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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1979

Electrical enclosure hydrogen intrusion study

As a cost savings measure for the space shuttle program, the feasibility of substituting dry air for nitrogen as the purge gas used to minimize the probability of fire and explosions which could erupt from propellant vapor (hydrogen) diffusion into the electrical enclosures at Launch Complex 39 was investigated. It was concluded that: (1) Hydrogen concentrations of approximately 1% were obtained in an electrical enclosure under design purge conditions. (2) Hydrogen concentrations exceeding the lower explosive limit, 4%, could probably be obtained within the enclosure under worst case conditions. (3) Most of the hydrogen intrusion into the enclosure probably occurred at the point with the shortest leak path, such as the door seal. (4) More stringent electrical enclosure design requirements should be imposed before air is using as a purge gas.

Welch, P. J.↗
DOE OSTI2021

Report on High Energy Arcing Fault Experiments: Experimental Results from Open Box Enclosures

This report documents an experimental program designed to investigate High Energy Arcing Fault (HEAF) phenomena. The experiments focus on providing data to better characterize the arc to improve the prediction of arc energy emitted during a HEAF event. An open box experiment allow for direct observation of the arc, which allows diagnostic instrumentation to record the phenomenological data needed for better characterization of the arc energy source term. The data collected supports characterization of the arc and arc jet, enclosure breach, material loss, and electrical properties. These results will be used to better characterizing the hazard for improvements in fire probabilistic risk assessment (PRA) realism. The experiments were performed at KEMA Labs located in Chalfont, Pennsylvania. The experimental design, setup, and execution were completed by staff from the NRC, the National Institute of Standards and Technology (NIST), Sandia National Laboratories (SNL) and KEMA Labs. In addition, representatives from the Electric Power Research Institute (EPRI) observed some of the experimental setup and execution. The HEAF experiments were performed between August 22, 2020 and September 18, 2020 on near-identical 51 cm (20 in) cube metal boxes suspended from a Unistrut support structure. The three-phase arcing fault was initiated at the ends of the conductors oriented vertically and located at the center of the box. Either aluminum or copper conductors were used for the conductors. The low-voltage experiments used 1 000 volts AC, while the medium-voltage experiments used 6 900 volts AC consistent with other recently completed experiments. Durations of the experiment ranged from 1 s to 5 s with fault currents ranging from 1 kA to 30 kA. Real-time electrical operating conditions, including voltage, current and frequency, were measured during the experiments. Heat fluxes and incident energies were measured with plate thermometers, radiometers, and slug calorimeters at various locations around the electrical enclosures. The experiments were documented with normal and high-speed videography, infrared imaging and photography.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Report on High Energy Arcing Fault Experiments

This report documents an experimental program designed to investigate High Energy Arcing Fault (HEAF) phenomena for medium voltage electrical switchgear containing aluminum conductors. This report covers full-scale laboratory experiments using representative nuclear power plant (NPP) three-phase electrical equipment. Electrical, thermal, and pressure data were recorded for each experiment and documented in this report. This report covers four of the fourteen planned medium voltage electrical enclosure experiments. Subsequent reports will document the additional experiments performed in the future. The experiments were performed at KEMA Labs located in Chalfont, Pennsylvania. The experimental design, setup, and execution were completed by staff from the United States Nuclear Regulatory Commission (NRC), the National Institute of Standards and Technology (NIST), Sandia National Laboratories (SNL) and KEMA. In addition, representatives from the Electric Power Research Institute (EPRI) observed some of the experimental setups and execution. The HEAF experiments were performed on four near-identical units of General Electric metal-clad medium voltage switchgear. The three-phase arcing fault was initiated on the primary cable connection bus. All four experiments used the same system voltage (6.9 kV) but varied the current and duration. Real-time electrical operating conditions, including voltage, current and frequency, were measured during the experiments. Heat fluxes and incident energies were measured with plate thermometers and slug calorimeters at various locations around the electrical enclosures. Internal enclosure pressures were measured during the experiments. The experiments were documented with normal and high-speed videography, infrared imaging, and photography. Insights from the experimental series included timing information related to enclosure breach, event progression, mass loss measurements for electrodes and steel enclosures, peak pressure rise, particle analysis, along with visual and thermal imaging data to better understand and characterize the hazard. These results will be used in subsequent efforts to advance the state of knowledge related to HEAF.

