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All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Impact of Solar Array Designs on High Voltage Operations

As power levels of advanced spacecraft climb above 25 kW, higher solar array operating voltages become attractive. Even in today s satellites, operating spacecraft buses at 100 V and above has led to arcing in GEO communications satellites, so the issue of spacecraft charging and solar array arcing remains a design problem. In addition, micrometeoroid impacts on all of these arrays can also lead to arcing if the spacecraft is at an elevated potential. For example, tests on space station hardware disclosed arcing at 75V on anodized A1 structures that were struck with hypervelocity particles in Low Earth Orbit (LEO) plasmas. Thus an understanding of these effects is necessary to design reliable high voltage solar arrays of the future, especially in light of the Vision for Space Exploration of NASA. In the future, large GEO communication satellites, lunar bases, solar electric propulsion missions, high power communication systems around Mars can lead to power levels well above 100 kW. As noted above, it will be essential to increase operating voltages of the solar arrays well above 80 V to keep the mass of cabling needed to carry the high currents to an acceptable level. Thus, the purpose of this paper is to discuss various solar array approaches, to discuss the results of testing them at high voltages, in the presence of simulated space plasma and under hypervelocity impact. Three different types of arrays will be considered. One will be a planar array using thin film cells, the second will use planar single or multijunction cells and the last will use the Stretched Lens Array (SLA - 8-fold concentration). Each of these has different approaches for protection from the space environment. The thin film cell based arrays have minimal covering due to their inherent radiation tolerance, conventional GaAs and multijunction cells have the traditional cerium-doped microsheet glasses (of appropriate thickness) that are usually attached with Dow Corning DC 93-500 silicone adhesive. In practice, these cover glasses and adhesive do not cover the cell edges. Finally, in the SLA, the entire cell and cell edges are fully encapsulated by a cover glass that overhangs the cell perimeter and the silicone adhesive covers the cell edges providing a sealed environment. These three types of blanket technology have been tested at GRC and Auburn. The results of these tests will be described. For example, 15 modules composed of four state-of-the-art 2x4 cm GaAs solar cells with 150 pm cover glasses connected in two-cell series strings were tested at high voltage, in plasma under hypervelocity impact. A picture of one of the modules is shown in figure 1. These were prepared by standard industry practice from a major supplier and had efficiencies above 18%. The test results and other fabrication factors that influenced the tests will be presented. In addition, results for SLA segments tested under the same conditions will be presented. Testing of thin film blankets at GRC will also be presented. Figure 1 : Typical GaAs Solar Cell Module These results will show significant differences in resistance to arcing that are directly related to array design and manufacturing procedures. Finally, the approaches for mitigating the problems uncovered by these tests will be described. These will lay the foundation for future higher voltage array operation, even including voltages above 300-600 V for direct drive SEP applications.

Brandhorst, Henry W., Jr.↗
NASA NTRS1991

Next generation: In-space transportation system(s)

The development of the next generation In-Space Transportation System presents a unique challenge to the design of a propulsion system for the Space Exploration Initiative (SEI). Never before have the requirements for long-life, multiple mission use, space basing, high reliability, man-rating, and minimum maintenance come together with performance in one system that must protect the lives of space travelers, support the mission logistics needs, and do so at an acceptable cost. The challenge that is presented is to quantify the bounds of these requirements. The issue is one of degree. The length of acceptable life in space, the time it takes for reuse to pay off, and the degree to which space basing is practical (full, partial, or expended) are the issues that determine the reusable bounds of a design and include dependability, contingency capabilities, resilency, and minimum dependence on a maintenance node in preparation for and during a mission. Missions to planet earth, other non-NASA missions, and planetary missions will provide important but less demanding requirements for the transportation systems of the future. The mission proposed for the SEI require a family of transportation vehicles to meet the requirements for establishing a permanent human presence on the Moon and eventually on Mars. Specialized vehicles are needed to accomplish the different phases of each mission. These large scale missions require assembly in space and will provide the greatest usage of the planned integrated transportation system. The current approach to defining the In-Space Transportation System for the SEI Moon missions with later Mars mission applications is presented. Several system development options, propulsion concepts, current/proposed activities are reviewed, and key propulsion design criteria, issues, and technology challenges for the next generation In-Space Transportation System(s) are outlined.

