C), making solar arrays a viable option for many near-term Saturn mission concepts. Emerging technologies like LILToptimized solar cells have recently demonstrated even higher efficiencies of 37% at 9.5AU and -165°C and 30% lower mass than the state-of-art, offering the prospect of ~3W/kg array-level, end-of-life specific powers under Saturn conditions. Having already demonstrated the tremendous utility of RTGs on Mars and in deep-space missions (e.g., Galileo at Jupiter, New Horizons at Pluto), NASA is now developing and demonstrating new TE materials and modules (e.g., skutterudites, La3-x Te4, and Zintls) for increasing RTG specific power (up to >8.5 W/kg), which strongly impacts an RTG’s mass, fuel utilization, and modularity in the power system trade domain. New accomplishments in both areas highlight the renewed requisite for updated comparisons and trade-offs in power output, specific power and mass, cost, mechanical and electrical integration, new technology timelines, and natural radiation impacts between new LILT-optimized photovoltaic technologies and next-generation RTG technologies. This work discusses and demonstrates how new LILT-based technologies are now allowing one to consider and design solar power systems for Saturn orbit and beyond, and are changing the potential cost-mass trade-offs between emerging solar power technologies and newly-envisioned RTG technologies. Key updated system mass and cost trade-offs between high-performance LILT solar technologies and new RTG technologies are presented, reinforcing and refining power selection criteria supporting possible future NASA deep-space science and exploration missions to Mars, the Jupiter system (Europa, Ganymede), the Saturn system (Titan, Enceladus), Uranus, and beyond. Key trade-offs in other above-mentioned interdisciplinary factors between these two power technologies are also discussed.

Bairstow, Brian K.↗

Design, Manufacturing, and Validation of an Optimized Electric Machine Enabled by 3D Printing

The collaboration between the National Laboratory of the Rockies (NLR) and LaunchPoint Electric Propulsion Solutions, Inc. (LaunchPoint) focuses on manufacturing and additive design of electric machines enabled by DOE’s program for three-dimensional printing (MADE3D) as applied to advanced drivetrains and their impact on turbine capital cost and lifetime energy production. Initial efforts will focus on the rotor structure and rotor core of the drivetrain including the active materials (electrical steel and magnets) and could later expand to the stator. The verification activities will be conducted with an instrumented electric machine and a small dynamometer.

17 WIND ENERGY↗

Development of a Large Scale, High Speed Wheel Test Facility

Draper Laboratory, with its internal research and development budget, has for the past two years been funding a joint effort with the Massachusetts Institute of Technology (MIT) for the development of a large scale, high speed wheel test facility. This facility was developed to perform experiments and carry out evaluations on levitation and propulsion designs for MagLev systems currently under consideration. The facility was developed to rotate a large (2 meter) wheel which could operate with peripheral speeds of greater than 100 meters/second. The rim of the wheel was constructed of a non-magnetic, non-conductive composite material to avoid the generation of errors from spurious forces. A sensor package containing a multi-axis force and torque sensor mounted to the base of the station, provides a signal of the lift and drag forces on the package being tested. Position tables mounted on the station allow for the introduction of errors in real time. A computer controlled data acquisition system was developed around a Macintosh IIfx to record the test data and control the speed of the wheel. This paper describes the development of this test facility. A detailed description of the major components is presented. Recently completed tests carried out on a novel Electrodynamic (EDS) suspension system, developed by MIT as part of this joint effort are described and presented. Adaptation of this facility for linear motor and other propulsion and levitation testing is described.

Kondoleon, Anthony↗