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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 NTRS2000

Thermally Regenerative Battery with Intercalatable Electrodes and Selective Heating Means

The battery contains at least one electrode such as graphite that intercalates a first species from the electrolyte disposed in a first compartment such as bromine to form a thermally decomposable complex during discharge. The other electrode can also be graphite which supplies another species such as lithium to the electrolyte in a second electrode compartment. The thermally decomposable complex is stable at room temperature but decomposes at elevated temperatures such as 50 C. to 150 C. The electrode compartments are separated by a selective ion permeable membrane that is impermeable to the first species. Charging is effected by selectively heating the first electrode.

Sharma, Pramod K.↗
NASA NTRSDate not supplied

Thermal Management Challenges and Technology Options for Lunar Regenerative Fuel Cells

Regenerative Fuel Cells (RFCs) enable lunar surface hardware, from pressurized rovers to surface habitats, to survive the lunar night by providing the required energy storage with a lower mass than state of the art battery systems. RFCs consist of fuel cell and electrolyzer electrochemical stack(s), a fluidic balance of plant, and electrical balance of plant. Fuel cells operate by converting the stored chemical energy of reactants into DC electrical power, heat, and water. When supplied DC power from an available external source, electrolyzers regenerate the reactants through electrolysis. The balance of plant is a critical part of the integrated system consisting of many individual components and provides fluid pressure management and conditioning, fluid storage, and thermal management. Component technology development is required to create an RFC system that will be capable of surviving the harsh lunar environment and maximize specific energy (W-hr/kg). One critical component requiring development includes a kW-scale high flux thermal switch. The primary requirement for the thermal switch is the ability to maintain low thermal resistance with the RFC heat rejection interface during the lunar day to maximize heat rejection while switching to a high thermal resistance during the lunar night such that the RFC can conserve as much thermal energy as possible. Different technology including freeze tolerant pumped loop, passive louvers, and variable conductance heat pipes were assessed as potential solutions. NASA is exploring development options through internal and external partnerships to develop this technology critical for a spaceflight RFC system.

Energy Storage↗
NASA NTRS2016

An Overview of Power, Energy Storage, and Conversion Efforts for 2014 SBIR Phases I and II

Technological innovation is the overall focus of NASA's Small Business Innovation Research (SBIR) program. The program invests in the development of innovative concepts and technologies to help NASA's mission directorates address critical research and development needs for agency projects. NASA's Small Business Innovation Research (SBIR) program focuses on technological innovation by investing in development of innovative concepts and technologies to help NASA mission directorates address critical research needs for Agency programs. This report highlights 15 of the innovative SBIR 2014 Phase I and II projects that focus on one of NASA Glenn Research Center's six core competencies-Power, Energy Storage and Conversion. The technologies cover a wide spectrum of applications such as high-radiation-tolerant ceramic voltage isolators, development of hermetic sealing glasses for solid oxide fuel cells, rechargeable lithium metal cells, high-efficiency direct methane solid oxide fuel cell systems, Li metal protection for high-energy space batteries, isolated bidirectional direct current converters for distributed battery energy applications, and high-efficiency rad-hard ultrathin Si photovoltaic cell technology for space. Each article describes an innovation and technical objective and highlights NASA commercial and industrial applications. This report provides an opportunity for NASA engineers, researchers, and program managers to learn how NASA SBIR technologies could help their programs and projects, and lead to collaborations and partnerships between the small SBIR companies and NASA that would benefit both.

flywheels↗
NASA NTRS1991

EMU evolution

Evolution of Extravehicular Mobility Unit (EMU) technology is necessary to support the Extravehicular Activity (EVA) requirements of the Space Station Freedom Program and those of the Space Exploration Initiative (SEI). Key qualities supporting long-duration missions include technologies that are highly reliable, durable, minimize logistics requirements, and are in-flight maintainable and serviceable. While these qualities are common to SSF and SEI EVA, development paths will differ where specific mission requirements impose different constraints. Development of reusable, regenerative technologies is necessary to minimize the logistics penalties. Increased battery discharge/recharge cycle life and usable wet life, compact high current density fuel cells, reusable CO2 absorbing media, and thermal radiation coupled with venting heat rejection technologies are just some methods of reducing consumables. Development must strive for durable, reliable systems that are in-flight serviceable and maintainable, which are vital for missions where logistics capabilities are extremely constrained. Key areas include suit components (e.g., gloves, boots, and cooling garments), and life support hardware such as fans, pumps, instrumentation, and emergency O2 systems. Higher pressure suits will reduce EVA prebreathe requirements and pre-EVA operations overall. Many challenges of higher pressure suits have been addressed by on-going development. Emphasis on glove development is necessary to provide low fatigue, dexterous glove mobility at higher suit pressures. Minimum impact hooks and scars which support an advanced SSF EMU have been identified. These accommodations permit upgrades that support servicing of low volume, high pressure oxygen systems, and hydrogen technologies such as fuel cell, and venting hydrogen heat rejection systems.

