Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “assembly processes”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,549 records · Page 86

Battery Performance and Cost Modeling for Electric-Drive Vehicles (A Manual for BatPaC v5.0)

This manual details the fifth version of the Battery Performance and Cost (BatPaC v5.0) model developed at Argonne National Laboratory for lithium-ion battery packs used in transportation (file “BatPaC 5.0 2022-07-22.xlsm”). BatPaC is a publicly available model that performs a bottom-up lithium-ion battery design and cost calculation. The model designs the battery for a specified power, energy, and vehicle type (i.e., hybrid, plug-in hybrid, or full-electric). The cost of the designed battery is calculated by accounting for every step in the lithium-ion battery manufacturing process. The original model and manual were publicly peer-reviewed by battery experts assembled by the U.S. Environmental Protection Agency. This revised model and manual include changes made in response to comments received from users and the observed trajectory of the industry.

25 ENERGY STORAGE↗

Development of High Temperature (>700°C) Molten Salt Pump Technology for Generation 3 Solar Power Tower Systems

Bearings are required for long-shafted pumps historically used in concentrating solar thermal power applications. For molten chloride salts, bearings for such service conditions are not commercially available, nor has a design been demonstrated to work. Therefore, a project was sponsored by the Department of Energy’s Solar Energy Technologies Office for the development and demonstration of a submerged bearing for use in chloride salt pumps. This project’s tasks covered the tribological testing of candidate materials and the design, fabrication, testing, and post-test analysis of full-scale salt-compatible bearings. This work expands upon previous work. The effects of potential particulate in the salt were investigated through tribological bench testing. Through 11 tests, the MgO particulate size and concentration in a molten chloride salt were varied, and the effects on friction, wear rate, and wear characteristics were recorded. Novel journal bearings for chloride salt service were designed and fabricated based on these results. The bearings were of a relevant scale (i.e., for a 1.5 in. pump shaft) to demonstrate the technology with respect to further scale-up. The bearings were made of Haynes 244 and Yttria Partially Stabilized Zirconia. A custom bearing test rig, salt tanks, and associated infrastructure (e.g., heaters, tanks, transfer lines, gas flow control) were designed, procured, and installed. A few issues were encountered in the system fabrication process, resulting in delay of the project schedule. The system was successfully fabricated and assembled. Heating, cover gas, and pump motor systems were integrated into the control logic. This progress of the bearing test system represents a significant step forward towards demonstrating this promising technology. Nevertheless, the project ended before testing of the full-scale bearings could be performed.

14 SOLAR ENERGY↗

IER 516 - Zirconium Test Assembly (ZTA) Preliminary Experimental Design [Slides]

Zirconium present in large quantities in criticality safety applications such as fuel manufacturing and processing facilities, and in commercial thermal nuclear reactors. ICSBEP lacks benchmarks optimized for zirconium sensitivity to validate zirconium evaluations. Evaluators lack isotopic differential nuclear data in regions of high importance to fission systems.

K-PSO 2.0↗

One-Dimensional (1D) Nanostructured Materials for Energy Applications

At present, the world is at the peak of production of traditional fossil fuels. Much of the resources that humanity has been consuming (oil, coal, and natural gas) are coming to an end. The human being faces a future that must necessarily go through a paradigm shift, which includes a progressive movement towards increasingly less polluting and energetically viable resources. In this sense, nanotechnology has a transcendental role in this change. For decades, new materials capable of being used in energy processes have been synthesized, which undoubtedly will be the cornerstone of the future development of the planet. In this review, we report on the current progress in the synthesis and use of one-dimensional (1D) nanostructured materials (specifically nanowires, nanofibers, nanotubes, and nanorods), with compositions based on oxides, nitrides, or metals, for applications related to energy. Due to its extraordinary surface–volume relationship, tunable thermal and transport properties, and its high surface area, these 1D nanostructures have become fundamental elements for the development of energy processes. The most relevant 1D nanomaterials, their different synthesis procedures, and useful methods for assembling 1D nanostructures in functional devices will be presented. Applications in relevant topics such as optoelectronic and photochemical devices, hydrogen production, or energy storage, among others, will be discussed. The present review concludes with a forecast on the directions towards which future research could be directed on this class of nanostructured materials.

