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NASA NTRS1988

Wear of liquid nitrogen-cooled 440C bearing steels in an oxygen environment

This paper presents up-to-date findings of the research being conducted to understand the mechanism of sliding wear in unlubricated 440C bearing steels under oxidative conditions. A sliding wear test rig has been designed and built with a cylinder-on-flat geometry. The equipment is capable of testing specimens under high axial loads and sliding speeds in a simulated LOX environment. Samples of 440C steel, quenched and tempered to a hardness of Rc 56, were tested under a load of 890 N and a sliding speed of 2.05 m/sec for total sliding distances of up to 5.54 km. Flash temperatures during these tests were measured with an IR camera and a fast digital recorder. Microstructural and microanalytical data from the worn surfaces and the debris particles are analyzed extensively, along with wear rates, flash temperatures, surface profiles, hardnesses, and residual stresses, in the context of oxidation and wear theories.

Chaudhuri, Dilip K.↗

NASA NTRS2001

Temperature Humidity and Sea Level Pressure Increments Induced by 1DVAR Analysis of GPS Refractivity

The Global Positioning System (GPS) transmitted signals are affected by the atmosphere. Using the radio occultation technique, where a receiver is placed on a low-Earth-orbiting platform. it is possible to perform soundings. by measuring the bending angles of the rays. The information can be converted into atmospheric refractivity. We have developed a one dimensional variational (1DVAR) analysis that uses GPS/MET 1995 refractivity and 6-hour FVDAS (Finite Volume Data Assimilation System) forecasts as background information to constrain the retrievals. The analysis increments are defined as 1DVAR minus background temperature, humidity and sea level pressure. Before assimilating the 1DVAR profiles into the FVDAS. the increments need to be understood. First, some bias could be induced in the retrievals when confronted with actual biased data: second. bias in the back-round could create undesired bias in the retrievals. Anv bias in the analyses will ultimately change the climatology of the model the retrievals will be assimilated into. We relate the increments to the reduction of the difference between observed minus computed refractivity profiles. We also point out the difference in the mean increments using backgrounds which have assimilated either NESDIS TIROS Operational Vertical Sounder (TOVS) operational retrievals or Data Assimilation Office (DAO) TOVS interactive retrievals. The climatology of the model in terms of refractivity is significantly different and this impacts the GPS 1DVAR increments. This testifies that changing the basic load of assimilated data has an influence on the impact the GPS data may have in a DAS.

Poli, Paul↗

NASA NTRS2006

Capillary Limit of a Miniature Loop Heat Pipe with Multiple Evaporators and Multiple Condensers

An experimental investigation of a miniature loop heat pipe with multiple evaporators and multiple condensers were conducted in order to evaluate its capillary limit. The experimental tests were conducted by varying heat load to one or both evaporators, with and without active temperature control of compensation chamber (CC) using the thermoelectric devices, and variable tilts between the evaporators and the CCs. The physical process of the loop and thermal conductance of the heat leak from evaporator to (CC) were discussed based on the test results. The difference of the temperature profiles between with and without active control of CC temperature was evaluated. The effect of the gravity on capillary limit and CC temperature was also evaluated by comparing the test result in horizontal position with that in vertical position. The loop recovery after capillary limit was exceeded was also described.

Ku, Jentung↗

NASA NTRS2017

Transient Thermal Analyses of Passive Systems on SCEPTOR X-57

As efficiency, emissions, and noise become increasingly prominent considerations in aircraft design, turning to an electric propulsion system is a desirable solution. Achieving the intended benefits of distributed electric propulsion (DEP) requires thermally demanding high power systems, presenting a different set of challenges compared to traditional aircraft propulsion. The embedded nature of these heat sources often preclude the use of traditional thermal management systems in order to maximize performance, with less opportunity to exhaust waste heat to the surrounding environment. This paper summarizes the thermal analyses of X-57 vehicle subsystems that don't employ externally air-cooled heat sinks. The high-power battery, wires, high-lift motors, and aircraft outer surface are subjected to heat loads with stringent thermal constraints. The temperature of these components are tracked transiently, since they never reach a steady-state equilibrium. Through analysis and testing, this report demonstrates that properly characterizing the material properties is key to accurately modeling peak temperature of these systems, with less concern for spatial thermal gradients. Experimentally validated results show the thermal profile of these systems can be sufficiently estimated using reduced order approximations.