42 ENGINEERING↗
DOE OSTI2021

Report on High Energy Arcing Fault Experiments: Experimental Results from Low-Voltage Switchgear Enclosures

This report documents an experimental program designed to investigate High Energy Arcing Fault (HEAF) phenomena for low-voltage metal enclosed switchgear containing aluminum conductors. This report covers full-scale laboratory experiments using representative nuclear power plant (NPP) three-phase electrical equipment. Electrical, thermal, and pressure data were recorded for each experiment and documented in this report. This report covers experiments performed on two low-voltage switchgear units with each unit consisting of two vertical sections. The data collected supports characterization of the low-voltage HEAF hazard and these results will be used to support potential improvements in fire probabilistic risk assessment (PRA) methods. The experiments were performed at KEMA Labs located in Chalfont, Pennsylvania. The experimental design, setup, and execution were completed by staff from the NRC, the National Institute of Standards and Technology (NIST), Sandia National Laboratories (SNL) and KEMA. In addition, representatives from the Electric Power Research Institute (EPRI) observed some of the experimental setup and execution. The HEAF experiments were performed between August 26 and Augsut 29, 2019 on nearidentical Westinghouse Type DS low-voltage metal-enclosed indoor switchgear. The threephase arcing fault was initiated on the aluminum main bus or in select cases on the copper bus stabs near the breaker. These experiments used either nominal 480 volts AC or 600 volts AC. Durations of the experiments ranged from approximately 0.4 s to 8.3 s with fault currents ranging from approximately 9.2 kA to 19.3 kA. Real-time electrical operating conditions, including voltage, current and frequency, were measured during the experiments. Heat fluxes and incident energies were measured with plate thermometers, radiometers, and slug calorimeters at various locations around the electrical enclosures. Environmental measurements of breakdown, conductivity and electromagnetics were also taken. The experiments were documented with normal and high-speed videography, infrared imaging and photography. The results, while limited, indicated the difficulty in maintaining and sustaining low-voltage arcs on aluminum components of sufficient duration and at a single point as observed operating experience.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

HERO WEC V1 Upgrades - SolidWorks Models (WEC, RO System, and Submersible Pump Housing)

The attached zip files include SolidWorks pack-and-go assemblies of NREL's HERO WEC (hydraulic and electric reverse osmosis wave energy converter), the reverse osmosis (RO) assembly, and the submersible pump assembly that is used to provide flow to the RO assembly in the electric configuration. These 3 models were upgraded in 2023 from their baseline models. The HERO WEC model does not include all aspects of the design (i.e. RO system, electrical enclosure, hose, cable), it only includes the WEC and PTO (power take-off) design. This model supersedes the old MHKDR model submission, linked below. The RO model file includes a SolidWorks (version 2023) pack-and-go assembly of the RO assembly that was used for HERO WEC as it was upgraded in 2023. This model ONLY includes the RO assembly and not the WEC, hoses, etc. The submersible pump enclosure model includes a SolidWorks (version 2023) pack-and-go assembly of the submersible pump assembly that is used to provide flow to the RO assembly in the electric configuration HERO WECas it was upgraded in 2023. This model ONLY includes the submersible pump assembly and not the WEC, RO system, hoses, etc. This work has been developed by the National Renewable Energy Laboratory, operated by Alliance for Sustainable Energy, LLC, for the U.S. Department of Energy (DOE) under Contract No. DE-AC36-08GO28308. Funding provided U.S. Department of Energy Office of Energy Efficiency and Renewable Energy Water Power Technologies Office.

16 TIDAL AND WAVE POWER↗
NASA NTRS2019

On the Maximum Expected Electric Field in Electrically Small, Undermoded Enclosures

This paper reports the experimental validation of an improved statistical model for the prediction of maximum expected electric field in electrically small and under-moded enclosures. The aerospace community is interested in application of Hill's statistical models to design of avionics boxes for shielding effectiveness and for tailoring EMC test requirements for critical applications. However, it is observed that the probability distribution for mean-squared electric field in an electrically small enclosure differs from the exponential distribution which is widely used in reverberation chamber testing. It is postulated here that the difference is attributable to the under-moded character of the small enclosure.

Bremner, Paul↗
NASA NTRS2019

On the Maximum Expected Electric Field in Electrically Small, Undermoded Enclosures

This paper reports the experimental validation of an improved statistical model for the prediction of maximum expected electric field in electrically small and under-moded enclosures. The aerospace community is interested in application of Hill’s statistical models to design of avionics boxes for shielding effectiveness and for tailoring EMC test requirements for critical applications. However, it is observed that the probability distribution for mean-squared electric field (|E(sub x)|(exp 2)) in an electrically small enclosure differs from the exponential distribution which is widely used in reverberation chamber testing. It is postulated here that the difference is attributable to the under-moded character of the small enclosure. We will define “under-moded” as the condition where a single excitation frequency does not excite enough closely spaced resonant modes to achieve Hill’s assumption of an isotropic (or fully diffuse) plane wave field in the enclosure.