Machín, Abniel (ORCID:0000000341343344)↗

A research program in magnetogasdynamics utilizing hypervelocity coaxial plasma generators

A broadly-gauged research program in magnetogasdynamics utilizing hypervelocity coaxial plasma generators is presented. A complete hypervelocity coaxial plasma generator facility was assembled and tested. Significant progress was made in the direction of understanding the important processes in the interaction of hypervelocity MGD flow with transverse applied fields. It is now proposed to utilize the accumulated experimental capability and theoretical analysis in application to the analysis and design parameterization of pulsed magnetogasdynamic direct energy convertor configurations.

Spight, C.↗

ATS-6 - UCSD auroral particles experiment

The University of California at San Diego Auroral Particles Experiment aboard Applications Technology Satellite-6 (ATS-6) is discussed. The experiment is designed to investigate the time development of geomagnetic substorm particles, the confinement and loss of such particles, and the roles of plasma wave instabilities and characteristic system periodicities in substorm and general magnetospheric processes. The instrumentation includes a complement of five electrostatic charged particle detectors. Two detector assemblies are capable of rotation through 220 deg. The electrostatic curved plate energy/unit charge analyzers are ovoid, requiring particles to be bent only 55 deg to obtain azimuthal focusing. The inside of the plates is serrated to eliminate particles striking the sides. A post-analysis electrostatic lens consisting of two wire grids, one at the potential of the inner plate and one at the potential of ground, focuses particles strongly upon the center of the sensor. A spiraltron particle sensor detects the charged particles. The system has an energy range of five orders of magnitude with a lower extreme of less than 1 eV. Preliminary data are presented to illustrate phenomena which are observed as a result of the novel features described.

Mauk, B. H.↗

Automated Array Assembly, Phase 2

The Automated Array Assembly Task, Phase 2 of the Low Cost Silicon Solar Array Project is a process development task. The contract provides for the fabrication of modules from large area tandem junction cells (TJC). During this quarter, effort was focused on the design of a large area, approximately 36 sq cm, TJC and process verification runs. The large area TJC design was optimized for minimum I squared R power losses. In the TJM activity, the cell-module interfaces were defined, module substrates were formed and heat treated and clad metal interconnect strips were fabricated.

Carbajal, B. G.↗

Use of MSC/NASTRAN for the thermal analysis of the Space Shuttle Orbiter braking system

A description is given of the thermal modeling and analysis effort being conducted to investigate the transient temperature and thermal stress characteristics of the Space Shuttle Orbiter brake components and subsystems. Models are constructed of the brake stator as well as of the entire brake assembly to analyze the temperature distribution and thermal stress during the landing and braking process. These investigations are carried out on a UNIVAC computer system with MSC/NASTRAN Version 63. Analytical results and solution methods are presented and comparisons are made with SINDA results.

Shu, James↗

Heavy Nucleus Collector (HNC) project for the NASA Long Duration Exposure Facility (LDEF)

The primary goal of the heavy nucleus collector (HNC) experiment was to obtain high resolution composition measurements for cosmic ray nuclei in the platinum-lead and actinide region of the periodic table. Secondary objectives include studies of selected groups of elements of lower charge. These goals were to be realized by orbiting a large area array of dielectric nuclear track detectors in space for several years. In this time sufficient actinide nuclei would be collected to determine the nucleosynthetic age of the cosmic radiation and the relative mix of r- and s-process elements in the cosmic ray source. The detector consists of approximately 50 trays assembled in pressurized canisters. Each tray would contain 8 half-stacks (4 stacks total) and an event thermometer which would record the temperature of each event at the time of exposure. Each stack would contain 7 layers of Rodyne-P, CR-39 and Cronar plastic track detectors interleaved with copper stripping foils. Upon return to Earth, detectors would be removed for analysis. Ultraheavy nuclei would have left tracks through the detector sheets that would be made visible after etching in a hot sodium hydroxide solution.

Tarle, Gregory↗

Advanced technology development for image gathering, coding, and processing

Three overlapping areas of research activities are presented: (1) Information theory and optimal filtering are extended to visual information acquisition and processing. The goal is to provide a comprehensive methodology for quantitatively assessing the end-to-end performance of image gathering, coding, and processing. (2) Focal-plane processing techniques and technology are developed to combine effectively image gathering with coding. The emphasis is on low-level vision processing akin to the retinal processing in human vision. (3) A breadboard adaptive image-coding system is being assembled. This system will be used to develop and evaluate a number of advanced image-coding technologies and techniques as well as research the concept of adaptive image coding.

