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All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Free-Piston Stirling Power Conversion Unit for Fission Power System, Phase II Final Report

In Phase II, the manufacture and testing of two 6-kW(sub e)Stirling engines was completed. The engines were delivered in an opposed 12-kW(sub e) arrangement with a common expansion space heater head. As described in the Phase I report, the engines were designed to be sealed both hermetically and with a bolted O-ring seal. The completed Phase II convertor is in the bolted configuration to allow future disassembly. By the end of Phase II, the convertor had passed all of the final testing requirements in preparation for delivery to the NASA Glenn Research Center. The electronic controller also was fabricated and tested during Phase II. The controller sets both piston amplitudes and maintains the phasing between them. It also sets the operating frequency of the machine. Details of the controller are described in the Phase I final report. Fabrication of the direct-current to direct-current (DC-DC) output stage, which would have stepped down the main controller output voltage from ~700 to 120 V(sub DC), was omitted from this phase of the project for budgetary reasons. However, the main controller was successfully built, tested with the engines, and delivered. We experienced very few development issues with this high-power controller. The project extended significantly longer than originally planned because of yearly funding delays. The team also experienced several hardware difficulties along the development path. Most of these were related to the different thermal expansions of adjacent parts constructed of different materials. This issue was made worse by the large size of the machine. Thermal expansion problems also caused difficulties in the brazing of the opposed stainless steel sodium-potassium (NaK) heater head. Despite repeated attempts Sunpower was not able to successfully braze the opposed head under this project. Near the end of the project, Glenn fabricated an opposed Inconel NaK head, which was installed prior to delivery for testing at Glenn. Engine development prior to this was performed using both single- and dual-opposed (common expansion space) Inconel heads with clamp-on electric heaters.

Free-piston Stirling Power Conversion Unit↗
NASA NTRS2010

Free-Piston Stirling Power Conversion Unit for Fission Surface Power, Phase I Final Report

This report summarizes the design of a 12 kW dual opposed free-piston Stirling convertor and controller for potential future use in space missions. The convertor is heated via a pumped NaK loop and cooling is provided by a pumped water circuit. Convertor efficiency is projected at 27 percent (AC electrical out/heat in). The controller converts the AC electrical output to 120 Vdc and is projected at 91 percent efficiency. A mechanically simple arrangement, based on proven technology, was selected in which the piston is resonated almost entirely by the working space pressure swing, while the displacer is resonated by planar mechanical springs in the bounce space.

Wood, J. Gary↗
NASA NTRS2016

Fission Surface Power Technology Demonstration Unit Test Results

The Fission Surface Power (FSP) Technology Demonstration Unit (TDU) is a system-level demonstration of fission power technology intended for use on manned missions to Mars. The Baseline FSP systems consists of a 190 kWt UO2 fast-spectrum reactor cooled by a primary pumped liquid metal loop. This liquid metal loop transfers heat to two intermediate liquid metal loops designed to isolate fission products in the primary loop from the balance of plant. The intermediate liquid metal loops transfer heat to four Stirling Power Conversion Units (PCU), each of which produce 12 kWe (48 kW total) and reject waste heat to two pumped water loops, which transfer the waste heat to titanium-water heat pipe radiators. The FSP TDU simulates a single leg of the baseline FSP system using an electrically heater core simulator, a single liquid metal loop, a single PCU, and a pumped water loop which rejects the waste heat to a Facility Cooling System (FCS). When operated at the nominal operating conditions (modified for low liquid metal flow) during TDU testing the PCU produced 8.9 kW of power at an efficiency of 21.7% resulting in a net system power of 8.1 kW and a system level efficiency of 17.2%. The reduction in PCU power from levels seen during electrically heated testing is the result of insufficient heat transfer from the NaK heater head to the Stirling acceptor, which could not be tested at Sunpower prior to delivery to GRC. The maximum PCU power of 10.4 kW was achieved at the maximum liquid metal temperature of 875 K, minimum water temperature of 350 K, 1.1 kg/s liquid metal flow, 0.39 kg/s water flow, and 15.0 mm amplitude at an efficiency of 23.3%. This resulted in a system net power of 9.7 kW and a system efficiency of 18.7 %.