Rouen, M.↗
NASA NTRS1983

Space power technology into the 21st Century

The space power systems of the early 21st century are discussed. The capabilities which are anticipated to evolve from today's state of the art and the technology development programs presently in place or planned for the remainder of the century are emphasized. The power system technologies considered include: solar thermal, nuclear, radioisotope, photovoltaic, thermionic, thermoelectric, and dynamic conversion systems such as the Brayton and Stirling cycles. Energy storage technologies considered include: nickel hydrogen biopolar batteries, advanced high energy rechargeable batteries, regenerative fuel cells, and advanced primary batteries. The present state of the art of these space power and energy technologies is discussed along with their projections, trends and goals. A speculative future mission model is postulated which includes manned orbiting space stations, manned lunar bases, unmanned Earth orbital and interplanetary spacecraft, manned interplanetary missions, military applications, and Earth to space and space to space transportation systems. The various space power/energy system technologies which are anticipated to be operational by the early 21st century are matched to these missions.

Faymon, K. A.↗
NASA NTRS1984

Space power technology into the 21st century

This paper discusses the space power systems of the early 21st century. The focus is on those capabilities which are anticipated to evolve from today's state-of-the-art and the technology development programs presently in place or planned for the remainder of the century. The power system technologies considered include solar thermal, nuclear, radioisotope, photovoltaic, thermionic, thermoelectric, and dynamic conversion systems such as the Brayton and Stirling cycles. Energy storage technologies considered include nickel hydrogen biopolar batteries, advanced high energy rechargeable batteries, regenerative fuel cells, and advanced primary batteries. The present state-of-the-art of these space power and energy technologies is discussed along with their projections, trends and goals. A speculative future mission model is postulated which includes manned orbiting space stations, manned lunar bases, unmanned earth orbital and interplanetary spacecraft, manned interplanetary missions, military applications, and earth to space and space to space transportation systems. The various space power/energy system technologies anticipated to be operational by the early 21st century are matched to these missions.

Faymon, K. A.↗
NASA NTRS1984

Space station - Technology development

The NASA manned space station program's systems technology effort involves the development of novel techniques that will reduce the scope of tasks neeeded for design, development, testing and evaluation of the hardware. Operations technology efforts encompass analyses that will define those techniques best able to improve the efficiency and reduce the costs of space station functions. The technology objective for data management calls for a fault-tolerant, distributed, expandable and adaptable, as well as repairable and user-friendly, flight data management system that employs state-of-the-art hardware and software. The space station's power system includes the largest element, a 'solar blanket', and the heaviest component, the batteries, of all the subsystems. A thermal management system for the power system is of paramount importance. Attention is also given to the exacting demands of attitude control and stabilization and a regenerative life support system of the requisite capacity and reliability.

Carlisle, R. F.↗
NASA NTRS1977

The 25 kN space station

The capabilities of photovoltaic, nuclear reactor, and solar thermal systems are assessed for the space construction base. Topics covered include Brayton conversion, thermionic conversion, and thermo-electric conversion. The effectiveness of nickel cadmium and nickel hydrogen batteries are discussed as well as that of regenerative fuel cells. The verification of long cycle life for nickel hydrogen systems is recommended.

Clark, B.↗
NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗
NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

additive manufacturing↗
NASA NTRS1991

NASA's Office of Aeronautics and Exploration Technology space power flight projects

NASA created a program called In-STEP (in-space technology experiments program) to give the aerospace community an opportunity to validate advanced technologies in space. In-STEP has funded feasibility studies for the following experiments in the power technology arena: a microsphere insulation investigation, a utilized regenerative fuel cell experiment, an inflatable solar collector experiment, a moving belt radiator experiment, and a liquid drop radiator experiment. The following experiments are currently in the experiment definition phase: an integrated two-phase thermal experiment, an electrolysis performance experiment, and a sodium sulfur battery experiment. Three In-STEP experiments are entering the hardware fabrication phase: thermal energy storage technology, solar array module plasma interaction, and heat pipe performance experiments. Each of these experiments is described, with an emphasis on the benefits of technology validation.