Huck, Friedrich O.↗

Preliminary design of a lunar construction utility vehicle

Construction of a lunar base, prior to manned occupancy, is one of the most demanding technological challenges facing space system designers today. A flexible lunar construction machine is needed that can be operated remotely and that can perform a variety of construction tasks over a wide range of lunar conditions. A preliminary lunar construction utility vehicle (LCUV) design has been developed as part of a capstone design course at Old Dominion University and is described in this summary report. The design requirements are taken from a 1988 USRA Summer Design Report entitled The Lunar Split Mission: A Robotic Constructed Lunar Base Scenario, and from the proceedings of a workshop hosted by United Technologies Corporation entitled Report of the In Situ Resources Utilization Workshop. The first report describes a bootstrap base concept in which a minimum of essential surface elements are delivered and configured such that minimum EVA is required to bring the initial base on-line. The base is to be built in three phases, the first of which will be unmanned, while the second and third will be manned. The key to these concepts is the development of a semiautonomous, telerobotic lunar construction utility vehicle (LCUV). The tasks required of this robotic vehicle during the phase 1 build-up are as follows: (1) surface element transportation, handling, and assembly; (2) soil excavation and movement for site preparation; (3) radiation protection and materials processing; and (4) repair and maintenance of surface elements. In order to meet the stated requirements, the LCUV must be: (1) transformable to perform a wide variety of tasks; (2) self supporting; (3) designed to allow for telerobotic control as well as autonomous operation; (4) able to transport one fully configured space station common module (SSCM); (5) upgradable to allow for future growth; and (6) easy to maintain.

Bryant, C. A.↗

Ultrasonic Inspection Of Welds On Tube Fittings

Scanning ultrasonic apparatus designed for use in nondestructive inspection of electron-beam welds between heat-exchanger tube and end fittings. Includes ultrasonic probe, scanning mechanism, ultrasonic-signal-generating and -processing circuits, and computers. Not necessary to immerse any part of apparatus or tube/fitting assembly in water during inspection. Output ultrasonic-test signals displayed on computer to reveal defects.

Ray, Arjun N.↗

Advanced Technology Composite Fuselage - Manufacturing

The goal of Boeing's Advanced Technology Composite Aircraft Structures (ATCAS) program is to develop the technology required for cost-and weight-efficient use of composite materials in transport fuselage structure. Carbon fiber reinforced epoxy was chosen for fuselage skins and stiffening elements, and for passenger and cargo floor structures. The automated fiber placement (AFP) process was selected for fabrication of stringer-stiffened and sandwich skin panels. Circumferential and window frames were braided and resin transfer molded (RTM'd). Pultrusion was selected for fabrication of floor beams and constant-section stiffening elements. Drape forming was chosen for stringers and other stiffening elements cocured to skin structures. Significant process development efforts included AFP, braiding, RTM, autoclave cure, and core blanket fabrication for both sandwich and stiffened-skin structure. Outer-mold-line and inner-mold-line tooling was developed for sandwich structures and stiffened-skin structure. The effect of design details, process control and tool design on repeatable, dimensionally stable, structure for low cost barrel assembly was assessed. Subcomponent panels representative of crown, keel, and side quadrant panels were fabricated to assess scale-up effects and manufacturing anomalies for full-scale structures. Manufacturing database including time studies, part quality, and manufacturing plans were generated to support the development of designs and analytical models to access cost, structural performance, and dimensional tolerance.

Wilden, K. S.↗

Organic Protomolecule Assembly in Igneous Minerals

C-H stretching bands in the infrared spectrum of single crystals of nominally high purity, laboratory-grown MgO and of natural upper mantle olivine provide an "organic" signature that closely resembles the symmetrical and asymmetrical C-H stretching modes of aliphatic -CH2- units. The C-H stretching bands indicate that H20 and CO2, dissolved in the matrix of these minerals, converted to form H2 and chemically reduced C, which in turn formed C-H entities, probably through segregation into defects such as dislocations. Heating causes the C-H bonds to pyrolyze and the C-H stretching bands to disappear, but annealing at 70 C causes them to reappear within a few days or weeks. Modeling dislocations in MgO suggests that the segregation of C can lead to Cx chains, x less than or equal to 4, with the terminal C atoms anchored to the MgO matrix by bonding to two U. Allowing H2 to react with such Cx chains leads to [O2C(CH2)2CO2] or similar precipitates. It is suggested that such Cx-Hy-Oz entities represent protomolecules from which derive the short-chain carboxylic and dicarboxylic and of the medium-chain fatty acids that have been solvent-extracted from crushed MgO and olivine single crystals, respectively. Thus it appears that the hard, dense matrix of igneous minerals represents a medium in which protomolecular units can be assembled. During weathering of rocks the protomolecular units turn into complex organic molecules. These processes may have provided stereochemically constrained organics to the early Earth that were crucial to the emergence of Life.