fission power technology↗
NASA NTRS1985

Activity and accomplishments of dish/Stirling electric power system development

The development of the solar parabolic-dish/Stirling-engine electricity generating plant known as the dish/Stirling electric power system is described. The dish/Stirling electric power system converts sunlight to electricity more efficiently than any known existing solar electric power system. The fabrication and characterization of the test bed concentrators that were used for Stirling module testing and of the development of parabolic dish concentrator No. 2, an advanced solar concentrator unit considered for use with the Stirling power conversion unit is discussed.

Livingston, F. R.↗
NASA NTRS2016

Fission Surface Power Technology Demonstration Unit Test Results

The Fission Surface Power (FSP) Technology Demonstration Unit (TDU) is a system-level demonstration of fission power technology intended for use on manned missions to Mars. The Baseline FSP systems consists of a 190 kWt UO2 fast-spectrum reactor cooled by a primary pumped liquid metal loop. This liquid metal loop transfers heat to two intermediate liquid metal loops designed to isolate fission products in the primary loop from the balance of plant. The intermediate liquid metal loops transfer heat to four Stirling Power Conversion Units (PCU), each of which produce 12 kWe (48 kW total) and reject waste heat to two pumped water loops, which transfer the waste heat to titanium-water heat pipe radiators. The FSP TDU simulates a single leg of the baseline FSP system using an electrically heater core simulator, a single liquid metal loop, a single PCU, and a pumped water loop which rejects the waste heat to a Facility Cooling System (FCS). When operated at the nominal operating conditions (modified for low liquid metal flow) during TDU testing the PCU produced 8.9 kW of power at an efficiency of 21.7 percent resulting in a net system power of 8.1 kW and a system level efficiency of 17.2 percent. The reduction in PCU power from levels seen during electrically heated testing is the result of insufficient heat transfer from the NaK heater head to the Stirling acceptor, which could not be tested at Sunpower prior to delivery to the NASA Glenn Research Center (GRC). The maximum PCU power of 10.4 kW was achieved at the maximum liquid metal temperature of 875 K, minimum water temperature of 350 K, 1.1 kg/s liquid metal flow, 0.39 kg/s water flow, and 15.0 mm amplitude at an efficiency of 23.3 percent. This resulted in a system net power of 9.7 kW and a system efficiency of 18.7 percent.

Facility Cooling System↗
NASA NTRS2013

Cold-End Subsystem Testing for the Fission Power System Technology Demonstration Unit

The Fission Power System (FPS) Technology Demonstration Unit (TDU) consists of a pumped sodiumpotassium (NaK) loop that provides heat to a Stirling Power Conversion Unit (PCU), which converts some of that heat into electricity and rejects the waste heat to a pumped water loop. Each of the TDU subsystems is being tested independently prior to full system testing at the NASA Glenn Research Center. The pumped NaK loop is being tested at NASA Marshall Space Flight Center; the Stirling PCU and electrical controller are being tested by Sunpower Inc.; and the pumped water loop is being tested at Glenn. This paper describes cold-end subsystem setup and testing at Glenn. The TDU cold end has been assembled in Vacuum Facility 6 (VF 6) at Glenn, the same chamber that will be used for TDU testing. Cold-end testing in VF 6 will demonstrate functionality; validated coldend fill, drain, and emergency backup systems; and generated pump performance and system pressure drop data used to validate models. In addition, a low-cost proof-of concept radiator has been built and tested at Glenn, validating the design and demonstrating the feasibility of using low-cost metal radiators as an alternative to highcost composite radiators in an end-to-end TDU test.

