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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 NTRS1988

Oxygen separation from air using zirconia solid electrolyte membranes

Air separation using a zirconia solid electrolyte membrane is a possible alternative source of oxygen. The process of zirconia oxygen separation is reviewed, and an oxygen plant concept using such separation is described. Potential cell designs, stack designs, and testing procedures are examined. Fabrication of the materials used in a zirconia module as well as distribution plate design and fabrication are examined.

Suitor, J. W.↗
NASA NTRS1990

Ongoing nickel-hydrogen energy storage device testing at George C. Marshall Space Flight Center

The primary objective of the testing is to characterize Ni-H2 cells for successful integration into the electrical power system (EPS) of the Hubble Space Telescope (HST). A broad spectrum of Ni-H2 design technology is encompassed by the testing configurations; tests include cells with dates of manufacture as early as 1976. The database includes cells of varied storage times, capacity, plate design, stack design, terminal configuration, pressure vessel thickness, separator material, potassium hydroxide (KOH) concentration, and thermal control. Currently, 196 Ni-H2 cells are being tested, grouped as follows: 12 RNH-35-3, 14 RNH-30-1, 22 HST cells (1 battery, flight spare lot), 132 HST cells (6 batteries, test modules 1 and 2, called TM1 and TM2), 12 HST cells (3 four-cell packs, TM1, TM2, flight spare module FSM), and 4 HST cells (engineering lot). In addition to the characterization and life testing, an extensive thermal vacuum and purge test was conducted in November 1989 and February 1990 using the HST FSM (3 batteries composed of 69 HST cells from the flight spare lot) to help verify thermal design. A report is presented of the progress, significant findings, and future objectives of the testing.

Lowery, John E.↗
NASA NTRS1992

Nickel hydrogen cell design: A designer's aspect

Information is given to give insight into the methodology of nickel hydrogen cell design and the decipherment of the battery cell reference guide that was distributed to many of Gates Energy Products' customers. Cell design, stacking design, charge capacity, and dynamic response are discussed in general terms.

Rehm, Raymond↗
NASA NTRS1977

Multistack nickel-hydrogen units

A typical 625 Inconel pressure vessel, equipped with four thermocouples, has voltage taps not only for the cell, but for each of the several packs inside the container. In a two-stack design, a weld ring is used to separate the packs which, joined together, form one solid group. In the four-stack design, stacks are separated mechanically with about half inch Plexiglas and are connected through the center. Electrolytes are forced out by vacuum. The two stack design is intended for 500 psi and was pressure tested up to 1,000. The problem of electrolyte shorts is discussed and possible solutions for its correction are given.

Smith, J.↗
NASA NTRS1987

Design, fabrication and delivery of a miniature Cassegrainian concentrator solar array system

The optical design of the miniature Cassegrainian concentrator (MCC) element was improved for both offpoint and onpoint power capability. The cell stack design has shown no losses under the high short term thermal stresses imposed by component level test and is projected to be capable of greater than five years thermal cycle life in low Earth orbit. The structural design met all requirements for stiffness and flatness and requires adjustable inserts for fine tuning of the GFRP structure to meet flatness goals. The completed, fully populated small and large MCC panels deliverable under this contract perform electrically as expected. A solid acceptance inspection program to guarantee quality of all purchased parts, and continued manufacturing process improvements will make the MCC design a viable low cost alternative to standard flat panel technology. Minor improvements to the cell stack design of the MCC element can make significant improvements in both the performance and manufacturability of the MCC system.

Kruer, Mark A.↗
NASA NTRS1987

Development of an alkaline fuel cell subsystem

A two task program was initiated to develop advanced fuel cell components which could be assembled into an alkaline power section for the Space Station Prototype (SSP) fuel cell subsystem. The first task was to establish a preliminary SSP power section design to be representative of the 200 cell Space Station power section. The second task was to conduct tooling and fabrication trials and fabrication of selected cell stack components. A lightweight, reliable cell stack design suitable for the SSP regenerative fuel cell power plant was completed. The design meets NASA's preliminary requirements for future multikilowatt Space Station missions. Cell stack component fabrication and tooling trials demonstrated cell components of the SSP stack design of the 1.0 sq ft area can be manufactured using techniques and methods previously evaluated and developed.