Huffaker, Fredrick↗
NASA NTRS1993

Approaches to solar cell design for pulsed laser power receivers

Using a laser to beam power from Earth to a photovoltaic receiver in space could be a technology with applications to many space missions. Extremely high average-power lasers would be required in a wavelength range of 700-1000 nm. However, high-power lasers inherently operate in a pulsed format. Existing solar cells are not well designed to respond to pulsed incident power. To better understand cell response to pulsed illumination at high intensity, the PC-1D finite-element computer model was used to analyze the response of solar cells to continuous and pulsed laser illumination. Over 50 percent efficiency was calculated for both InP and GaAs cells under steady-state illumination near the optimum wavelength. The time-dependent response of a high-efficiency GaAs concentrator cell to a laser pulse was modeled, and the effect of laser intensity, wavelength, and bias point was studied. Three main effects decrease the efficiency of a solar cell under pulsed laser illumination: series resistance, L-C 'ringing' with the output circuit, and current limiting due to the output inductance. The problems can be solved either by changing the pulse shape or designing a solar cell to accept the pulsed input. Cell design possibilities discussed are a high-efficiency, light-trapping silicon cell, and a monolithic, low-inductance GaAs cell.

Jain, Raj K.↗
NASA NTRS1996

Development of an Outreach Program for NASA: "NASA Ambassadors"

It is widely known that the average American citizen has either no idea or the wrong impression of what NASA is doing. The most common impression is that NASA's sole mission is to build and launch spacecraft and that the everyday experience of the common citizen would be impacted very little if NASA failed to exist altogether. Some feel that most of NASA's efforts are much too expensive and that the money would be better used on other efforts. Others feel that most of NASA's efforts either fail altogether or fail to meet their original objectives. Yet others feel that NASA is so mired in bureaucracy that it is no longer able to function. The goal of the NASA Ambassadors Program (NAP) is to educate the general populace as to what NASA's mission and goals actually are, to re-excite the "man on the street" with NASA's discoveries and technologies, and to convince him that NASA really does impact his everyday experience and that the economy of the U.S. is very dependent on NASA-type research. Each of the NASA centers currently run a speakers bureau through its Public Affairs Office (PAO). The speakers, NASA employees, are scheduled on an "as available" status and their travel is paid by NASA. However, there are only a limited number of them and their message may be regarded as being somewhat biased as they are paid by NASA. On the other hand, there are many members of NASA's summer programs which come from all areas of the country. Most of them not only believe that NASA's mission is important but are willing and able to articulate it to others. Furthermore, in the eyes of the public, they are probably more effective as ambassadors for NASA than are the NASA employees, as they do not derive their primary funding from it. Therefore it was decided to organize materials for them to use in presentations to general audiences in their home areas. Each person who accepted these materials was to be called a "NASA Ambassador".

Lebo, George R.↗
NASA NTRS1999

A Study of Flame Propagation on Water-Mist Laden Gas Mixtures in Microgravity

The use of water mists (very fine water sprays) for fire suppression is currently receiving increased attention as a replacement technology for halogen-based chemical agents-such as Halon 1301 (CF3Br)--the manufacturing of which has been banned by the Montreal Protocol due to their high ozone depletion potential. Water mist technology has been found effective for a wide range of applications such as Class B pool fires, shipboard machinery, aircraft cabins, computers, and electronic equipment. There are five distinct mechanisms by which water droplets may interact with a flame. First, the high enthalpy of vaporization of water (2450 kJ/kg) leads to heat removal from the flame front as the liquid droplets turn to steam. Second, as water vaporizes its volume increases approximately three orders of magnitude, which leads to the dilution of the oxygen and vaporized fuel required to maintain the flame. The third effect is the recombination of H-atoms and other radicals on the droplet surface. A fourth effect of water mists in fires is the retardation of surface propagation rates due to the wetting of walls and surfaces. The last potential impact of fine water mists affects the radiative propagation of the fire by forming an optically thick barrier to infrared radiation which prevents ignition of the unburned regions. Unfortunately, little fundamental information exists on the interaction of a flame with a water mist. To date, there is no widely accepted interpretation of the critical concentration of droplets required to suppress a flame or of the fundamental mechanisms involved in flame extinguishment by water mists. One of the main obstacles to obtaining such understanding is the difficulty of providing a simple, well-defined experimental setup for the flame front/water mist interaction. Some of the difficulty stems from the problem of generating, distributing and maintaining a homogeneous concentration of droplets throughout a chamber while gravity depletes the concentration and alters the droplet size by coalescence and agglomeration mechanisms. Experiments conducted in the absence of gravity provide an ideal environment to study the interaction of water mists and flames by eliminating these distorting effects. In addition, microgravity eliminates the complex flow patterns induced between the flame front and the water droplets. The long duration and quality of microgravity in space flights provide the required conditions to perform the setup and monitoring of flame suppression experiments. Consequently, a series of experiments have been identified to be performed on the Combustion Module (CM-2) in the Space Shuttle. These consist of measuring the extinguishing capability of a water mist on a premixed flame propagating along a tube. These experiments should provide the necessary data to obtain further understanding of the water mist suppression phenomena that can be later used to design and manufacture appropriate fire suppression systems. In preparation for the orbital flights, experiments have been conducted on low-gravity ground facilities to obtain the preliminary data necessary to define the scientific objectives and technical issues of the spacecraft experiments.

