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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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The objective of this study is to propose a new total hydrogen containment process to enable the testing required for NTP engine development. This H2 removal process comprises of two unit operations: an oxygen-rich burner and a shell-and-tube type of heat exchanger. This new process is demonstrated by simulation of the steady state operation of the engine firing at nominal conditions.
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The systems engineering process for thermal nuclear propulsion requirements and configuration definition is described in outline and graphic form. Functional analysis and mission attributes for a Mars exploration mission are also addressed.
Cryogenic rocket engines requiring a cooling process to thermally condition the engine to operating temperature can be made more efficient if cooling propellants can be burned. Tank head idle and pumped idle modes can be used to burn propellants employed for cooling, thereby providing useful thrust. Such idle modes required the use of a heat exchanger to vaporize oxygen prior to injection into the combustion chamber. During December 1988, Pratt and Whitney conducted a series of engine hot firing demonstrating the operation of two new, previously untested oxidizer heat exchanger designs. The program was a second iteration of previous low thrust testing conducted in 1984, during which a first-generation heat exchanger design was used. Although operation was demonstrated at tank head idle and pumped idle, the engine experienced instability when propellants could not be supplied to the heat exchanger at design conditions.
A probabilistic thermal margin process has been performed to design the flexible thermal protection system (FTPS) and select entry trajectory constraints given an acceptable risk level for the Low-Earth Orbit Flight Test of and Inflatable Decelerator (LOFTID) project. Uncertainties exist in atmospheric entry aeroheating environments and the predicted thermal response of thermal protection system (TPS) material. Entry vehicle TPS is often over-sized to mitigate uncertainty by combining conservative bounding scenarios together. The probabilistic thermal margin process allows engineers to make informed aeroshell design, flight design, and FTPS performance risk trades while preventing excessive FTPS margin from being applied. This paper describes the uncertainty analysis methodology used to carry out a probabilistic thermal margin process used for LOFTID’s aeroshell and explains how the calculated probability of exceeding flight allowable temperatures is used to design the FTPS and establish nominal flight design constraints. This probabilistic thermal margin process had never been applied to entry, decent, and landing design for a flown entry vehicle and it is one of the LOFTID project’s goals to demonstrate its merits.
The Instrument Design Laboratory (IDL), part of NASA Goddard Space Flight Center’s Integrated Design Center (IDC), is a concurrent and collaborative environment which allows for rapid development of science instrumentation concepts within the span of less than two weeks. Science goals set by a Principal Investigator from government, industry or academia are translated into engineering requirements, from which a team of engineers spanning multiple disciplines use an established study process and a suite of analysis tools to work towards an instrument point design. As part of this process, a staff thermal engineer is tasked with designing a thermal control system which meets all incoming thermal requirements, while iterating real-time with other subsystems to ensure compatibility and functionality as a completed system. Thermal engineers on spaceflight projects typically have weeks or months to develop thermal models. However, the severe time limitation in this conceptual study setting makes thermal design particularly difficult, as rapid thermal modeling solely over the span of a few days is required to develop the instrument thermal design and understand the performance over its intended mission, especially if the instrument concept contains multiple thermal challenges such as dynamic environments or high heat dissipating components. In this paper, the authors provide a condensed guide for the most efficient ways to develop thermal models and conduct thermal analysis within the span of one-to-two weeks, as informed by decades of design experience and best practices in the IDL. The authors also focus on quick methods for determining worst-case thermal environments, deciding which modeling details are essential at this early phase, and quantifying the engineering resources necessary for thermal control. This paper concludes with specific thermal design tips for different instrument types across the electromagnetic spectrum.
A process for depositing a mullite coating on a silicon-based material, such as those used to form articles exposed to high temperatures and including the hostile thermal environment of a gas turbine engine. The process is generally to thermally spray a mullite powder to form a mullite layer on a substrate, in which the thermal spraying process is performed so that the mullite powder absorbs a sufficient low level of energy from the thermal source to prevent evaporation of silica from the mullite powder. Processing includes deposition parameter adjustments or annealing to maintain or reestablish phase equilibrium in the mullite layer, so that through-thickness cracks in the mullite layer are avoided.
