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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,657 records · Page 92

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NASA NTRS2023

Application of Bioengineering in Space Exploration - Sleep Study System

Bioengineering has spread roots far and wide among the needs of space exploration. The field creates many of paths to generate information from a variety of sources. One such source is the astronauts on the International Space Station (ISS). As of now the investigation is focused on the quality of sleep of crew members during a long duration flight. Our team is investing time into a piece of hardware’s comfort, waste, and operability. The hardware was not originally designed for space; therefore, the device must be modified to function at a optimal level in space. The design not made for space has generated some ailments, such as discomfort and decreased mobility. A function of the internship was to produce designs that would manage the wires to increase mobility and comfort. The wires excess slack was reduced by the part that was designed. The piece was adjustable, so the patient may adjust the system to their comfort and space compatible material was used. This product will help control the direction and length of the wires, thereby aiding in comforting the patient. This multifaceted design may be used in future for all other wire management for wearable biomedical sensor on orbit.

Biomedical↗

NASA NTRSDate not supplied

A New Test Methodology for Evaluating Fire Risk Due to Electrical Faults in Oxygen-Enriched Environments

This paper discusses a new test methodology for assessing the safe use of materials found in spacecraft that may be exposed to electrical faults, as performed at the NASA White Sands Test Facility. “Wire-break” testing, modeled after the Cleveland Open Cup method, identifies the conditions under which pyrolyzed material transitions from a brief flash to a propagating flame. The approach focuses on fuel mass liberated through pyrolysis, mixed with oxygen, and ignited by a piloted ignition (spark due to fusion of wire) to achieve flame propagation with the least energy. The test approach attempts to find energy density thresholds derived using I²t values from current-induced heating of various test materials and wire characteristics. The application of the data provides a useful approach to mitigating fire risks in space systems by correlating threshold data to real-world designs and scaling factors, including oxygen pressure, wire diameter, heat sinking, and contained smoke volume. Several case studies, including Apollo missions and hypothetical scenarios, illustrate practical applications of these thresholds to enhance fire safety design considerations in space environments.

methodology↗

NASA NTRS2026

Mechanical Design and Operation of a Novel Lunar Environment Structural Test Rig (LESTR)

The Lunar Environment Structural Test Rig (LESTR) was developed to address a critical gap in mechanical property data for metal alloy wire materials under lunar-relevant conditions down to 40 K. Conventional aerospace material databases provide thermophysical properties for bulk metals over a wide temperature range, but validated mechanical and physical property data below 77 K, particularly for small-diameter wires, remain limited and are generally the exception rather than the rule. These conditions are essential for Artemis mission hardware such as shape memory alloy (SMA) rover tires. LESTR’s design requirements were to combine a high-stiffness electrodynamic load frame with closed- cycle cryogenic cooling, high-vacuum capability (10–6 torr), and noncontact optical strain measurement to enable tensile, four-point bend, and fatigue testing of wires or other materials and geometries at temperatures from 40 to 125 K. These considerable requirements were merged with the need to lower the barrier of testing for the end user as measured in terms of cost-per-test cycle, safety improvement, and reduction in upkeep costs associated with state-of-the-art solutions associated with cryomechanical material characterization. The system incorporates modular gripping and alignment fixtures; precision thermal management using cryocoolers and embedded heaters; and integrated instrumentation for displacement, load, temperature, and vacuum control. Calibration procedures establish correlations between tooling and specimen temperature, ensuring accurate thermal conditions across the design envelope unbound by cryofluid conditions in heritage immersion-based test systems. Initial validation tests using Inconel (Special Metals Corp.) wire demonstrated accurate ultimate strength and post-yield behavior. The load frame operation was also verified under representative service conditions, including thermal cycling and prolonged fatigue loading. By generating mechanical property data at ultralow temperatures, LESTR fills a critical gap in existing materials databases and provides a scalable platform for iterative alloy development and durability assessment for planetary hardware. This capability supports NASA’s long-term objectives for surface exploration by enabling design confidence for components operating in extreme cryogenic environments.

LESTR↗

DOE OSTI2020

As-run thermal-hydraulic analysis of the EPRI-3 experiment

The EPRI-3 experiment was designed to irradiate various types of reactor internal component steels at a temperature of 288°C. The specimens were irradiated in an instrumented test train inside a pressurized water loop in the center lobe of the ATR during cycles 155B and 158B. Temperature was monitored using thermocouples placed at the top of the test train and melt wires placed within the test train. The purpose of this analysis is to calculate specimen temperature using measured data on reactor power and as-run calculations of heating rates of the test train. The experiment contains four thermocouples and several melt wires spanning the temperature range 239°C to 327°C. The accuracy of the model is assessed by comparing the measured and calculated in-pile tube inlet to outlet temperature difference, comparing the measured and calculated thermocouple temperatures, and comparing the calculated melt wire temperature to the temperature range indicated by examination of the melt wires.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Reconstruction for Liquid Argon TPC Neutrino Detectors Using Parallel Architectures.