Abbud-Madrid, A.↗
NASA NTRS1997

Alternative Perspectives on Risk

The goal of the commercial air transport system is to provide air transportation to the flying public at an acceptable cost with minimal risk. in an ideal situation these three goals would support each other. In fact, it is sometimes the case that the goals conflict: getting passengers to their destinations on time may conflict with fixing a minor mechanical malfunction that may or may not impact safety; flying a route that will avoid turbulence, thereby providing passengers with a more comfortable ride, may consume more fuel; managing traffic density may mean aircraft are delayed or must use an approach that will result in a long taxi to their gates, costing time and fuel. Various players in the system--pilots, dispatchers, controllers, as well as managers in the airline carriers and traffic management system--make decisions every day that involve trade-offs of benefits and costs. The prospect of revisions in the air traffic management system, with shifts in responsibilities from controllers to users, including airline operations center personnel and pilots, means that individuals may be performing either new jobs or old jobs under new guidance. It will be essential to know how the various players (a) perceive the risks and benefits associated with the decisions they will make under the old and new control structures, and (b) how much risk they are willing to accept in making decisions. Risk is here defined as the probability and magnitude of negative events (after Slovic, 1987). Of primary interest are risks associated with traffic, weather, and operational factors such as schedule, fuel consumption, and passenger service. Previous research has documented differences between groups in perceptions of risks associated with both everyday and aviation related situations. Risk perception varies as a function of familiarity with the situation, degree to which one is potentially affected by the risk, the level of control one has over the situation, and one's level of experience and responsibility in the situation. In our presentation we will consider several factors that may influence differences in risk perception, risk tolerance and risk management among the three major categories of participants in the aviation system (pilots, dispatchers, and controllers). Primary factors that may affect risk attitudes (the collective term we will use for the three components of risk) include: expertise or job-specific knowledge or training, personal involvement or vulnerability to consequences, goals, time horizon (imminence of consequences), span of control and type of control, and information or technology support. These will be considered in the context of five different types of risk (physical threat, economic, social, legal, and ethical). A study designed to study differences between pilots and controllers in their perceptions and responses to traffic risks under the present and a user-preferred control situation will be described. Future studies involving dispatchers' risk perceptions regarding various types of risk will be discussed.

Davison, Jeannie↗
NASA NTRS2007

Experimental Evaluation of an Integrated Datalink and Automation-Based Strategic Trajectory Concept

This paper presents research on the interoperability of trajectory-based automation concepts and technologies with modern Flight Management Systems and datalink communication available on many of today s commercial aircraft. A tight integration of trajectory-based ground automation systems with the aircraft Flight Management System through datalink will enable mid-term and far-term benefits from trajectory-based automation methods. A two-way datalink connection between the trajectory-based automation resident in the Center/TRACON Automation System and the Future Air Navigation System-1 integrated FMS/datalink in NASA Ames B747-400 Level D simulator has been established and extensive simulation of the use of datalink messages to generate strategic trajectories completed. A strategic trajectory is defined as an aircraft deviation needed to solve a conflict or honor a route request and then merge the aircraft back to its nominal preferred trajectory using a single continuous trajectory clearance. Engineers on the ground side of the datalink generated lateral and vertical trajectory clearances and transmitted them to the Flight Management System of the 747; the airborne automation then flew the new trajectory without human intervention, requiring the flight crew only to review and to accept the trajectory. This simulation established the protocols needed for a significant majority of the trajectory change types required to solve a traffic conflict or deviate around weather. This demonstration provides a basis for understanding the requirements for integration of trajectory-based automation with current Flight Management Systems and datalink to support future National Airspace System operations.