Bremner, P. G.↗
DOE OSTI2022

HERO WEC V1.0 - SolidWorks Model

The attached zip file includes a SolidWorks pack-and-go assembly of NREL's HERO WEC (hydraulic and electric reverse osmosis wave energy converter) V1.0. This model does not include all aspects of the design (i.e. RO (reverse osmosis) system, electrical enclosure, hose, cable) it only includes the WEC and PTO (power take-off) design.

16 TIDAL AND WAVE POWER↗
NASA NTRS2008

TEM Cell Testing of Cable Noise Reduction Techniques From 2 MHz to 200 MHz - Part 1

This paper presents empirical results of cable noise reduction techniques as demonstrated in a TEM cell operating with radiated fields from 2 - 200 MHz. It is the first part of a two-paper series. This first paper discusses cable types and shield connections. In the second paper, the effects of load and source resistances and chassis connections are examined. For each topic, well established theories are compared to data from a real-world physical system. Finally, recommendations for minimizing cable susceptibility (and thus cable emissions) are presented. There are numerous papers and textbooks that present theoretical analyses of cable noise reduction techniques. However, empirical data is often targeted to low frequencies (e.g. <50 KHz) or high frequencies (>100 MHz). Additionally, a comprehensive study showing the relative effects of various noise reduction techniques is needed. These include the use of dedicated return wires, twisted wiring, cable shielding, shield connections, changing load or source impedances, and implementing load- or source-to-chassis isolation. We have created an experimental setup that emulates a real-world electrical system, while still allowing us to independently vary a host of parameters. The goal of the experiment was to determine the relative effectiveness of various noise reduction techniques when the cable is in the presence of radiated emissions from 2 MHz to 200 MHz. The electronic system (Fig. 1) consisted of two Hammond shielded electrical enclosures, one containing the source resistance, and the other containing the load resistance. The boxes were mounted on a large aluminium plate acting as the chassis. Cables connecting the two boxes measured 81 cm in length and were attached to the boxes using standard D38999 military-style connectors. The test setup is shown in Fig. 2. Electromagnetic fields were created using an HP8657B signal generator, MiniCircuits ZHL-42W-SMA amplifier, and an EMCO 5103 TEM cell. Measurements were taken using an Agilent E4401B spectrum analyzer and HP1141a differential probes.

Bradley, Arthur T.↗
NASA NTRS1973

Design study report. Volume 1: Transport unit

Results are presented of mechanical and thermal analyses of the transport mechanism and its pressurized enclosure, and electrical and thermal analyses of those circuits within the enclosure.

Source record↗
DOE OSTI2021

Development of Efficient Process for Manufacturing of Thermoplastic Composites with Tailored Properties (CRADA 511)

This is a collaborative effort between Battelle Memorial Institute as manager and operator of Pacific Northwest National Laboratory (PNNL) and ESI North America Inc. (“ESI” or “Participant”) to apply computation and data analytics to the challenge of light weighting with a focus on the battery enclosures of electric vehicles (EVs). EVs use heavy batteries to increase range and power. A complex-shaped battery enclosure is required to meet a host of challenging performance requirements. The ability to virtually develop composite parts such as battery enclosure with tailored properties to meet required performance will be highly valuable to the automotive industry. However, efficient simulation of composite-manufacturing processes remains a challenging issue since simulation involves multiscale models in space and time, highly non-linear and anisotropic behavior, strongly coupled multi-physics, and complex geometries. This work will advance the state of the art by reducing the computational burden of composite optimization by using simulation data from a limited number of configurations off-line and then developing a reduced order model (ROM) using data analytics and machine learning (ML). Develop a data driven approach to link features of the material and manufacturing processes to the mechanical properties of thermoplastic composite parts.

42 ENGINEERING↗
DOE OSTI2023

Predicting High Energy Arcing Fault Zones of Influence for Aluminum Using an Arc Flash Modeling Approach: Evaluation of a model bias, uncertainty, parameter sensitivity and zone of influence estimation

This report documents the development of an arc flash hazard model to calculate the incident energy and zone of influence from high energy arcing faults involving aluminum. The NRC has identified the potential for (HEAFs) involving aluminum to increase the damage zone beyond what is currently postulated in fire probabilistic risk assessment (PRA) methodologies. To estimate the hazard from HEAFs involving aluminum an arc flash model was developed. Differences between the initial model and nuclear power plant (NPP) fire PRA scenarios were identified. Modification of the initial model established from existing literature and test data was used to minimize these differences. The developed model was evaluated against NRC datasets to understand the model prediction and relative uncertainties. Finally, a range of fire PRA zone of influences (ZOI) were developed based on the developed model, target fragility estimates and update HEAF PRA methodology. The results were developed to support an NRC LIC-504 evaluation in tandem with other modeling efforts. The report documents the effort and provides a reference for any future advancements in arc flash modeling.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Finite Element Analysis and Machine Learning Guided Design of Carbon Fiber Organosheet-Based Battery Enclosures for Crashworthiness