Source record↗
NASA NTRS1981

Cell module and fuel conditioner development

A phosphoric acid fuel cell (PAFC) stack design having a 10 kW power rating for operation at higher than atmospheric pressure based on the existing Mark II design configuration is described. Functional analysis, trade studies and thermodynamic cycle analysis for requirements definition and system operating parameter selection purposes were performed. Fuel cell materials and components, and performance testing and evaluation of the repeating electrode components were characterized. The state of the art manufacturing technology for all fuel cell components and the fabrication of short stacks of various sites were established. A 10 kW PAFC stack design for higher pressure operation utilizing the top down systems engineering aproach was developed.

Feret, J. M.↗
NASA NTRS1982

Cell module and fuel conditioner development

The efforts performed to develop a phosphoric acid fuel cell (PAFC) stack design having a 10 kW power rating for operation at higher than atmospheric pressure based on the existing Mark II design configuration are described. The work involves: (1) Performance of pertinent functional analysis, trade studies and thermodynamic cycle analysis for requirements definition and system operating parameter selection purposes, (2) characterization of fuel cell materials and components, and performance testing and evaluation of the repeating electrode components, (3) establishment of the state-of-the-art manufacturing technology for all fuel cell components at Westinghouse and the fabrication of short stacks of various sites, and (4) development of a 10 kW PAFC stack design for higher pressure operation utilizing the top down systems engineering approach.

Feret, J. M.↗
NASA NTRS1992

Lightweight bipolar storage battery

An apparatus [10] is disclosed for a lightweight bipolar battery of the end-plate cell stack design. Current flow through a bipolar cell stack [12] is collected by a pair of copper end-plates [16a,16b] and transferred edgewise out of the battery by a pair of lightweight, low resistance copper terminals [28a,28b]. The copper terminals parallel the surface of a corresponding copper end-plate [16a,16b] to maximize battery throughput. The bipolar cell stack [12], copper end-plates [16a,16b] and copper terminals [28a,28b] are rigidly sandwiched between a pair of nonconductive rigid end-plates [20] having a lightweight fiber honeycomb core which eliminates distortion of individual plates within the bipolar cell stack due to internal pressures. Insulating foam [30] is injected into the fiber honeycomb core to reduce heat transfer into and out of the bipolar cell stack and to maintain uniform cell performance. A sealed battery enclosure [ 22] exposes a pair of terminal ends [26a,26b] for connection with an external circuit.

Rowlette, John J.↗
NASA NTRS2021

PEM Fuel Cell MODEL for Conceptual Design of Hydrogen eVTOL Aircraft

A model and software for design and analysis of a Proton Exchange Membrane fuel cell (PEMFC) system are developed for hydrogen eVTOL aircraft. Examples are provided of stacks designed for 80 kWe and 500 kWe net electrical power. Examples are provided of eVTOL designed for 250 and 400 lb payload. The trade-offs included stack characteristics, hydrogen storage characteristics, and aircraft payload and range. The objectives were to identify the key technology drivers of a hydrogen rotorcraft, establish technology targets for a viable aircraft, and recommend research to address the fundamental pre-competitive barriers. The current U.S. infrastructure on hydrogen informed the targets and recommendations. The key conclusion is that the advances made in cell electrochemical power density over the last decade might allow a PEMFC system to meet, or even beat, piston engine powered light-utility rotorcraft. The development must focus on the key drivers of a hydrogen eVTOL. The drivers are ultra-light stack cooling and short-term hydrogen storage. A stack system of net electrical power 100−150 kWe with specific power 1.1 kWe/kg including air, cooling, and electrical subsystems, and a tank storage of 15% weight fraction hydrogen are the minimum targets to meet the performance of a modern piston-engine rotorcraft, with a range of 180 nautical miles, payload of 400 lb, and gross weight of about 1400 lb. This is defined as the objective aircraft. If only one target is met, an aircraft of half the range could be produced, with a 30% greater gross take-off weight. This is defined as an intermediate aircraft. Because definitive conclusions are premature without weights and loads data on a flight-worthy stack system, it is recommended that a fuel cell powered hydrogen eVTOL demonstrator be built and flown. The existing hydrogen infrastructure for cars provide ample opportunity to create a pilot program. About 12 metric tons of retail hydrogen are available for cars every day in California, which is less than 0.05% of the yearly hydrogen production in the U.S.. A hypothetical fleet of 100 aircraft, operating 3 flights a day, would increase the demand by 2.25 tons per day and require 140 MWh of renewable electricity for green hydrogen.