Mueller, Eric↗
DOE OSTI2025

Fuel cells for single-aisle regional aircraft: System configuration, performance and cost

A hydrogen fuel cell propelled electric aircraft can compete with incumbent turbofan technologies for single-aisle regional aircraft by coupling design of stack, air handling, thermal management, propulsion, and airframe to optimize performance. The stack operates at 95°C to facilitate heat rejection during take-off and below 75°C during cruise to extend lifetime and is oversized to satisfy power requirements at end of life. A multi-stage turbocompressor with a compression ratio >10 is selected to reach high stack power density at 11,300-m cruise altitude. The propulsion system is configured to accommodate air handling within the core duct, an inclined heat exchanger in the outer duct to limit the nacelle size, and variable area nozzles to independently control mass flows through the core and bypass ducts. The airframe is modified for maximum lift coefficient and longer balanced field length for dramatically reduced thrust during take-off, and the fuselage is stretched by 20% to store liquid hydrogen (LH 2 ). Modularization of power systems promotes safety in one engine inoperative scenarios and allows reaching specific power metrics for stack, balance-of-plant and fuel cell system (FCS), necessary for acceptable take-off weight. In conclusion, cost parity requires increase in FCS lifetime, LH 2 cost reduction, and improved FCS specific power.

Catalyst durability↗
NASA NTRS2004

History of Sulphur Content Effects on the Thermal Stability of RP-1 under Heated Conditions

As technologies advance in the aerospace industry, a strong desire has emerged to design more efficient, longer life, reusable liquid hydrocarbon fueled rocket engines. To achieve this goal, a more complete understanding of the thermal stability and chemical makeup of the hydrocarbon propellant is needed. Since the main fuel used in modern liquid hydrocarbon systems is RP-1, there is concern that Standard Grade RP-1 may not be a suitable propellant for future-generation rocket engines due to concern over the outdated Mil-Specification for the fuel. This current specification allows high valued limits on contaminants such as sulfur compounds, and also lacks specification of required thermal stability qualifications for the fuel. Previous studies have highlighted the detrimental effect of high levels of mercaptan sulfur content (^50 ppm) on copper rocket engine materials, but the fuel itself has not been studied. While the role of sulfur in other fuels (e.g., aviation, diesel, and automotive fuels) has been extensively studied, little has been reported on the effects of sulfur levels in rocket fuels. Lower RP-1 sulfur concentrations need to be evaluated and an acceptable sulfur limit established before RP-1 can be recommended for use as the propellant for future launch vehicles. (5 tables, 8 figures, 9 refs.)

ASTM METHOD D-5623↗
NASA NTRS2019

Challenges in Qualification of Thermal Protection Systems in Extreme Entry Environments

Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heat shield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heat shield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heat shield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (>2000 W/sq. cm heat flux and >2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heat shield for Extreme Entry Environments (HEEET). Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions. Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions. Examples include: (1) Bounding aeroheating parameters (heat flux, pressure, shear and enthalpy) in ground facilities. How to certify TPS if environments can't be bounded or aeroheating parameters can't be simultaneously achieved. (2) Higher uncertainties in ground test environments (facility calibration and analytical predictions) at extreme conditions. (3) Testing in flows similar to planetary atmosphere composition (H2/He for Gas and Ice Giants). (4) Test sample size limitations for qualifying seam designs. (5) Lack of computational tools capable of simulating all significant aspects of TPS performance (including initiation and propagation of failures). This presentation will provide recommendations on how the EDL community can address these challenges and mitigate some of the risks involved in flying TPS materials at extreme conditions. Examples include: (1) Dedicated activity to understanding TPS failure modes. Develop computational tools capable of modelling fluid interaction with material's thermostructural response. Validate these tools through failure testing. A better understanding of failure mechanisms may eliminate the need to fully bound all aeroheating parameters in ground testing. (2) Enhancements to current testing facilities to simulate flight-like ablation mechanism (ex. testing in Nitrogen at Ames Interaction Heating Facility to limit oxidation in favor of more sublimation). (3) Improved characterization of test conditions with new diagnostic methods and determination of environment uncertainty through rigorous statistical analysis of available data. (4) Design margin policies that are directly tied to uncertainties in ground test environments and modelling fidelity