Thermal Analyses↗

NASA NTRS1994

Simulation of Shuttle launch G forces and acoustic loads using the NASA Ames Research Center 20G centrifuge

The high cost and long times required to develop research packages for space flight can often be offset by using ground test techniques. This paper describes a space shuttle launch and reentry simulating using the NASA Ames Research Center's 20G centrifuge facility. The combined G-forces and acoustic environment during shuttle launch and landing were simulated to evaluate the effect on a payload of laboratory rates. The launch G force and acoustic profiles are matched to actual shuttle launch data to produce the required G-forces and acoustic spectrum in the centrifuge test cab where the rats were caged on a free-swinging platform. For reentry, only G force is simulated as the aero-acoustic noise is insignificant compared to that during launch. The shuttle G-force profiles of launch and landing are achieved by programming the centrifuge drive computer to continuously adjust centrifuge rotational speed to obtain the correct launch and landing G forces. The shuttle launch acoustic environment is simulated using a high-power, low-frequency audio system. Accelerometer data from STS-56 and microphone data from STS-1 through STS-5 are used as baselines for the simulations. This paper provides a description of the test setup and the results of the simulation with recommendations for follow-on simulations.

Shaw, T. L.↗

DOE OSTI2016

Defect Detection in Fuel Cell Gas Diffusion Electrodes Using Infrared Thermography

Polymer electrolyte membrane fuel cells are energy conversion devices that offer high power densities and high efficiencies for mobile and other applications. Successful introduction into the marketplace requires addressing cost barriers such as production volumes and platinum loading. For cost reduction, it is vital to minimize waste and maximize quality during the manufacturing of platinum-containing electrodes, including gas diffusion electrodes (GDEs). In this work, we report on developing a quality control diagnostic for GDEs, involving creating an ex situ exothermic reaction on the electrode surface and using infrared thermography to measure the resulting temperature profile. Experiments with a moving GDE containing created defects were conducted to demonstrate the applicability of the diagnostic for real-time web-line inspection.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

GFCCLib: Scalable and efficient coupled-cluster Green's function library for accurately tackling many-body electronic structure problems

Coupled-cluster Green’s function (GFCC) calculation has drawn much attention in the recent years for targeting the molecular and material electronic structure problems from a many-body perspective in a systematically improvable way. However, GFCC calculations on scientific computing clusters usually suffer from expensive higher di- mensional tensor contractions in the complex space, expensive inter-process communi- cation, and severe load imbalance, which limits it’s routine use for tackling electronic structure problems. Here we present a numerical library prototype that is specifically designed for large-scale GFCC calculations. The design of the library is focused on a systematically optimal computing strategy to improve its scalability and efficiency. The performance of the library is demonstrated by the relevant profiling analysis of running GFCC calculations on remote giant computing clusters. The capability of the library is highlighted by computing a wide near valence band of a fullerene C60 molecule for the first time at the GFCCSD level that shows excellent agreement with the experimental spectrum.

Peng, Bo↗

DOE OSTI2013

Measurement of ortho-positronium properties in liquid scintillators

Pulse shape discrimination in liquid scintillator detectors is a well-established technique for the discrimination of heavy particles from light particles. Nonetheless, it is not efficient in the separation of electrons and positrons, as they give rise to indistinguishable scintillator responses. This inefficiency can be overtaken through the exploitation of the formation of ortho-Positronium (o-Ps), which alters the time profile of light pulses induced by positrons. We characterized the o-Ps properties in the most commonly used liquid scintillators, i.e. PC, PXE, LAB, OIL and PC + PPO. In addition, we studied the effects of scintillator doping on the o-Ps properties for dopants currently used in neutrino experiments, Gd and Nd. Further measurements for Li-loaded and Tl-loaded liquid scintillators are foreseen. We found that the o-Ps properties are suitable for enhancing the electron-positron discrimination.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Divertor detachment in the pre-fusion power operation phase in ITER during application of resonant magnetic perturbations

Detachment of the divertor plasma during application of resonant magnetic perturbation (RMP) fields is evaluated for hydrogen H-mode plasma during the first pre-fusion power operation (PFPO-1) phase in ITER by 3D plasma boundary modelling with EMC3–EIRENE. Plasma response effects from a linearized, resistive, single fluid MHD model are discussed, which includes partial screening of the externally applied field—but also field amplification near the separatrix. Furthermore, this field amplification is found to play a pivotal role for the magnetic footprint on the divertor targets, but is sensitive to model parameters. Extensions of the footprint beyond the straight portions of the ITER vertical divertor targets, optimized for high stationary heat flux handling, may be possible depending on the level of toroidal rotation in the plasma. Exhaust from the bulk plasma is guided by the helical corrugations (lobes) of the perturbed separatrix, and this results in an upstream heat flux that is distributed over these lobes with lower peak values than in the typical radial heat flux profiles seen in the absence of magnetic perturbations. As a consequence, an earlier onset (with respect to the upstream density) of detachment is found in the traditional strike zone when RMPs are applied, but secondary, non-axisymmetric strike locations appear—and those remain attached at temperatures above 10 eV. Neon seeding can mitigate these non-axisymmetric heat loads, but this becomes less efficient for large magnetic footprints.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Reliability and Lifetime Prediction Model of Sintered Silver Under High-Temperature Cycling