PEM↗
NASA NTRS2005

Investigation of Ruthenium Dissolution in Advanced Membrane Electrode Assemblies for Direct Methanol Based Fuel Cell Stacks

Dissolution of ruthenium was observed in the 80-cell stack. Duration testing was performed in single cell MEAs to determine the pathway of cell degradation. EDAX analysis on each of the single cell MEAs has shown that the Johnson Matthey commercial catalyst is stable in DMFC operation for 250 hours, no ruthenium dissolution was observed. Changes in the hydrophobicity of the cathode backing papers was minimum. Electrode polarization analysis revealed that the MEA performance loss is attributed to changes in the cathode catalyst layer. Ruthenium migration does not seem to occur during cell operation but can occur when methanol is absent from the anode compartment, the cathode compartment has access to air, and the cells in the stack are electrically connected to a load (Shunt Currents). The open-to-air cathode stack design allowed for: a) The MEAs to have continual access to oxygen; and b) The stack to sustain shunt currents. Ruthenium dissolution in a DMFC stack can be prevented by: a) Developing an internally manifolded stacks that seal reactant compartments when not in operation; b) Bringing the cell voltages to zero quickly when not in operation; and c) Limiting the total number of cells to 25 in an effort to limit shunt currents.

alternative power sources↗
NASA NTRS1997

Fuel Cell Power Plant Initiative: Preliminary Design of a Fixed-Base LFP/SOFC Power System - Volume 2

This report documents the preliminary design for a military fixed-base power system of 3 MWe nominal capacity using Westinghouse's tubular Solid Oxide Fuel Cell [SOFC] and Haldor Topsoe's logistic fuels processor [LFP]. The LFP provides to the fuel cell a methane rich sulfur free fuel stream derived from either DF-2 diesel fuel, or JP-8 turbine fuel. Fuel cells are electrochemical devices that directly convert the chemical energy contained in fuels such as hydrogen, natural gas, or coal gas into electricity at high efficiency with no intermediate heat engine or dynamo. The SOFC is distinguished from other fuel cell types by its solid state ceramic structure and its high operating temperature, nominally 1000'C. The SOFC pioneered by Westinghouse has a tubular geometry closed at one end. A power generation stack is formed by aggregating many cells in an ordered array. The Westinghouse stack design is distinguished from other fuel cell stacks by the complete absence of high integrity seals between cell elements, cells, and between stack and manifolds. Further, the reformer for natural gas [predominantly methane] and the stack are thermally and hydraulically integrated with no requirement for process water. The technical viability of combining the tubular SOFC and a logistic fuels processor was demonstrated at 27 kWe scale in a test program sponsored by the Advanced Research Projects Agency [ARPA) and carried out at the Southern California Edison's [SCE] Highgrove generating station near San Bernardino, California in 1994/95. The LFP was a breadboard design supplied by Haldor Topsoe, Inc. under subcontract to Westinghouse. The test program was completely successful. The LFP fueled the SOFC for 766 hours on JP-8 and 1555 hours of DF-2. In addition, the fuel cell operated for 3261 hours on pipeline natural gas. Over the 5582 hours of operation, the SOFC generated 118 MVVH of electricity with no perceptible degradation in performance. The LFP processed military specification JP-8 and DF-2 removing the sulfur and reforming these liquid fuels to a methane rich gaseous fuel. Results of this program are documented in a companion report titled 'Final Report-Solid Oxide Fuel Cell/ Logistic Fuels Processor 27 kWe Power System'.