Neutrinos are particles that interact rarely, so identifying them re-quires large detectors which produce lots of data. Processing this data with thecomputing power available is becoming more dicult as the detectors increasein size to reach their physics goals. In liquid argon time projection chambers(TPCs) the charged particles from neutrino interactions produce ionization elec-trons which drift in an electric field towards a series of collection wires, and thesignal on the wires is used to reconstruct the interaction. The MicroBooNEdetector currently collecting data at Fermilab has 8000 wires, and planned fu-ture experiments like DUNE will have 100 times more, which means that thetime required to reconstruct an event will scale accordingly. Modernization ofliquid argon TPC reconstruction code, including vectorization, parallelizationand code portability to GPUs, will help to mitigate these challenges. The liquidargon TPC hit finding algorithm within theLArSoftframework used acrossmultiple experiments has been vectorized and parallelized. This increases thespeed of the algorithm on the order of ten times within a standalone version onIntel architectures. This new version has been incorporated back intoLArSoftso that it can be generally used. These methods will also be applied to otherlow-level reconstruction algorithms of the wire signals such as the deconvolu-tion. The applications and performance of this modernized liquid argon TPCwire reconstruction will be presented.

Berkman, Sophie↗

DOE OSTI2020

Thermal Analysis of Large Area Additive Manufacturing Resistance Heating Composites for Out of Oven/Autoclave Applications

Additive Manufacturing (AM) of carbon fiber (CF) reinforced composite has received growing attention because of the design flexibility, superior mechanical properties, improved thermal properties, and weight reduction. Autoclave tooling was proven to be a successful application for large scale AM technology. The capital cost, and cost associated with heating, and cycle time in a conventional autoclave process is relatively high. Thus, an innovative design of AM mold with an efficient heating scheme is essential. This study represents an innovative method of the resistive heating of composite molds which does not require a room size oven for heating during the curing processing. Therefore, it has the potential to reduce the operating cost drastically. For the design validation and feasibility study, we performed a numerical analysis of the wire embedded and AM mold parts. The goal of this study is to determine and optimize the thermal behavior of the printed mold with embedded wire technology. It is anticipated that the larger distance between the embedded wires along the printing direction (z-direction) increase the cold spot, on the other hand, a close distance of the wire can create the unwanted localize heating, thus melting. Constant thermal properties of the 20 wt.% short CF reinforced acrylonitrile butadiene styrene (ABS) was used for the simulation purpose. Thermal characterization was set to 100°C to avoid the thermal deformation or bulging on the part surface.

billah, Kazi↗

DOE OSTI2021

Digital microfluidic systems with electrode bus and methods for droplet manipulation

The present disclosure relates to digital microfluidic systems having an electrode bus controlled by a single actuation input, and methods for droplet manipulation using the electrode bus. Particularly, aspects are directed to a digital microfluidic system including a first group of droplet actuation electrodes formed in a substrate, a first wiring bus formed in the substrate and connected to each electrode in the first group of droplet actuation electrodes, and a first single point of actuation connected to the first wiring bus; and a second group of droplet actuation electrodes formed in the substrate, a second wiring bus formed in the substrate and connected to each electrode in the second group of droplet actuation electrodes, and a second single point of actuation connected to the second wiring bus.

Gach, Philip↗

DOE OSTI2024

Target Multiwire for the Fermilab Booster Neutrino Beamline

The Booster Neutrino Beamline experiment re-quested a new secondary electron emission multiwire profile monitor installation. The device had to be durable in high radiation conditions and mounted within a large 10-foot airtight steel fixture for installation near the beam target. Previous iterations of multiwire suffered radiation damage to both the connectors and wires. To ensure accurate horizontal and vertical beam profile measurements, an updated design was pro-posed, designed, and constructed. The new BNB multiwire utilizes 3 mil diameter gold-plated tungsten sense wires soldered to vertical and horizontal Alumi-na-96 ceramic planes, 50 wires per plane. Radiation hard Kapton insulated 30-gauge wires carry the output signals. Profiles are readout through charge integrator scanner electronics. This paper will detail the design and functionality of the BNB target multiwire and present relevant beam profile data.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Thermal Analysis of Large Area Additive Manufacturing Resistance Heating Composites for Out of Oven/Autoclave Applications

billah, Kazi↗

DOE OSTI2024

On-PIC Light Source Integration & Micro-dispensing of Solder Paste for Flip Chip Application