Although excellent reliability has been reported for sintered silver as a die-attach material under both thermal and power cycling loads in power electronics applications, the promise of this material as a large-area attachment at temperatures beyond 200 degrees C needs to be investigated. This paper presents insights into the thermomechanical behavior and reliability of sintered silver under extreme thermal cycling conditions. In this study, we bonded sintered silver samples and subjected it to a thermal cycling profile of -40 °C to 200 °C with high ramp rates. We periodically monitored samples under thermal cycling to detect the presence of any failure mechanisms using a scanning acoustic microscope. We also included 95Pb5Sn solder in the study to obtain reference data. Results show the occurrence of cracks in sintered silver followed by a rapid rate of crack growth that exceeded the failure criterion in just 50 cycles. The predominant failure mechanism we observed was adhesive failure. As a large-area attachment, solder exhibited a higher reliability than sintered silver but failed within 100 cycles. Finally, we performed thermomechanical modeling to compute strain energy density values and correlated these with the experimentally observed crack growth rates to formulate a lifetime prediction model for sintered silver.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2017

An assessment of thermodynamic merits for current and potential future engine operating strategies

The present work compares the fundamental thermodynamic underpinnings (i.e., working fluid properties and heat release profile) of various combustion strategies with engine measurements. The approach employs a model that separately tracks the impacts on efficiency due to differences in rate of heat addition, volume change, mass addition, and molecular weight change for a given combination of working fluid, heat release profile, and engine geometry. Comparative analysis between measured and modeled efficiencies illustrates fundamental sources of efficiency reductions or opportunities inherent to various combustion regimes. Engine operating regimes chosen for analysis include stoichiometric spark-ignited combustion and lean compression-ignited combustion including HCCI, SA-HCCI, RCCI, GCI, and CDC. Within each combustion regime, effects such as engine load, combustion duration, combustion phasing, combustion chamber geometry, fuel properties, and charge dilution are explored. Model findings illustrate that even in the absence of losses such as heat transfer or incomplete combustion, the maximum possible thermal efficiency inherent to each operating strategy varies to a significant degree. Additionally, the experimentally measured losses are observed to be unique within a given operating strategy. The findings highlight the fact that in order to create a roadmap for future directions in ICE technologies, it is important to not only compare the absolute real-world efficiency of a given combustion strategy, but to also examine the measured efficiency in context of what is thermodynamically possible with the working fluid and boundary conditions prescribed by a strategy.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Laboratory Testing of the Temperature Sensor Qualification Device

The Temperature sensor Qualification Device (TQD) has been developed and tested under laboratory conditions to evaluate its thermal performance and the reliability of its retractable sensor system. The TQD is designed to provide an isothermal environment for temperature sensors in both test and reference zones during irradiation experiments. Initial testing revealed minimal radial and azimuthal temperature variations but identified a significant axial gradient. To address this, design modifications were implemented, including enhanced insulation and the addition of a small heater at the device's top. These changes are expected to produce a more uniform axial temperature profile, though further testing is recommended prior to irradiation. The retractable sensor mechanism was rigorously tested, achieving 1,350 cycles at room temperature and 332 cycles at 400°C before failure. The primary failure mechanism was the thermocouple becoming stuck in the wire guide or capillary tube. Based on these results, design improvements were proposed, such as incorporating a load cell for force monitoring and a stepper motor for precise sensor positioning.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2026

Gear Test Assembly - Experimental Testing and Analysis of Gears and Bearings - FY2026