Briggs, Mazwell↗
NASA NTRS2013

Cold-end Subsystem Testing for the Fission Power System Technology Demonstration Unit

The Fission Power System (FPS) Technology Demonstration Unit (TDU) consists of a pumped sodium-potassium (NaK) loop that provides heat to a Stirling Power Conversion Unit (PCU), which converts some of that heat into electricity and rejects the waste heat to a pumped water loop. Each of the TDU subsystems is being tested independently prior to full system testing at the NASA Glenn Research Center. The pumped NaK loop is being tested at NASA Marshall Space Flight Center; the Stirling PCU and electrical controller are being tested by Sunpower Inc.; and the pumped water loop is being tested at Glenn. This paper describes cold-end subsystem setup and testing at Glenn. The TDU cold end has been assembled in Vacuum Facility 6 (VF 6) at Glenn, the same chamber that will be used for TDU testing. Cold-end testing in VF 6 will demonstrate functionality; validated cold-end fill, drain, and emergency backup systems; and generated pump performance and system pressure drop data used to validate models. In addition, a low-cost proof-of concept radiator has been built and tested at Glenn, validating the design and demonstrating the feasibility of using low-cost metal radiators as an alternative to high-cost composite radiators in an end-to-end TDU test.

Briggs, Maxwell↗
NASA NTRS2010

Testing of Liquid Metal Components for Nuclear Surface Power Systems

The Early Flight Fission Test Facility (EFF-TF) was established by the Marshall Space Flight Center (MSFC) to provide a capability for performing hardware-directed activities to support multiple in-space nuclear reactor concepts by using a non-nuclear test methodology. This includes fabrication and testing at both the module/component level and near prototypic reactor configurations. The EFF-TF is currently supporting an effort to develop an affordable fission surface power (AFSP) system that could be deployed on the Lunar surface. The AFSP system is presently based on a pumped liquid metal-cooled (Sodium-Potassium eutectic, NaK-78) reactor design. This design was derived from the only fission system that the United States has deployed for space operation, the Systems for Nuclear Auxiliary Power (SNAP) 10A reactor, which was launched in 1965. Two prototypical components recently tested at MSFC were a pair of Stirling power conversion units that would be used in a reactor system to convert heat to electricity, and an annular linear induction pump (ALIP) that uses travelling electromagnetic fields to pump the liquid metal coolant through the reactor loop. First ever tests were conducted at MSFC to determine baseline performance of a pair of 1 kW Stirling convertors using NaK as the hot side working fluid. A special test rig was designed and constructed and testing was conducted inside a vacuum chamber at MSFC. This test rig delivered pumped NaK for the hot end temperature to the Stirlings and water as the working fluid on the cold end temperature. These test were conducted through a hot end temperature range between 400 to 550C in increments of 50 C and a cold end temperature range from 30 to 70 C in 20 C increments. Piston amplitudes were varied from 6 to 1 1mm in .5 mm increments. A maximum of 2240 Watts electric was produced at the design point of 550 hot end, 40 C cold end with a piston amplitude of 10.5mm. This power level was reached at a gross thermal efficiency of 28%. A baseline performance map was established for the pair of 1kW Stirling convertors. The performance data will then be used for design modification to the Stirling convertors. The ALIP tested at MSFC has no moving parts and no direct electrical connections to the liquid metal containing components. Pressure is developed by the interaction of the magnetic field produced by the stator and the current which flows as a result of the voltage induced in the liquid metal contained in the pump duct. Flow is controlled by variation of the voltage supplied to the pump windings. Under steady-state conditions, pump performance is measured for flow rates from 0.5-4.3 kg/s. The pressure rise developed by the pump to support these flow rates is roughly 5-65 kPa. The RMS input voltage (phase-to-phase voltage) ranges from 5-120 V, while the frequency can be varied arbitrarily up to 60 Hz. Performance is quantified at different loop temperature levels from 50 C up to 650 C, which is the peak operating temperature of the proposed AFSP reactor. The transient response of the pump is also evaluated to determine its behavior during startup and shut-down procedures.