Mahzari, Milad↗
DOE OSTI2022

Development and validation of a mathematical model of heart rate response to fluid perturbation

Physiological closed-loop controlled (PCLC) medical devices monitor and automatically adjust the patient’s condition by using physiological variables as feedback, ideally with minimal human intervention to achieve the target levels set by a clinician. PCLC devices present a challenge when it comes to evaluating their performance, where conducting large clinical trials can be expensive. Virtual physiological patients simulated by validated mathematical models can be utilized to obtain preclinical evidence of safety and assess the performance of the PCLC medical device during normal and worst-case conditions that are unlikely to happen in a limited clinical trial. A physiological variable that plays a major role during fluid resuscitation is heart rate (HR). For in silico assessment of PCLC medical devices regarding fluid perturbation, there is currently no mathematical model of HR validated in terms of its predictive capability performance. This paper develops and validates a mathematical model of HR response using data collected from sheep subjects undergoing hemorrhage and fluid infusion. The model proved to be accurate in estimating the HR response to fluid perturbation, where averaged between 21 calibration datasets, the fitting performance showed a normalized root mean square error (NRMSE) of 7.41 ± 2.8%. The model was also evaluated in terms of model predictive capability performance via a leave-one-out procedure (21 subjects) and an independent validation dataset (6 subjects). Two different virtual cohort generation tools were used in each validation analysis. The generated envelope of virtual subjects robustly met the defined acceptance criteria, in which 95% of the testing datasets presented simulated HR patterns that were within a deviation of 50% from the observed data. In addition, out of 16000 and 18522 simulated subjects for the leave one-out and independent datasets, the model was able to generate at least one virtual subject that was close to the real subject within an error margin of 9.56 ± 3.15% and 11.1 ± 1.22% NRMSE, respectively. In conclusion, the model can generate valid virtual HR physiological responses to fluid perturbation and be incorporated into future non-clinical simulated testing setups for assessing PCLC devices intended for fluid resuscitation.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS1999

Measurements of Nucleation-Mode Particle Size Distributions in Aircraft Plumes during SULFUR 6

This report summarizes the participation of the University of Denver in an airborne measurement program, SULFUR 6, which was undertaken in late September and early October of 1998 by the Deutsches Zentrum fur Luft und Raumfahrt (DLR). Scientific findings from two papers that have been published or accepted and from one manuscript that is in preparation are presented. The SULFUR 6 experiment was designed to investigate the emissions from subsonic aircraft to constrain calculations of possible atmospheric chemical and climatic effects. The University of Denver effort contributed toward the following SULFUR 6 goals: (1) To investigate the relationship between fuel sulfur content (FSC--mass of sulfur per mass of fuel) and particle number and mass emission index (El--quantity emitted per kg of fuel burned); (2) To provide upper and lower limits for the mass conversion efficiency (nu) of fuel sulfur to gaseous and particulate sulfuric acid; (3) To constrain models of volatile particle nucleation and growth by measuring the particle size distribution between 3 and 100 nm at aircraft plume ages ranging from 10(exp -1) to 10(exp 3) s; (4) To determine microphysical and optical properties and bulk chemical composition of soot particles in aircraft exhaust; and (5) To investigate the differences in particle properties between aircraft plumes in contrail and non-contrail situations. The experiment focused on emissions from the ATTAS research aircraft (a well characterized, but older technology turbojet) and from an in-service Boeing 737-300 aircraft provided by Lufthansa, with modem, high-bypass turbofan engines. Measurements were made from the DLR Dassault Falcon 900 aircraft, a modified business jet. The Atmospheric Effects of Aviation Program (AEAP) provided funding to operate an instrument, the nucleation-mode aerosol size spectrometer (N-MASS), during the SULFUR 6 campaign and to analyze the data. The N-MASS was developed at the University of Denver with the support of NOAA's Office of Global Programs and NASA's AEAP and measures particle size distributions in the 4-100 nm range.