To reach the next level benefits of photonic integrated circuits (PICs), the Integrated Photonic Systems Roadmap-International describes the necessity of either heterogeneous or hybrid integration of light sources [1]. A new approach for hybrid integration is Photonic Wire Bonding where 3D nanolithography is used to pattern a polymer waveguide that connects light sources to PIC waveguides. The waveguides resemble electrical wire bonds and essentially do the same as their electrical counterpart for packaging photonic chips together. In order to reap the full benefits of a photonic wire bonds, the light source must be carefully packaged. In this work I seek to expand RIT’s photonic packaging capability by establishing a packaging process to integrate light sources, specifically an Indium Phosphide distributed feedback lasers and a reflective semiconductor optical amplifiers, directly onto a photonic integrated circuits. Another necessary requirement for PIC packaging is densely integrated electrical connectivity. In this thesis I developed a fine pitch flip chip interconnect technique demonstrated using gold stud bumps in conjunction with micro-dispensed solder paste. This work opens the door to high density photonic flip chip applications. The micro-dispensed solder paste dots having diameters 50-125 µm are currently being tested at a pitch of 150 µm . The gold stud bumps are formed with 1mil gold wire creating bumps with a diameter of 40-60 µm depending on specific parameter values. These capabilities will allow RIT to assemble and test novel photonic integrated devices, cutting down on the time and cost associated with third party assembly and tests facilities. Thereby keeping RIT at the forefront of photonic research.

Wongk, Nicole↗

DOE OSTI2024

Sensors for passively measuring a maximum temperature of a nuclear reactor, and related methods

A sensor for passively measuring a maximum temperature within a nuclear reactor comprises a substrate, and a plurality of melt wires within a cavity defined within the substrate, at least one melt wire of the plurality of melt wires exhibiting a variable melting temperature along a length of the at least one melt wire. Related sensors and methods of forming the sensors are also disclosed.

Daw, Joshua↗

DOE OSTI2024

Metallization and stringing for back-contact solar cells

Metallization and stringing methods for back-contact solar cells, and resulting solar cells, are described. In an example, in one embodiment, a method involves aligning conductive wires over the back sides of adjacent solar cells, wherein the wires are aligned substantially parallel to P-type and N-type doped diffusion regions of the solar cells. The method involves bonding the wires to the back side of each of the solar cells over the P-type and N-type doped diffusion regions. The method further includes cutting every other one of the wires between each adjacent pair of the solar cells.

Terao, Akira↗

DOE OSTI2022

Peculiarities of planar shockwave interaction with air–water interface and solid target

We present the results of the research on underwater electrical explosion of planar copper wire arrays, accompanied by the generation of a planar shock, using the synchrotron-based phase-contrast radiography imaging capabilities of the ID19 beamline at the European Synchrotron Radiation Facility. It is shown that the interaction of a strong shock with an air–water interface leads to additional acceleration of the wire expansion due to a rarefaction wave along with the emergence of micro-jets. In the case of a target placed above the array, we observed the formation of a cavity between the array and the target due to the interaction of two rarefaction waves. Furthermore, the results of two-dimensional hydrodynamic simulations of the wire explosion and the interaction of the generated shock with the water–air and water-target interfaces showed good agreement with experimental results.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Validating Intra-Plate Power Distributions in the Advanced Test Reactor

We report that the neutronics software, HELIOS, was validated in 2015 for performing core reload design and safety analysis of the Advanced Test Reactor. However, when HELIOS was benchmarked against historic fission-wire measurements (i.e., zero-power full-core measurements) a statistically resolved calculation-to-measurement bias was discovered. The azimuthal power along each fuel plate computed by HELIOS has consistently shown to under-predict measurements made by fission-wires in historic zero-power tests near the fuel element side-plates. It was hypothesized during the HELIOS software validation work, that this bias is attributable to local moderation in coolant vents in the side-plates axially just above and below the fission-wires on the fuel-plate edges. This work used detailed MCNP and MC21 models of the side-plate vents to test this hypothesis. By comparing the average azimuthal biases between HELIOS, and 2D and 3D MCNP models, and a 3D MC21 model, it was found that the HELIOS azimuthal bias is not due to the measurement.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