Polzin, Kurt A.↗
NASA NTRS2015

Pressure Loss Predictions of the Reactor Simulator Subsystem at NASA GRC

Testing of the Fission Power System (FPS) Technology Demonstration Unit (TDU) is being conducted at NASA GRC. The TDU consists of three subsystems: the Reactor Simulator (RxSim), the Stirling Power Conversion Unit (PCU), and the Heat Exchanger Manifold (HXM). An Annular Linear Induction Pump (ALIP) is used to drive the working fluid. A preliminary version of the TDU system (which excludes the PCU for now), is referred to as the RxSim subsystem and was used to conduct flow tests in Vacuum Facility 6 (VF 6). In parallel, a computational model of the RxSim subsystem was created based on the CAD model and was used to predict loop pressure losses over a range of mass flows. This was done to assess the ability of the pump to meet the design intent mass flow demand. Measured data indicates that the pump can produce 2.333 kg/sec of flow, which is enough to supply the RxSim subsystem with a nominal flow of 1.75 kg/sec. Computational predictions indicated that the pump could provide 2.157 kg/sec (using the Spalart-Allmaras turbulence model), and 2.223 kg/sec (using the k- turbulence model). The computational error of the predictions for the available mass flow is -0.176 kg/sec (with the S-A turbulence model) and -0.110 kg/sec (with the k-epsilon turbulence model) when compared to measured data.

Turbulence Models↗
NASA NTRS2016

Pressure Loss Predictions of the Reactor Simulator Subsystem at NASA Glenn Research Center

Testing of the Fission Power System (FPS) Technology Demonstration Unit (TDU) is being conducted at NASA Glenn Research Center. The TDU consists of three subsystems: the reactor simulator (RxSim), the Stirling Power Conversion Unit (PCU), and the heat exchanger manifold (HXM). An annular linear induction pump (ALIP) is used to drive the working fluid. A preliminary version of the TDU system (which excludes the PCU for now) is referred to as the "RxSim subsystem" and was used to conduct flow tests in Vacuum Facility 6 (VF 6). In parallel, a computational model of the RxSim subsystem was created based on the computer-aided-design (CAD) model and was used to predict loop pressure losses over a range of mass flows. This was done to assess the ability of the pump to meet the design intent mass flow demand. Measured data indicates that the pump can produce 2.333 kg/sec of flow, which is enough to supply the RxSim subsystem with a nominal flow of 1.75 kg/sec. Computational predictions indicated that the pump could provide 2.157 kg/sec (using the Spalart-Allmaras (S‒A) turbulence model) and 2.223 kg/sec (using the k- turbulence model). The computational error of the predictions for the available mass flow is ‒0.176 kg/sec (with the S-A turbulence model) and -0.110 kg/sec (with the k- turbulence model) when compared to measured data.

Mass Flow↗
NASA NTRS1984

United Stirling's Solar Engine Development: the Background for the Vanguard Engine

The development and testing resulting in the Vanguard engine and some of the characteristics of the Stirling engine based power conversion unit are described. The major part of the solar engine development is concentrated to the three different areas, the receiver, the lubrication system and the control system. Five engines are on test within the solar project. The function of the components are validated in actual solar tests.

Holgersson, S.↗
NASA NTRS2010

Recent Advances in Power Conversion and Heat Rejection Technology for Fission Surface Power

Under the Exploration Technology Development Program, the National Aeronautics and Space Administration (NASA) and the Department of Energy (DOE) are jointly developing Fission Surface Power (FSP) technology for possible use in human missions to the Moon and Mars. A preliminary reference concept was generated to guide FSP technology development. The concept consists of a liquid-metal-cooled reactor, Stirling power conversion, and water heat rejection, with Brayton power conversion as a backup option. The FSP project has begun risk reduction activities on some key components with the eventual goal of conducting an end-to-end, non-nuclear, integrated system test. Several power conversion and heat rejection hardware prototypes have been built and tested. These include multi-kilowatt Stirling and Brayton power conversion units, titanium-water heat pipes, and composite radiator panels.