Brock, Charles A.↗
NASA NTRSDate not supplied

Pterodactyl: 6-DOF Integration of Guidance and Control Algorithms in Genesis

The NASA-funded Pterodactyl project seeks to advance the current state-of-the-art for entry vehicles by developing novel guidance and control technologies for Deployable Entry Vehicles. This paper builds upon the Pterodactyl architecture that employed eight individually articulating flaps with two options for guidance, bank angle modulation with the Fully Numerical Predictor Corrector Entry Guidance (FNPEG) technique and angle of attack and sideslip modulation with FNPEG uncoupled range control. These, with a linear quadratic regulator controller, have previously been presented in separate 3-DOF trajectory simulations, one for translational motion and another for rotational dynamics. This work will show results for integrated 6-DOF simulations, leveraging recent advancements in trajectory simulation tools, namely the Julia-based Genesis package. Results show similar performance for both schemes when compared to the previously presented 3-DOF results once the controllers were adequately tuned. Angle of attack and sideslip modulation necessitated a controller designed at high dynamic pressure conditions, and bank angle modulation necessitated a controller designed at lower dynamic pressure conditions. Notably, angle of attack and sideslip modulation could not achieve the parachute deploy point target Mach number of 2, when only tuning the controller gains, thus future work will be needed to tune guidance specific parameters to achieve acceptable range targeting and guidance command tracking.

DEV↗
NASA NTRS2004

Research Capabilities for Oil-Free Turbomachinery Expanded by New Rotordynamic Simulator Facility

A new test rig has been developed for simulating high-speed turbomachinery shafting using Oil-Free foil air bearing technology. Foil air journal bearings are self-acting hydrodynamic bearings with a flexible inner sleeve surface using air as the lubricant. These bearings have been used in turbomachinery, primarily air cycle machines, for the past four decades to eliminate the need for oil lubrication. More recently, interest has been growing in applying foil bearings to aircraft gas turbine engines. They offer potential improvements in efficiency and power density, decreased maintenance costs, and other secondary benefits. The goal of applying foil air bearings to aircraft gas turbine engines prompted the fabrication of this test rig. The facility enables bearing designers to test potential bearing designs with shafts that simulate the rotating components of a target engine without the high cost of building actual flight hardware. The data collected from this rig can be used to make changes to the shaft and bearings in subsequent design iterations. The rest of this article describes the new test rig and demonstrates some of its capabilities with an initial simulated shaft system. The test rig has two support structures, each housing a foil air journal bearing. The structures are designed to accept any size foil journal bearing smaller than 63 mm (2.5 in.) in diameter. The bearing support structures are mounted to a 91- by 152-cm (3- by 5-ft) table and can be separated by as much as 122 cm (4 ft) and as little as 20 cm (8 in.) to accommodate a wide range of shaft sizes. In the initial configuration, a 9.5-cm (3.75-in.) impulse air turbine drives the test shaft. The impulse turbine, as well as virtually any number of "dummy" compressor and turbine disks, can be mounted on the shaft inboard or outboard of the bearings. This flexibility allows researchers to simulate various engine shaft configurations. The bearing support structures include a unique bearing mounting fixture that rotates to accommodate a laserbased alignment system. This can measure the misalignment of the bearing centers in each of 2 translational degrees of freedom and 2 rotational degrees of freedom. In the initial configuration, with roughly a 30.5-cm- (12-in.-) long shaft, two simulated aerocomponent disks, and two 50.8-cm (2-in.) foil journal bearings, the rig can operate at 65,000 rpm at room temperature. The test facility can measure shaft displacements in both the vertical and horizontal directions at each bearing location. Horizontal and vertical structural vibrations are monitored using accelerometers mounted on the bearing support structures. This information is used to determine system rotordynamic response, including critical speeds, mode shapes, orbit size and shape, and potentially the onset of instabilities. Bearing torque can be monitored as well to predict the power loss in the foil bearings. All of this information is fed back and forth between NASA and the foil bearing designers in an iterative fashion to converge on a final bearing and shaft design for a given engine application. In addition to its application development capabilities, the test rig offers several unique capabilities for basic bearing research. Using the laser alignment system mentioned earlier, the facility will be used to map foil air journal bearing performance. A known misalignment of increasing severity will be induced to determine the sensitivity of foil bearings to misalignment. Other future plans include oil-free integral starter generator testing and development, and dynamic load testing of foil journal bearings.