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms and Engineering Test Loop (METL) at Argonne National Laboratory (ANL). While designed to accommodate a variety of components intended for use in advanced compact in-vessel transfer machine, the focus of GTA been the testing of large radial spur gears. The performance of the components used in GTA motivates the choices made in the design, components, and material choices for the forthcoming METL test articles; the Gripper Test Assembly (GrTA), and the Bearing Test Assembly (BTA). To date, GTA has completed nine experimental testing campaigns and achieved over 21 million revolutions under prototypic sodium fast reactor loads and operating conditions. This report provides an overview and results for the two most recent experiments Campaign #8 and Campaign #9. `Campaign #8 was the first campaign to make use of a set of nickel alloy radial spur gears, made from Hastelloy C-22HS, and combined with heat-treated tapered roller bearings. The bearings and torque profile used allowed Campaign #8 to be directly compared with Campaign #1 where Inconel 718 gears were used instead. Campaign #8 attained 1,058,880 shaft revolutions within 23% of the 1,314,855 revolutions achieved in Campaign #1. These results demonstrate that the heat-treated tapered roller bearings show consistent increased lifetimes, approximately three times longer than for non heat-treated taper rollers, and that the particular material of the gear does not play a substantial role in performance. Similar to Campaign #7 where bearing failure resulted in fragmentation and transport of bearing material into the gear teeth led to tooth damage in the Inconel gears, a similar process led to the damage of the Hastelloy gears. Subsequent NDE analysis showed that the damage was only limited to the tooth surface and does not extend into the gear interiors. Based on the NDE reports, the Hastelloy gears can be reconditioned and put back into service for future campaigns as was done for the Inconel gears. Reconditioned Inconel 718 gears damaged in Campaign #7 were returned to service in Campaign #9 and paired with non heat-treated tapered roller bearings. In Campaign #9 a novel set of operating conditions were implemented whereby the gears and bearings were cycled between hot, submerged refueling conditions where fuel handling operations occurred and cold, dry, and inert conditions where the sodium was drained and the vessel was allowed to cool simulating long, ex-vessel storage of the fuel handling machine. A total of eight of these operating cycles were achieved before a bearing failure occurred after the accumulation of 475,692 shaft revolutions were achieved. During Campaign #9, one of the drive motors was damaged and over the course of a 240 day standby period, the entire GTA drive system was upgraded from a 480VAC system to a 240VAC system that provided the opportunity to consolidate wall-space in the METL facility and provide more space for additional test articles being installed in the coming year. The over 475,000 shaft revolutions achieved in Campaign #9 eclipses the previous record for lifetime of non heat-treated tapered roller bearings held by Campaign #3 of 392,000 shaft revolutions. Further analysis and future campaigns hope to shed light on the cause of this approximately 17% increase in lifetime.

42 ENGINEERING↗

NASA NTRS1979

Evaluation of urethane for feasibility of use in wind turbine blade design

A preliminary evaluation was conducted of the use of cast urethane as a possible material for low-cost blades for wind turbines. Specimen test data are presented for ultimate tensile strength, elastic modulus, flexural strain, creep, and fatigue properties of a number of urethane formulations. Data are also included for a large-scale urethane blade section composed of cast symmetrical half-profiles tested as a cantilever beam. Based on these results, an analysis was conducted of a full-scale blade design of cast urethane that meets the design specifications of the rotor blades for the NASA/DOE experimental 100-kW MOD-0 wind turbine. Because of the low value of elastic modulus for urethane (around 457 000 psi), the design loads would have to be carried by metal reinforcement. Considerations for further evaluation are noted.

Lieblein, S.↗

NASA NTRS2008

The 2006 Cape Canaveral Air Force Station Range Reference Atmosphere Model Validation Study and Sensitivity Analysis to the National Aeronautics and Space Administration's Space Shuttle

NASA's Space Shuttle utilizes atmospheric thermodynamic properties to evaluate structural dynamics and vehicle flight performance impacts by the atmosphere during ascent. Statistical characteristics of atmospheric thermodynamic properties at Kennedy Space Center (KSC) used in Space. Shuttle Vehicle assessments are contained in the Cape Canaveral Air Force Station (CCAFS) Range Reference Atmosphere (RRA) Database. Database contains tabulations for monthly and annual means (mu), standard deviations (sigma) and skewness of wind and thermodynamic variables. Wind, Thermodynamic, Humidity and Hydrostatic parameters 1 km resolution interval from 0-30 km 2 km resolution interval 30-70 km Multiple revisions of the CCAFS RRA database have been developed since initial RRA published in 1963. 1971, 1983, 2006 Space Shuttle program utilized 1983 version for use in deriving "hot" and "cold" atmospheres, atmospheric density dispersions for use in vehicle certification analyses and selection of atmospheric thermodynamic profiles for use in vehicle ascent design and certification analyses. During STS-114 launch preparations in July 2005 atmospheric density observations between 50-80 kft exceeded density limits used for aerodynamic ascent heating constraints in vehicle certification analyses. Mission specific analyses were conducted and concluded that the density bias resulted in small changes to heating rates and integrated heat loading on the vehicle. In 2001, the Air Force Combat Climatology Center began developing an updated RRA for CCAFS.