High-rate heavy-ion tracking using MWPCs and PPACs with an Anti-Discharge Unit

This work reports on the development of two robust, heavy-ion beam tracking concepts operating at low pressure (< 15 Torr) for high rate applications (> 200 kHz). The first concept consists of a Multi-Wire Proportional Counter (MWPC) with a central anode consisting of 12 μm Au-plated Tungsten wires spaced 1 mm from each other. The anode grid is sandwiched between two segmented cathodes aligned orthogonally in the two dimensions for (x,y) particle localization. The second detector is a Parallel-Plate Avalanche Counter (PPAC) that uses the same readout geometry as the MWPC, but replaces the wire anode with a 150 nm silver layer deposited on both sides of a thin (< 1 mg/cm 2 ) polypropylene foil. Additionally, the bias circuitry for the PPAC anode central foil is equipped with an Anti-Discharge Unit (ADU) to prevent transitions from proportional operation to streamer formation, thereby avoiding damaging discharges. The localization capability of both detectors was tested with a low-rate alpha-particle source (241-Am). A position resolution of < 1 mm (FWHM) was achieved under stable, high-gas-gain (> 1000) operating conditions. Their performance in terms of detection efficiency as a function of the isotope charge (Z) was determined by irradiating the detectors with a cocktail beam (Z ≤ 15) with energy of ∼ 100 MeV/u. Full detection efficiency is maintained for all available fragments under optimal operational conditions (i.e., voltage bias). Full detection efficiency was achieved at rates above 200 kHz by irradiating the detectors with a 1 cm diameter 238 U beam at an energy of 143 MeV/u.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Mechanical Solution for Existing Conductors

The rapid growth in energy demand, driven by advancements in AI technology, renewable energy integration, and increased industrial activity, highlights the need for innovative solutions to improve the resiliency and efficiency of the power grid. This report details the fire testing of GridWrap’s Composite WiRe Wrap, to evaluate the wrap's ability to enhance conductor performance under wildfire-simulated conditions. Conductors were prepared and tested in a controlled environment at 400°C for 18 minutes, during which sag and temperature data were recorded. The results demonstrated that the unwrapped conductor sagged 3/16ths of an inch, while the WiRe Wrapped conductor sagged only 1/16th of an inch under identical conditions, indicating a significant improvement in mechanical performance. This project, conducted as part of a collaborative effort between BEA (Idaho National Laboratory’s managing contractor) and GridWrap, Inc., demonstrates the potential of grid-enhancing technologies like WiRe Wrap to reduce sag, increase grid resiliency, and support the future energy landscape. By validating the performance of such technologies in real-world scenarios, this work provides critical insights for industry adoption, benefiting both grid operators and U.S. taxpayers through improved reliability, reduced emissions, and enhanced energy delivery.

24 - POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

ON PROCESS STABILITY IN WAAM-CMT OF ALUMINUM ALLOYS

Wire-arc additive manufacturing (WAAM) has become a cost-efficient metal additive manufacturing process. However, depositing aluminum with WAAM is challenging due to its sensitivity to heat input (linear energy density), which can cause undesirable surface topology waviness if not controlled. Thus, a process window is needed that can produce stable geometry and deposition conditions while minimizing production times. In this study, 5183 aluminum alloy wire is used to deposit 10-layer walls with varying wire feed speeds (WFS) and traverse speeds (TS) (at a constant WFS/TS ratio) and varying interpass temperature (IPT). In-situ process data consisting of optical contact-tip-workpiece-distance (CTWD) and current/voltage measurements are collected to determine process condition stability throughout the build. Part geometry is measured using a 3D scanner and build porosity is characterized via digital X-ray. A process window is identified that produces stable surface topology and process conditions at a minimal production time.

aluminum alloy↗

NASA NTRS2016

An Assessment of the Icing Blade and the SEA Multi-Element Sensor for Liquid Water Content Calibration of the NASA GRC Icing Research Tunnel

The Icing Research Tunnel at NASA Glenn has recently switched from using the Icing Blade to using the SEA Multi-Element Sensor (also known as the multi-wire) for its calibration of cloud liquid water content. In order to peform this transition, tests were completed to compare the Multi-Element Sensor to the Icing Blade, particularly with respect to liquid water content, airspeed, and drop size. The two instruments were found to compare well for the majority of Appendix C conditions. However, it was discovered that the Icing Blade under-measures when the conditions approach the Ludlam Limit. This paper also describes data processing procedures for the Multi-Element Sensor in the IRT, including collision efficiency corrections, mounting underneath a splitter plate, and correcting for a jump in the compensation wire power. Further data is presented to describe the repeatability of the IRT with the Multi-Element Sensor, health-monitoring checks for the instrument, and a sensing-element configuration comparison. Ultimately these tests showed that in the IRT, the multi-wire is a better instrument for measuring cloud liquid water content than the blade.

aircraft icing↗