Mason, Lee↗
NASA NTRS2017

Electrically Heated Testing of the Kilowatt Reactor Using Stirling Technology (KRUSTY) Experiment Using a Depleted Uranium Core

The Kilopower project aims to develop and demonstrate scalable fission-based power technology for systems capable of delivering 110 kW of electric power with a specific power ranging from 2.5 - 6.5 Wkg. This technology could enable high power science missions or could be used to provide surface power for manned missions to the Moon or Mars. NASA has partnered with the Department of Energys National Nuclear Security Administration, Los Alamos National Labs, and Y-12 National Security Complex to develop and test a prototypic reactor and power system using existing facilities and infrastructure. This technology demonstration, referred to as the Kilowatt Reactor Using Stirling TechnologY (KRUSTY), will undergo nuclear ground testing in the summer of 2017 at the Nevada Test Site. The 1 kWe variation of the Kilopower system was chosen for the KRUSTY demonstration. The concept for the 1 kWe flight system consist of a 4 kWt highly enriched Uranium-Molybdenum reactor operating at 800 degrees Celsius coupled to sodium heat pipes. The heat pipes deliver heat to the hot ends of eight 125 W Stirling convertors producing a net electrical output of 1 kW. Waste heat is rejected using titanium-water heat pipes coupled to carbon composite radiator panels. The KRUSTY test, based on this design, uses a prototypic highly enriched uranium-molybdenum core coupled to prototypic sodium heat pipes. The heat pipes transfer heat to two Advanced Stirling Convertors (ASC-E2s) and six thermal simulators, which simulate the thermal draw of full scale power conversion units. Thermal simulators and Stirling engines are gas cooled. The most recent project milestone was the completion of non-nuclear system level testing using an electrically heated depleted uranium (non-fissioning) reactor core simulator. System level testing at the Glenn Research Center (GRC) has validated performance predictions and has demonstrated system level operation and control in a test configuration that replicates the one to be used at the Device Assembly Facility (DAF) at the Nevada National Security Site. Fabrication, assembly, and testing of the depleted uranium core has allowed for higher fidelity system level testing at GRC, and has validated the fabrication methods to be used on the highly enriched uranium core that will supply heat for the DAF KRUSTY demonstration.

Briggs, Maxwell H.↗
NASA NTRS2018

Electrically Heated Testing of the Kilowatt Reactor Using Stirling TechnologY (KRUSTY) Experiment Using a Depleted Uranium Core

The Kilopower project aims to develop and demonstrate scalable fission-based power technology for systems capable of delivering 1 to 10 kW of electric power with a specific power ranging from 2.5 to 6.5 W/kg. This technology could enable high-power science missions or could be used to provide surface power for manned missions to the Moon or Mars. NASA has partnered with the U.S. Department of Energy's National Nuclear Security Administration, Los Alamos National Laboratory, Nevada National Security Site (NNSS), and Y−12 National Security Complex to develop and test a prototypic reactor and power system using existing facilities and infrastructure. This technology demonstration, referred to as the "Kilowatt Reactor Using Stirling TechnologY (KRUSTY)," will undergo nuclear ground testing by the end of calendar year (CY) 2017 at the NNSS. The 1-kWe variation of the Kilopower system was chosen for the KRUSTY demonstration. The concept for the 1-kWe flight system consists of a 4 kWt highly enriched uranium-molybdenum reactor operating at 800 degC coupled to sodium heat pipes. The heat pipes deliver heat to the hot ends of eight 125-W Stirling convertors producing a net electrical output of 1 kW. Waste heat is rejected using titanium-water heat pipes coupled to carbon composite radiator panels. The KRUSTY test, based on this design, uses a prototypic highly enriched uranium-molybdenum core coupled to prototypic sodium heat pipes. The heat pipes transfer heat to two Advanced Stirling Convertors (ASC−E2s) and six thermal simulators, which simulate the thermal draw of full-scale power conversion units. Thermal simulators and Stirling engines are gas cooled. The most recent project milestone was the completion of nonnuclear system-level testing using an electrically heated depleted uranium (DU) (nonfissioning) reactor core simulator at the NASA Glenn Research Center. System-level testing has validated performance predictions and has demonstrated system-level operation and control in a test configuration that replicates the one to be used at the Device Assembly Facility (DAF) at the NNSS. Fabrication, assembly, and testing of the DU core has allowed for higher fidelity system-level testing at Glenn, and has validated the fabrication methods to be used on the highly enriched uranium core that will supply heat for the DAF KRUSTY demonstration.