Chmielewski, Art B.↗
NASA NTRS2004

Research Symposium II

Contents include the following: High power density motors. The training process of the organization development and training office. Modeling and analysis of a regenerative fuel cell propulsion system for a high altitude long endurance. Increasing the thermal stability of aluminum titanate for solid oxide mJEL cell anodes. Microstructural evaluation of forging parameters for superalloy disks. Epoxy adgesives for stator magnet assembly in stirling radioisotope generator. Nickel-Hydrogen and lithium ion space batteries. Statistical and prediction modeling of the Ka band using experimental results from ACTS propagation terminals at 20.185 and 27.505 GHz.

Source record↗
NASA NTRS1984

Flywheel energy storage for spacecraft

Flywheel energy storage systems have been studied to determine their potential for use in spacecraft. This system was found to be superior to alkaline secondary batteries and regenerative fuel cells in most of the areas that are important in spacecraft applications. Of special importance, relative to batteries, are lighter weight, longer cycle and operating life, and high efficiency which minimizes solar array size and the amount of orbital makeup fuel required. In addition, flywheel systems have a long shelf life, give a precise state of charge indication, have modest thermal control needs, are capable of multiple discharges per orbit, have simple ground handling needs, and have the capability of generating extremely high power for short durations.

Gross, S.↗
NASA NTRS1984

The potential impact of new power system technology on the design of a manned space station

Larger, more complex spacecraft of the future such as a manned Space Station will require electric power systems of 100 kW and more, orders of magnitude greater than the present state of the art. Power systems at this level will have a significant impact on the spacecraft design. Historically, long-lived spacecraft have relied on silicon solar cell arrays, a nickel-cadmium storage battery and operation at 28 V dc. These technologies lead to large array areas and heavy batteries for a Space Station application. This, in turn, presents orbit altitude maintenance, attitude control, energy management and launch weight and volume constraints. Size (area) and weight of such a power system can be reduced if new higher efficiency conversion and lighter weight storage technologies are used. Several promising technology options including concentrator solar photovoltaic arrays, solar thermal dynamic and ultimately nuclear dynamic systems to reduce area are discussed. Also, higher energy storage systems such as nickel-hydrogen and the regenerative fuel cell (RFC) and higher voltage power distribution which add system flexibility, simplicity and reduce weight are examined. Emphasis is placed on the attributes and development status of emerging technologies that are sufficiently developed so that they could be available for flight use in the early to mid 1990's.

Fordyce, J. S.↗
NASA NTRS1984

The potential impact of new power system technology on the design of a manned Space Station

Larger, more complex spacecraft of the future such as a manned Space Station will require electric power systems of 100 kW and more, orders of magnitude greater than the present state of the art. Power systems at this level will have a significant impact on the spacecraft design. Historically, long-lived spacecraft have relied on silicon solar cell arrays, a nickel-cadmium storage battery and operation at 28 V dc. These technologies lead to large array areas and heavy batteries for a Space Station application. This, in turn, presents orbit altitude maintenance, attitude control, energy management and launch weight and volume constraints. Size (area) and weight of such a power system can be reduced if new higher efficiency conversion and lighter weight storage technologies are used. Several promising technology options including concentrator solar photovoltaic arrays, solar thermal dynamic and ultimately nuclear dynamic systems to reduce area are discussed. Also, higher energy storage systems such as nickel-hydrogen and the regenerative fuel cell (RFC) and higher voltage power distribution which add system flexibility, simplicity and reduce weight are examined. Emphasis placed on the attributes and development status of emerging technologies that are sufficiently developed so that they could be available for flight use in the early to mid 1990's.

Fordyce, J. S.↗
NASA NTRSDate not supplied

Regenerative Fuel Cell Systems for Lunar Surface Applications

A discrete Regenerative Fuel Cell (RFC), comprised of a Proton Exchange Membrane (PEM) Fuel Cell (FC) system integrated with a PEM Electrolyzer (EZ) system, can provide energy conversion and storage options for applications where batteries are not practical. This includes missions on the lunar surface where long charge and discharge periods result in extremely high battery system mass for sufficient energy storage. While both PEM FC and PEM EZ are mature terrestrial technologies, there is still a lot of development needed for aerospace applications. Integrating the PEM FC and PEM EZ systems together requires the integration of multiple thermal, fluid, and electrical subsystems, increasing the complexity of the overall RFC system. Additionally, Balance of Plant (BoP) components and subsystems play a crucial role in the effective performance to maximize the RFC round trip efficiency. This presentation will give a high-level overview of RFCs, select BoP components including a catalytic recombiner and gas drying equipment, and the current testing that is being done on the RFC project at NASA GRC.