Freund, Friedemann↗

Simulation of SEU Cross-sections using MRED under Conditions of Limited Device Information

This viewgraph presentation reviews the simulation of Single Event Upset (SEU) cross sections using the membrane electrode assembly (MEA) resistance and electrode diffusion (MRED) tool using "Best guess" assumptions about the process and geometry, and direct ionization, low-energy beam test results. This work will also simulate SEU cross-sections including angular and high energy responses and compare the simulated results with beam test data for the validation of the model. Using MRED, we produced a reasonably accurate upset response model of a low-critical charge SRAM without detailed information about the circuit, device geometry, or fabrication process

Lauenstein, J. M.↗

Rapid Turn Around BRIC-PDFU Payload: A New Paradigm for Spaceflight Experiments

In 2009, NASA's Fundamental Space Biology program provided an opportunity for investigators to propose for a quick-turn-around multi-user spaceflight experiment that focused on the model plant species Arabidopsis thaliana. This was a passive payload with no on-orbit power or communications available. An NRA was rapidly written (8/09), released (NNH09ZTT004N; 9/09), proposals were received (11/09) and peer reviewed with 3 PI groups selected for flight (1/10): (1) A-L Paul, University of Florida, (2) E. Blancaflor, Noble Foundation, (3) J. Kiss, Miami University. The investigators flew Arabidopsis seeds or callus cultures of their choosing (plated onto 60 mm diameter Petri dishes containing agarsolidified media) on the STS-131 Space Shuttle mission (launched 4/5/10) and the resulting plant tissues returned to earth on 4/20/10. Each petri dish was placed inside its own Petri Dish Fixation Unit (PDFU), which was assembled and loaded with either formaldehyde, glutaraldehyde or RNAlater for crew-facilitated on-orbit fixation. Five PDFUs plus a temperature data logger were loaded into each of 8 BRIC-PDFUs (Biological Research In Canisters PDFU). All eight BRIC-PDFUs were loaded into a half tray along with actuator equipment that the crew used for the fixations. Pre-flight turn-over was 28 hours prior to launch. The BRIC-PDFU assemblies were removed from the orbiter and handed over to the investigator teams for processing 5-6 hours after landing. This payload demonstrated a rapid response turnaround for flying multiple peer-reviewed science investigations using previously flown hardware and minimal ISS-resources. The approach used reduced both hardware/certification and PI costs. The time waiting for a flight opportunity for the selected Pls was minimal. This new paradigm for spaceflight experiments may provide a model for future flight research opportunities. The ultimate goal is to fly as many investigators as rapidly as possible and reinvigorate the space biology community while obtaining high-quality, peer-reviewed science.

Levine, Howard G.↗

Temporary Urine and Brine Stowage System (TUBSS) Materials Selection and Testing

Storing wastewater in the event of a system anomaly is a necessity for closed loop water recovery systems. The temporary urine and brine stowage system (TUBSS) is an assembly used to store and transfer pre-treated urine (PTU) and brine for processing or disposal at a later date. This paper describes the selection and testing of several candidate materials from both a chemical and material strength standpoint. In addition, this paper will provide results of testing as well as lessons learned from the project, culminating in the successful launch of the hardware.

Carrigan, Caitlin↗

Improved Dynamic Modeling of the Cascade Distillation Subsystem and Analysis of Factors Affecting Its Performance

The Cascade Distillation Subsystem (CDS) is a rotary multistage distiller being developed to serve as the primary processor for wastewater recovery during long-duration space missions. The CDS could be integrated with a system similar to the International Space Station Water Processor Assembly to form a complete water recovery system for future missions. A preliminary chemical process simulation was previously developed using Aspen Custom Modeler® (ACM), but it could not simulate thermal startup and lacked detailed analysis of several key internal processes, including heat transfer between stages. This paper describes modifications to the ACM simulation of the CDS that improve its capabilities and the accuracy of its predictions. Notably, the modified version can be used to model thermal startup and predicts the total energy consumption of the CDS. The simulation has been validated for both NaC1 solution and pretreated urine feeds and no longer requires retuning when operating parameters change. The simulation was also used to predict how internal processes and operating conditions of the CDS affect its performance. In particular, it is shown that the coefficient of performance of the thermoelectric heat pump used to provide heating and cooling for the CDS is the largest factor in determining CDS efficiency. Intrastage heat transfer affects CDS performance indirectly through effects on the coefficient of performance.

Perry, Bruce A.↗