Briggs, Maxwell H.↗
NASA NTRS1988

Summary of aerospace and nuclear engineering activities

The Texas A&M Nuclear and Aerospace engineering departments have worked on five different projects for the NASA/USRA Advanced Design Program during the 1987/88 year. The aerospace department worked on two types of lunar tunnelers that would create habitable space. The first design used a heated cone to melt the lunar regolith, and the second used a conventional drill to bore its way through the crust. Both used a dump truck to get rid of waste heat from the reactor as well as excess regolith from the tunneling operation. The nuclear engineering department worked on three separate projects. The NEPTUNE system is a manned, outer-planetary explorer designed with Jupiter exploration as the baseline mission. The lifetime requirement for both reactor and power-conversion systems was twenty years. The second project undertaken for the power supply was a Mars Sample Return Mission power supply. This was designed to produce 2 kW of electrical power for seven years. The design consisted of a General Purpose Heat Source (GPHS) utilizing a Stirling engine as the power conversion unit. A mass optimization was performed to aid in overall design. The last design was a reactor to provide power for propulsion to Mars and power on the surface. The requirements of 300 kW of electrical power output and a mass of less than 10,000 Rg were set. This allowed the reactor and power conversion unit to fit within the Space Shuttle cargo bay.

Source record↗
NASA NTRS1993

Lunar electric power systems utilizing the SP-100 reactor coupled to dynamic conversion systems

An integration study was performed by Rocketdyne under contract to NASA-LeRC. The study was concerned with coupling an SP-0100 reactor to either a Brayton or Stirling power conversion system. The application was for a surface power system to supply power requirements to a lunar base. A power level of 550 kWe was selected based on the NASA Space Exploration Initiative 90-day study. Reliability studies were initially performed to determine optimum power conversion redundancy. This study resulted in selecting three operating engines and one stand-by unit. Integration design studies indicated that either the Brayton or Stirling power conversion systems could be integrated with the PS-100 reactor. The Stirling system had an integration advantage because of smaller piping size and fewer components. The Stirling engine, however, is more complex and heavier than the Brayton rotating unit, which tends to off-set the Stirling integration advantage. From a performance consideration, the Brayton had a 9 percent mass advantage, and the Stirling had a 50 percent radiator advantage.

Harty, Richard B.↗
NASA NTRS1991

Lunar electric power systems utilizing the SP-100 reactor coupled to dynamic conversion systems

An integration study was performed by coupling an SP-100 reactor to either a Brayton or Stirling power conversion subsystem. The application was for a surface power system to supply power requirements to a lunar base. A power level of 550 kWe was selected based on the NASA Space Exploration Initiative 90-day study. Reliability studies were initially performed to determine optimum power-conversion redundancy. This study resulted in selecting three operating engines and one standby unit. Integratiaon-design studies indicated that either the Brayton or Stirling power conversion subsystem could be integrated with the SP-100 reactor. The Stirling system had an integration advantage because of smaller piping size and fewer components. The Stirling engine, however, is more complex and heavier than the Brayton rotating unit, which tends to offset the Stirling integration advantage. From a performance consideration, the Brayton had a 9-percent mass advantage and the Stirling a 50-percent radiator-area advantage.

Harty, Richard B.↗
NASA NTRS1980

Cost and price estimate of Brayton and Stirling engines in selected production volumes

The methods used to determine the production costs and required selling price of Brayton and Stirling engines modified for use in solar power conversion units are presented. Each engine part, component and assembly was examined and evaluated to determine the costs of its material and the method of manufacture based on specific annual production volumes. Cost estimates are presented for both the Stirling and Brayton engines in annual production volumes of 1,000, 25,000, 100,000 and 400,000. At annual production volumes above 50,000 units, the costs of both engines are similar, although the Stirling engine costs are somewhat lower. It is concluded that modifications to both the Brayton and Stirling engine designs could reduce the estimated costs.

Fortgang, H. R.↗