Howard, Samuel A.↗
DOE OSTI2025

Project Title: Demonstration High Temperature Superconducting NonPlanar Stellarator Magnet with Advanced Manufactured Assemblies

This is the final report for the project “Demonstration High Temperature Superconducting Non- Planar Stellarator Magnet with Advanced Manufactured Assemblies”, funded by DOE, and performed by Type One Energy from September, 2020, to March 2024 involving the Fusion Technology Institute at the University of Wisconsin–Madison, the Plasma Science and Fusion Center (PSFC) at the Massachusetts Institute of Technology (MIT) and Commonwealth Fusion Systems (CFS) to design and fabricate the first non-planar HTS (REBCO) coil for a high-field stellarator based on the SPARC tokamak’s VIPER cable concept. Stellarators at high fields make high-temperature superconducting magnets necessary for a compact fusion device. But the asymmetric and non-planar nature of its components, especially the magnets make it difficult for scalable producibility. To address these challenges, two promising technologies have emerged: advanced manufacturing (AM) for the supporting plates for forming the magnets, and high-temperature superconducting (HTS) cables inside the plates. AM has advanced enough to produce stellarator components with the necessary geometric complexity, size, and the precision, leading to potentially significant reductions in production time, cost, and waste. The cost of HTS tape has decreased dramatically, and progress in HTS planar magnet development has reached a point where it can be proposed for application to complex 3D non-planar magnets. The main objective of this project is to develop, demonstrate and pre-commercialize a novel, non-planar HTS coil shape that remains superconducting to achieve production scalable reductions in time and cost and performance. The proposed technology is based on the novel concept of a precision sub-scale HTS nonplanar coil assembly. This project focuses on the design, fabrication, material optimization of cable design, and validation and demonstration of the high current carrying capability of superconducting magnets and their support in a complex 3D shape needed for application to stellarator magnetic plasma confinement. The specific objectives of this research program include: (1) The successful application of metal AM to build a precision sub-scale HTS nonplanar coil, (2) An HTS cable and cross-section design that can conform to the required nonplanar coil shape (bend radii as tight as 10-cm) and remains superconducting at an engineering current density of 1.35 kA/cm 2 at 77 K and 1 tesla at the conductor (5 kA in the cable). To achieve the above challenging goals, we have formed a multidisciplinary research team consisting of members from Type One Energy and UW-Madison, MIT PSFC and CFS with complementary skills and strong facilities. The team worked collaboratively on fundamental and applied research on the following three major technical areas: (1) Design, fabrication, and optimization of non-planar HTS Cable The ultimate goal of the project is to determine if commercial REBCO tapes and additive manufacturing can be used to fabricate high field (≥ 10T) non-planar coils with tight bending radii (≃ 100mm) and with a degradation of the critical current (Ic) smaller than 20% with respect to the expected performance. We started with shorter length cable to evaluate the scalability of the production process and eventually reached multiple turns for higher magnetic fields. Our findings suggest that a stellarator coil system of a relevant size, characterized by its asymmetric and non-planar components, can be fabricated using a formed cable in plate method. This system can be simulated using a large-scale modeling approach. The use of hybrid modeling 3 techniques will be pivotal in reducing the complexity of the model and in assessing expected performance in designs. (2) Modeling and simulation of the non-planar HTS Cable Multiphysics simulations are performed using the commercial software and are carried out in self-field conditions, involving 2D and 3D models and twisted around one slot of twist-pitched VIPER cable. Multiphysics simulations are mainly focused on the coil for the critical current evaluation, the magnetic field map, self-Lorentz forces and mechanical, and magnetothermal behavior and the quench dynamics. The detailed model and prediction of the superconducting performance of a stellarator-relevant demonstration cable from numerical simulations supports the results from the actual testing backing the results. A detailed description and results are provided in the later sections. (3) Design, fabrication, and optimization of support for the non-planar HTS Cable The team developed an additive manufactured (AM) coil positioning plate that formed into the required non-planar geometry (with bend radii as tight as 10-cm) and to acceptable tolerances required for a stellarator magnet: (+0.25-mm from ideal on dimensions of coil positioning plates and up to +1-mm from ideal for position of wound coil). The plate materials is also included in this selection process from fabrication and 3D printing perspective and commensurate with eventual application to a fusion reactor. From the cost effectiveness point of view, the HTS coil and plate has the potential to cost less than that made in conventional methods with less waste (<75% waste) reducing time (<50%) and cost (<50%), especially as the AM field matures. The application of advanced manufacturing in the construction of the support plates will also lead to cost reduction, as the cables can be easily replaced, thereby making the assembly modular. With such high primary cost and time savings, high current densities and magnetic field, the funded R&D work has validated the designs, proven the feasibility, and characterized the performance of the HTS coil and plate assembly, paving the way for a relevant-size stellarator coil system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Strategies for Computer-Aided Discovery of Novel Open-Shell Polymers