Carbon fiber composite can be a potential candidate for replacing metal-based battery enclosures of current electric vehicles (E.V.s) owing to its better strength-to-weight ratio and corrosion resistance. However, the strength of carbon fiber-based structures depends on several parameters that should be carefully chosen. Here, in this work, we implemented high throughput finite element analysis (FEA) based thermoforming simulation to virtually manufacture the battery enclosure using different design and processing parameters. Subsequently, we performed virtual crash simulations to mimic a side pole crash to evaluate the crashworthiness of the battery enclosures. This high throughput crash simulation dataset was utilized to build predictive models to understand the crashworthiness of an unknown set. Our machine learning (ML) models showed excellent performance (R 2 > 0.97) in predicting the crashworthiness metrics, i.e., crush load efficiency, absorbed energy, intrusion, and maximum deceleration during a crash. We believe that this FEA-ML work framework will be helpful in down select process parameters for carbon fiber-based component design and can be transferrable to other manufacturing technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Reduction in RF sheath rectification with insulating antenna enclosure walls

Abstract Radiofrequency (RF) sheath rectification is one of the most prominent deleterious effects associated with ion cyclotron range of frequencies (ICRF) heating in fusion plasmas. RF sheaths and associated effects, such as impurity generation and convective cell generation, need to be mitigated to ensure that ICRF is a viable option for heating in future fusion devices. Experiments were performed on the Large Plasma Device (LAPD) at UCLA to explore the effects of using electrically-insulating antenna enclosures on RF rectified sheaths. Three different enclosure side-wall materials were used, including copper, MACOR (electrically insulating), and MACOR over copper. In the case of the MACOR–copper side walls, the non-conductive MACOR material was exposed to the bulk plasma but a layer of copper was added below to allow for image currents to flow. All three of the experiments had similar plasma density, temperature, and background magnetic field. In the case of the copper enclosure, RF rectified potentials, many times the local electron temperature, and associated formation of convective cells were observed and reported Martin M. et al (2017 Phys. Rev. Lett. 119 205002). In the experiments with MACOR and MACOR–copper enclosures, RF rectification was significantly reduced. Additionally, these latter two experiments showed no evidence of convective cell formation. Although the results from the MACOR experiment are reminiscent of the results obtained in ASDEX-U with a three-strap antenna optimized to reduce image currents on the antenna limiters Bobkov V. et al (2016 Nucl. Fusion 56 084001), the MACOR–copper experiment seems to suggest that insulating plasma facing materials have at least an equally strong impact on reducing potential rectification.

Physics↗
DOE OSTI2021

Reference electrode for electrochemical measurements at high temperatures

A reference electrode which is stable over a wide range of temperatures, pressures and chemical conditions is provided. The subject reference electrode according to the present invention comprises a tubular enclosure composed of quartz having a distal, closed end and a proximal, open end. An insulating ceramic rod is seemingly connected to the opening in the closed distal end of the enclosure to form micro-cracks between the ceramic rod and the quartz enclosure (called a cracked junction, CJ). The CJ gives a very tortuous path for ion conduction from inside the reference electrode (RE) to a working electrode (WE). Inside the tubular enclosure is an electrical lead (e.g., a silver wire) disposed in an electrolyte comprising a mixture of alkaline metal salts (e.g., AgCl and KCl), extending from the electrolyte upward through a sealing means at the proximal end of the quartz enclosure.

Gervasio, Dominic Francis↗
NASA NTRS1979

Double-sided solar cell package

In a solar cell array of terrestrial use, an improved double-sided solar cell package, consisting of a photovoltaic cell having a metallized P-contact strip and an N-contact grid, provided on opposite faces of the cell, a transparent tubular body forming an enclosure for the cell. A pedestal supporting the cell from within the enclosure comprising an electrical conductor connected with the P-contact strip provided for each face of the cell, and a reflector having an elongated reflective surface disposed in substantially opposed relation with one face of the cell for redirecting light were also included.

Shelpuk, B.↗
NASA NTRS1995

(abstract) Electromagnetic Compatability Program to Accommodate a Spacecraft Magnetic Search Coil Experiment

A search coil is a very sensitive instrument that measures low frequency magnetic field radiation. In order for the search coil to achieve its objectives, an electromagnetic clean environment must be provided. On a spacecraft, there are many potential sources of low frequency magnetic field emitter. Consequently, a very stringent program is needed to control the emission from these sources. This paper describes the details of such a program.

systems electric motors enclosures shielding↗