Veyo, S.E.↗
NASA NTRS1985

Measurement of low energy cosmic rays aboard Spacelab-1

In December 1983 the first Spacelab mission was launched for a duration of 10 days. Aboard was the Kiel experiment Isotopic Stack designed for measurement of heavy cosmic ray nuclei with nuclear charge equal to or greater than 3 and energies up to some 100MeV/nuc. One part of the stack was rotated in well defined steps registered by an angle encoder to receive information on impact times of the nuclei. Using this time resolving system geomagnetically forbidden particles can be detected. The chemical composition and energy spectra of mainly CNO particles are examined using a rotated 300 microns m thick CR-39 foil beneath a fixed 100 microns m thick Kodak-Cellulose Nitrate foil. About 600 sq cm have been scanned yielding nearly 100 nuclear tracks within an energy range of approximately 8 to 30 MeV/nuc. The calibration is done by means of a postflight irradiation with 410 MeV/nuc Fe-56 at Berkeley Laboratory, California, USA. Relative abundances and energy spectra are presented.

Beaujean, R.↗
NASA NTRS2005

Proton-Exchange-Membrane Fuel Cell Powerplants Developed and Tested for Exploration Missions

Proton-exchange-membrane fuel cell (PEMFC) technology has received major attention for terrestrial applications, such as the automotive and residential markets, for the past 20 years. This attention has significantly advanced the maturity of the technology, resulting in ever more compact, efficient, reliable, and inexpensive PEMFC designs. In comparison to the terrestrial operating environment, the space operating environment is much more demanding. Microgravity to high-gravity loads and the need to use pure oxygen (rather than air) as the fuel cell oxidizer place more stringent demands on PEMFC technology. NASA and its partners from industry are leveraging terrestrial PEMFC advancements by conducting parallel space technology development for future exploration missions. A team from the NASA Glenn Research Center, NASA Johnson Space Center, and NASA Kennedy Space Center recently completed the first phase of a PEMFC powerplant development effort for exploration missions. The industry partners for this phase of the development effort were ElectroChem, Inc., and Teledyne Energy Systems, Inc. Under contract to Glenn, both of these industry partners successfully designed, fabricated, and tested a breadboard PEMFC powerplant in the 1- to 5-kW power range. These powerplants were based on existing company-proprietary fuel cell stack designs, combined with off-the-shelf components, which formed the balance of the powerplant design. Subsequent to the contractor development efforts, both powerplants were independently tested at Johnson to verify operational and performance characteristics, and to determine suitability for further technology development in the second phase of the NASA-led effort. Following the independent NASA testing, Teledyne Energy Systems, Inc., was selected to develop an engineering model PEMFC powerplant. This effort was initiated by the 2nd Generation Reusable Launch Vehicle (RLV) Program Office in 2001; it transitioned to the Next Generation Launch Technologies (NGLT) Program Office in 2003. The effort is now being funded by the Exploration Program Office. We plan to summarize the results from the ongoing engineering model PEMFC powerplant development in a future Research & Technology article.