Jessica Cashman↗
NASA NTRSDate not supplied

Performance of a Regenerative Fuel Cell System for the Lunar Surface

Regenerative fuel cells (RFCs) are an attractive energy storage solution for lunar missions as a technology capable of providing a higher specific energy (i.e., W∙h/kg) than state-of-the-art packaged Li-ion battery systems. An RFC consists of the (1 & 2) electrochemical stacks (chemical to electrical energy conversion to supply electricity to an external load, i.e. the fuel cell reaction, and electrical to chemical energy conversion of supplied electrical power to dissociate water into hydrogen and oxygen gases, i.e. water electrolysis), (3) fluidic conditioning, (4) reactant storage, (5) avionics, (6) power management and distribution (PMAD), and (7) thermal management. NASA’s Glenn Research Center has designed, assembled, and tested a breadboard RFC sys-tem capable of operating autonomously for multiple simulated lunar day/night cycles in a laboratory environment. The system is comprised of a non-flow through proton exchange membrane (PEM) fuel cell stack and a liquid-anode feed PEM electrolyzer (EZ) stack designed to electrochemically compress the reactants at balanced pressures up to 12.4 MPa (1800 psia). The fluidic conditioning, avionics, PMAD, and thermal management sub-systems are largely comprised of commercial-off-the-shelf components for this system-level development effort. The hardware is controlled by a CubeSat space processor running an operational program based on core flight architecture that can control the RFC hardware autonomously through a state machine with fault monitoring. The testing results highlighted here were completed with the system in an open-loop configuration such that reactants generated through water electrolysis were vented while gas cylinders supplied fuel cell operation. The breadboard operated autonomously, but there were five unplanned transitions to a safe state that required a manual restart after reviewing the data, determining a root cause, and implementing a solution. Four of the transitions were caused by the thermal management subsystem and the fifth was caused by a water management control issue in the EZ sub-system. The RFC system operated for over 550 hours with the final cycle being slightly abbreviated due to reasons unrelated to system performance.

Kerrigan Cain↗
NASA NTRSDate not supplied

Performance of a Regenerative Fuel Cell System for the Lunar Surface

Regenerative fuel cells (RFCs) are an attractive energy storage solution for lunar missions as a technology capable of providing a higher specific energy (i.e., W∙h/kg) than state-of-the-art packaged Li-ion battery systems. An RFC consists of the (1 & 2) electrochemical stacks (chemical to electrical energy conversion to supply electricity to an external load, i.e. the fuel cell reaction, and electrical to chemical energy conversion of supplied electrical power to dissociate water into hydrogen and oxygen gases, i.e. water electrolysis), (3) fluidic conditioning, (4) reactant storage, (5) avionics, (6) power management and distribution (PMAD), and (7) thermal management. NASA’s Glenn Research Center has designed, assembled, and tested a breadboard RFC sys-tem capable of operating autonomously for multiple simulated lunar day/night cycles in a laboratory environment. The system is comprised of a non-flow through proton exchange membrane (PEM) fuel cell stack and a liquid-anode feed PEM electrolyzer (EZ) stack designed to electrochemically compress the reactants at balanced pressures up to 12.4 MPa (1800 psia). The fluidic conditioning, avionics, PMAD, and thermal management sub-systems are largely comprised of commercial-off-the-shelf components for this system-level development effort. The hardware is controlled by a CubeSat space processor running an operational program based on core flight architecture that can control the RFC hardware autonomously through a state machine with fault monitoring. The testing results highlighted here were completed with the system in an open-loop configuration such that reactants generated through water electrolysis were vented while gas cylinders supplied fuel cell operation. The breadboard operated autonomously, but there were five unplanned transitions to a safe state that required a manual restart after reviewing the data, determining a root cause, and implementing a solution. Four of the transitions were caused by the thermal management subsystem and the fifth was caused by a water management control issue in the EZ sub-system. The RFC system operated for over 550 hours with the final cycle being slightly abbreviated due to reasons unrelated to system performance.

Kerrigan Cain↗