Organic π-conjugated polymers with a triplet ground state have been the focus of recent research for their interesting and unique electronic properties, arising from the presence of the two unpaired electrons. These compounds are usually built from alternating electron-donating and electron-accepting monomer pairs which lower the HOMO–LUMO gap and yield a triplet state instead of the typical singlet ground state. In this paper, we use density functional theory calculations to explore the design rules that govern the creation of a ground-state triplet conjugated polymer and find that a small HOMO–LUMO gap in the singlet state is the best predictor for the existence of a triplet ground state, compared to previous use of a pro-quinoidal bonding character. Furthermore, this work can accelerate the discovery of new stable triplet materials by reducing the computational resources needed for electronic-state calculations and the number of potential candidates for synthesis.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Orbital transfer vehicle oxygen turbopump technology. Volume 2: Nitrogen and ambient oxygen testing

The testing of a rocket engine oxygen turbopump using high pressure ambient temperature nitrogen and oxygen as the turbine drive gas in separate test series is discussed. The pumped fluid was liquid nitrogen or liquid oxygen. The turbopump (TPA) is designed to operate with 400 F oxygen turbine drive gas which will be demonstrated in a subsequent test series. Following bearing tests, the TPA was finish machined (impeller blading and inlet/outlet ports). Testing started on 15 February 1989 and was successfully concluded on 21 March 1989. Testing started using nitrogen to reduce the ignition hazard during initial TPA checkout. The Hydrostatic Bearing System requires a Bearing Pressurization System. Initial testing used a separate bearing supply to prevent a rubbing start. Two test series were successfully completed with the bearing assist supplied only by the pump second stage output which entailed a rubbing start until pump pressure builds up. The final test series used ambient oxygen drive and no external bearing assist. Total operating time was 2268 seconds. There were 14 starts without bearing assist and operating speeds up to 80,000 rpm were logged. Teardown examination showed some smearing of silverplated bearing surfaces but no exposure of the underlying monel material. There was no evidence of melting or oxidation due to the oxygen exposure. The articulating, self-centering hydrostatic bearing exhibited no bearing load or stability problems. The only anomaly was higher than predicted flow losses which were attributed to a faulty ring seal. The TPA will be refurbished prior to the 400 F oxygen test series but its condition is acceptable, as is, for continued operating. This was a highly successful test program.

Brannam, R. J.↗
NASA NTRS1996

A Flexible Alignment Fixture for the Fabrication of Replication Mandrels

NASA uses precision diamond turning technology to fabricate replication mandrels for its X-ray Calibration Facility (XRCF) optics. The XRCF optics are tubular, and the internal surface contains a parabolic profile over the first section and a hyperbolic profile over the last. The optic is fabricated by depositing layers of gold and nickel on to the replication mandrel and then separating it from the mandrel. Since the mandrel serves as a replication form, it must contain the inverse image of the surface. The difficulty in aligning the mandrel comes from the fabrication steps which it undergoes. The mandrel is rough machined and heat treated prior to diamond turning. After diamond turning, silicon rubber separators which are undercut in radius by 3 mm (0.12 in.) are inserted between the two end caps of the mandrel to allow the plating to wrap around the ends (to prevent flaking). The mandrel is then plated with a nickel-phosphor alloy using an electroless nickel process. At this point, the separators are removed and the mandrel is reassembled for the final cut on the DTM. The mandrel is measured for profile and finish, and polished to achieve an acceptable surface finish. Wrapping the plating around the edges helps to prevent flaking, but it also destroys the alignment surfaces between the parts of the mandrel that insure that the axes of the parts are coincident. Several mandrels have been realigned by trial-and-error methods, consuming significant amounts of setup time. When the mandrel studied in this paper was reassembled, multiple efforts resulted in a minimum radial error motion of 100 microns. Since 50 microns of nickel plating was to be removed, and a minimum plating thickness of 25 microns was to remain on the part, the radial error motion had to be reduced to less than 25 microns. The mandrel was therefore not usable in its current state.

Cuttino, James F.↗