Decker, Ryan↗

NASA NTRS2015

An Analytical Solution for Yaw Maneuver Optimization on the International Space Station and Other Orbiting Space Vehicles

This paper suggests a new method for optimizing yaw maneuvers on the International Space Station (ISS). Yaw rotations are the most common large maneuvers on the ISS often used for docking and undocking operations, as well as for other activities. When maneuver optimization is used, large maneuvers, which were performed on thrusters, could be performed either using control moment gyroscopes (CMG), or with significantly reduced thruster firings. Maneuver optimization helps to save expensive propellant and reduce structural loads ‐ an important factor for the ISS service life. In addition, optimized maneuvers reduce contamination of the critical elements of the vehicle structure, such as solar arrays. This paper presents an analytical solution for optimizing yaw attitude maneuvers. Equations describing pitch and roll motion needed to counteract the major torques during a yaw maneuver are obtained. A yaw rate profile is proposed. Also the paper describes the physical basis of the suggested optimization approach. In the obtained optimized case, the torques are significantly reduced. This torque reduction was compared to the existing optimization method which utilizes the computational solution. It was shown that the attitude profiles and the torque reduction have a good match for these two methods of optimization. The simulations using the ISS flight software showed similar propellant consumption for both methods. The analytical solution proposed in this paper has major benefits with respect to computational approach. In contrast to the current computational solution, which only can be calculated on the ground, the analytical solution does not require extensive computational resources, and can be implemented in the onboard software, thus, making the maneuver execution automatic. The automatic maneuver significantly simplifies the operations and, if necessary, allows to perform a maneuver without communication with the ground. It also reduces the probability of command errors. The suggested analytical solution provides a new method of maneuver optimization which is less complicated, automatic and more universal. A maneuver optimization approach, presented in this paper, can be used not only for the ISS, but for other orbiting space vehicles.

Dobrinskaya, Tatiana↗

DOE OSTI2023

Lubricant impacts on piston deposit formation in the Enterprise marine diesel research engine

The impact of lubricant formulation on piston deposits was studied using the Enterprise, a reduced-scale, single-cylinder, two-stroke crosshead marine diesel research engine. The Enterprise engine was specially designed for marine diesel lubricant research, with a custom reduced-scale cylinder lubricant injection system and extensive instrumentation of thermal boundary conditions on both the liner and piston. Lubricant conditions typical of full-scale marine diesel engines are obtained by matching mean piston speed, liner temperature profile, and combustion metrics to realistic values.Piston deposit thicknesses were measured after a set period of operation, with a focus on lubricant-based deposits on the lands and ring grooves, using both optical and contact-based measurement techniques. Engine operation for each lubricant was conducted according to a standardized protocol, with precise control of engine speed and load, cylinder lubricant injection rate, coolant temperatures, and system oil temperature; the liner and piston temperatures are continuously monitored during operation. After operation with each lubricant was completed, the engine was disassembled, and the piston and ring deposits were characterized. The piston was then thoroughly cleaned, and the lubricant system flushed, between each lubricant formulation being evaluated. The impacts on piston deposits of the lubricants being evaluated can thus be accurately quantified and are described herein.

Kaul, Brian↗

DOE OSTI2019

Tribology of incoloy 800HT for nuclear reactors under helium environment at elevated temperatures

Nickel-based alloy 800HT is considered one of the main candidate alloys for nuclear reactors with gas cooled high-temperature environment and, therefore, it is necessary to have a thorough understanding of the alloy tribological response for obtaining optimum operating and loading conditions. The current study investigated the wear and friction behavior of alloy 800HT using a customized high temperature tribometer to simulate the environment of helium cooled reactor up to 750 °C. The effect of temperature, contact load, environment, sliding distance and sliding speed on the alloy friction and wear were studied. To generalize the study for other applications, an investigation is also performed in air environment. The friction and wear coefficients have the highest values at high temperature helium atmosphere where the formation and stability of the oxide scales play an important role. Optical and contact profiling, scanning electron microscopy, as well as energy dispersive spectroscopy techniques were utilized to study the surface oxide. The analysis showed the presence of Fe-Cr-Ni rich oxide both in air and helium. Finally, the protective glazed layer did not form in helium in any condition, whereas in air and under specific conditions a stable protective oxide layer was observed.

36 MATERIALS SCIENCE↗