Hoberecht, Mark A.↗
NASA NTRSDate not supplied

Ground Test Stand Development for One-step Electrochemical Production of High-Pressure Oxygen

NASA designed a test rig, High-Pressure Oxygen Generation Assembly (HPOGA) to test a novel method of electrolysis as an alternative technology to the state-of-the-art Oxygen Generation Assembly (OGA) currently on the International Space Station (ISS). This approach involves utilizing a specialized electrolysis cell stack designed to both generate and compress high-pressure oxygen up to 3600 PSIG. The design eliminates the need for an external compressor and hydrogen separator, streamlining the oxygen generation process. HPOGA tests the viability of an electrolysis cell stack for extended life usage. Within the system, there are several key subsystems: nitrogen, high/low pressure oxygen, hydrogen, water recirculation, and water injection. The water injection subsystem supplies deionized (DI) water to a centralized reservoir for consumption. Subsequently, a water recirculation loop transfers the DI water across the cathode side of the electrolysis cell stack with constant flow rate. The result is a supply of hydrogen in the water loop and oxygen accumulation on the anode side of the cell stack. Hydrogen is evaporated out as part of the hydrogen sub-system which also measures hydrogen/oxygen concentration for safety. The oxygen subsystem is responsible for managing high pressure oxygen, O2 exhaust, and conducting hydrogen/oxygen concentration measurements. The nitrogen subsystem serves dual functions, purging the hydrogen/oxygen subsystems, and regulating pressure in both high/low-pressure O2 sections via pneumatic back pressure regulators. Various sensors monitor pressure, temperature, humidity, gas concentration and flow rate in each subsystem. This paper presents the design and testing of a comprehensive test stand, which serves to operate and functionally verify the performance of the electrolysis cell while offering valuable lessons learned.

electrolysis↗
NASA NTRS2003

Performance Evaluation of Electrochem's PEM Fuel Cell Power Plant for NASA's 2nd Generation Reusable Launch Vehicle

NASA's Next Generation Launch Technology (NGLT) program is being developed to meet national needs for civil and commercial space access with goals of reducing the launch costs, increasing the reliability, and reducing the maintenance and operating costs. To this end, NASA is considering an all- electric capability for NGLT vehicles requiring advanced electrical power generation technology at a nominal 20 kW level with peak power capabilities six times the nominal power. The proton exchange membrane (PEM) fuel cell has been identified as a viable candidate to supply this electrical power; however, several technology aspects need to be assessed. Electrochem, Inc., under contract to NASA, has developed a breadboard power generator to address these technical issues with the goal of maximizing the system reliability while minimizing the cost and system complexity. This breadboard generator operates with dry hydrogen and oxygen gas using eductors to recirculate the gases eliminating gas humidification and blowers from the system. Except for a coolant pump, the system design incorporates passive components allowing the fuel cell to readily follow a duty cycle profile and that may operate at high 6:1 peak power levels for 30 second durations. Performance data of the fuel cell stack along with system performance is presented to highlight the benefits of the fuel cell stack design and system design for NGLT vehicles.

Kimble, Michael C.↗
NASA NTRS2003

SUMI - The Solar Ultraviolet Magnetograph Investigation

Solar physics has been successful in characterizing the full vector magnetic field in the photosphere, where the ratio of gas pressure to magnetic pressure (Beta) is >1. However, at higher levels in the atmosphere, where Beta <<1 and flares and CMEs are believed to be triggered, observations are difficult, severely limiting the understanding of these processes. In response to this situation, we are developing SUMI (the Solar Ultraviolet Magnetograph Investigation) a unique instrument designed to measure the circular and linear polarization of upper chromospheric Mg II lines (280 nm) and circular polarization of transition region C IV lines (155 nm). To date the telescope mirrors have been built, tested and coated with dielectric stacks designed to reflect only the wavelengths of interest. We have also developed a unique UV polarimeter and completed the design of a high-resolution spectrograph that uses dual toroidal varied- line-space (TVLS) gratings. Incorporating measurements of those components developed so far, the revised estimate of the system throughput exceeds our original estimate by more than an order of magnitude. A sounding rocket flight is anticipated in 2006. Our objectives and progress are detailed in this presentation.

Porter, J. G.↗