A process for depositing a mullite coating on a silicon-based material, such as those used to form articles exposed to high temperatures and including the hostile thermal environment of a gas turbine engine. The process is generally to thermally spray a mullite powder to form a mullite layer on a substrate, in which the thermal spraying process is performed so that the mullite powder absorbs a sufficient low level of energy from the thermal source to prevent evaporation of silica from the mullite powder. Processing includes deposition parameter adjustments or annealing to maintain or reestablish phase equilibrium in the mullite layer, so that through-thickness cracks in the mullite layer are avoided.
System Design, Development, and Fabrication: Design, develop, and fabricate or procure MB-60 component hardware compliant with the imposed technical requirements and in sufficient quantities to fulfill the overall MB-60 development effort. System Development, Assembly, and Test: Manage the scope of the development, assembly, and test-related activities for MB-60 development. This scope includes engine-level development planning, engine assembly and disassembly, test planning, engine testing, inspection, anomaly resolution, and development of necessary ground support equipment and special test equipment. System Integration: Provide coordinated integration in the realms of engineering, safety, quality, and manufacturing disciplines across the scope of the MB-60 design and associated products development Safety and Mission Assurance, structural design, fracture control, materials and processes, thermal analysis. Systems Engineering and Analysis: Manage and perform Systems Engineering and Analysis to provide rigor and structure to the overall design and development effort for the MB-60. Milestone reviews, requirements management, system analysis, program management support Program Management: Manage, plan, and coordinate the activities across all portions of the MB-60 work scope by providing direction for program administration, business management, and supplier management.
Material systems and processes for the development of effective and durable thermal barriers for heavy duty diesel engines were investigated. Seven coating systems were evaluated for thermal conductivity, erosion resistance, corrosion/oxidation resistance, and thermal shock resistance. An advanced coating system based on plasma sprayed particle yttria stabilized zirconia (PS/HYSZ) was judged superior in these tests. The measured thermal conductivity of the selected coating was 0.893 W/m C at 371 C. The PS/HYSZ coating system was applied to the piston crown, fire deck and valves of a single cylinder low heat rejection diesel engine. The coated engine components were tested for 24 hr at power levels from 0.83 MPa to 1.17 MPa brake mean effective pressure. The component coatings survived the engine tests with a minimum of distress. The measured fire deck temperatures decreased 86 C (155 F) on the intake side and 42 C (75 F) on the exhaust side with the coating applied.
This paper presents results of development testing of various solar thermal parabolic dish modules and assemblies. Most of the tests were at modules and assemblies that used a dish-mounted, organic Rankine cycle turbine for production of electric power. Some tests were also run on equipment for production of process steam or for production of electricity using dish-mounted reciprocating steam engines. These tests indicate that early modules achieve efficiencies of about 18 percent in converting sunlight to electricity (excluding the inverter but including parasitics). A number of malfunctions occurred. The performance measurements, as well as the malfunctions and other operating experience, provided information that should be of value in developing systems with improved performance and reduced maintenance.
The NASA project to develop In-Situ Resource Utilization (ISRU) technologies, in partnership with commercial and international collaborators, has achieved full system demonstrations of oxygen production using native regolith simulants. These demonstrations included robotic extraction of material from the terrain, sealed encapsulation of material in a pressurized reactor; chemical extraction of oxygen from the material in the form of water, and the electrolysis of water into oxygen and hydrogen for storage and reuse. These successes have provided growing confidence in the prospects of ISRU oxygen production as a credible source for critical mission consumables in preparation for and during crewed missions to the moon and other destinations. Other ISRU processes, especially relevant to early lunar exploration scenarios, have also been shown to be practical, including the extraction of subsurface volatiles, especially water, and the thermal processing of surface materials for civil engineering uses and for thermal energy storage. This paper describes these recent achievements and current NASA ISRU development and demonstration activity. The ability to extract and process resources at the site of exploration into useful products such as propellants, life support and power system consumables; and radiation and rocket exhaust plume debris shielding, known as In-Situ Resource Utilization or ISRU, has the potential to significantly reduce the launch mass, risk, and cost of robotic and human exploration of space. The incorporation of ISRU into missions can also significantly influence technology selection and system development in other areas such as power, life support, and propulsion. For example. the ability to extract or produce large amounts of oxygen and/or water in-situ could minimize the need to completely close life support air and water processing system cycles, change thermal and radiation protection of habitats, and influence propellant selection for ascent vehicles and surface propulsive hoppers. While concepts and even laboratory work on evaluating and developing ISRU techniques such as oxygen extraction from lunar regolith have been going on since before the Apollo 11 Moon landing, no ISRU system has ever flown in space, and only recently have ISRU technologies been developed at a scale and at a system level that is relevant to actual robotic and human mission applications. Because ISRU hardware and systems have never been demonstrated or utilized before on robotic or human missions, architecture and mission planners and surface system hardware developers are hesitant to rely on ISRU products and services that are critical to mission and system implementation success. To build confidence in ISRU systems for future missions and assess how ISRU systems can best influence and integrate with other surface system elements, NASA, with international partners, are performing analog field tests to understand how to take advantage of ISRU capabilities and benefits with the minimum of risk associated with introducing this game-changing approach to exploration. This paper will describe and review the results of four analog field tests (Moses Lake in 6/08, Mauna Kea in 11/08. Flagstaff in 9/09; and Mauna Kea in 1/10) that have begun the process of integrating ISRU into robotic and human exploration systems and missions, and propose future ISRU-related analog field test activities that can be performed in collaboration with international space agencies.
This paper describes the process development for fabricating a high thermal conductivity NARloy-Z-Diamond composite (NARloy-Z-D) combustion chamber liner for application in advanced rocket engines. The fabrication process is challenging and this paper presents some details of these challenges and approaches used to address them. Prior research conducted at NASA-MSFC and Penn State had shown that NARloy-Z-40%D composite material has significantly higher thermal conductivity than the state of the art NARloy-Z alloy. Furthermore, NARloy-Z-40 %D is much lighter than NARloy-Z. These attributes help to improve the performance of the advanced rocket engines. Increased thermal conductivity will directly translate into increased turbopump power, increased chamber pressure for improved thrust and specific impulse. Early work on NARloy-Z-D composites used the Field Assisted Sintering Technology (FAST, Ref. 1, 2) for fabricating discs. NARloy-Z-D composites containing 10, 20 and 40vol% of high thermal conductivity diamond powder were investigated. Thermal conductivity (TC) data. TC increased with increasing diamond content and showed 50% improvement over pure copper at 40vol% diamond. This composition was selected for fabricating the combustion chamber liner using the FAST technique.
The intent of mechanical design is to deliver a hardware product that meets or exceeds customer expectations, while reducing cycle time and cost. To this end, an integrated mechanical design process enables the idea of parallel development (concurrent engineering). This represents a shift from the traditional mechanical design process. With such a concurrent process, there are significant issues that have to be identified and addressed before re-engineering the mechanical design process to facilitate concurrent engineering. These issues also assist in the integration and re-engineering of the thermal design sub-process since it resides within the entire mechanical design process. With these issues in mind, a thermal design sub-process can be re-defined in a manner that has a higher probability of acceptance, thus enabling an integrated mechanical design process. However, the actual implementation is not always problem-free. Experience in applying the thermal design sub-process to actual situations provides the evidence for improvement, but more importantly, for judging the viability and feasibility of the sub-process.
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Solar-thermal receiver used with circular parabolic concentrator to supply about 58 kW thermal power to Brayton engine or industrial process. Solar radiation focused into open end of cylindrical ceramic thermal inertial sleeve 8 in. in diameter that reradiates energy to helical heatexchanger tube surrounding sleeve.
The Thermal Spray Laboratory at NASA's Marshall Space Flight Center has developed and demonstrated a fabrication technique using Vacuum Plasma Spray (VPS) to form structural components from a tungsten/rhenium alloy. The components were assembled into an absorption cavity for a fully-functioning, ground test unit of a solar thermal propulsion engine. The VPS process deposits refractory metal onto a graphite mandrel of the desired shape. The mandrel acts as a male mold, forming the required contour and dimensions of the inside surface of the deposit. Tungsten and tungsten/25% rhenium were used in the development and production of several absorber cavity components. These materials were selected for their high temperature (less than 2500 C) strength. Each absorber cavity comprises 3 coaxial shells with two, double-helical flow passages through which the propellant gas flows. This paper describes the processing techniques, design considerations, and process development associated with forming these engine components.
This slide presentation reviews the validation of the thermal design for the Mars Scout Phoenix Payload. It includes a description of the Phoenix Mission, the science objectives, the timeline, and the flight system and payloads that were on the lander. The initial responsibility for the development and validation the thermal design was with the developers. This process lacked overall system engineering, there was a difference of thermal expertise, and the number of institutions involved complicated the interactions. The revised approach for payload thermal design validation is described.