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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Coated U3Si2 pellets with enhanced water and steam oxidation resistance

A method of forming a water resistant boundary on a fissile material for use in a water cooled nuclear reactor is described. The method comprises coating the fissile material, such as a pellet of U3Si2 and/or the grain boundaries, to a desired thickness with a suitable coating material, such as atomic layer deposition or a thermal spray process. The coating material may be any non-reactive material with a solubility at least as low as that of UO2. Exemplary coating materials include ZrSiO4, FeCrAl, Cr, Zr, Al—Cr, CrAl, ZrO2, CeO2, TiO2, SiO2, UO2, ZrB2, Na2O—B2O3—SiO2—Al2O3 glass, Al2O3, Cr2O3, carbon, and SiC, and combinations thereof. The water resistant layer may be overlayed with a burnable absorber layer, such as ZrB2 or B2O3—SiO2 glass.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Assessment of metadynamic recrystallization in single copper particle impacts by focused ion beam tomography

We study single Cu-on-Cu impacts relevant to cold spray deposition and quantitatively analyze the metadynamic recrystallization (mDRX) that takes place after the impact by virtue of lingering impact adiabatic heat. Unlike prior studies, the current full 3D tomographic analysis of the mDRX volume shows that mDRX is extremely common in such impacts, although it is often missed when examining 2D sections. We also report an unexpected trend: there is a “sour spot” for mDRX at velocities about 20–40 % above the velocity for particle adhesion. This non-monotonic trend is contrary to the expectations based on increasing adiabatic heating with velocity. With a schematic model, we show that the trend can be explained on the basis of heat transfer: cooling of the heat-affected region is limited by transport through the bonded regions at the particle-substrate interface. Thus, bonding has a prominent role in the heat dissipation process and the best bonded particles most rapidly bulk quench, avoiding mDRX. Here, the developed semi-empirical model aligns with the experimental findings and may help inform microstructural evolution during cold spray and post-spray processing.

FIB-SEM tomography↗
NASA NTRS2002

Effects of Humidity On the Flow Characteristics of PS304 Plasma Spray Feedstock Powder Blend

The effects of environmental humidity on the flow characteristics of PS304 feedstock have been investigated. Angular and spherical BaF2-CaF2 powder was fabricated by comminution and by atomization, respectively. The fluorides were added incrementally to the nichrome, chromia, and silver powders to produce PS304 feedstock. The powders were dried in a vacuum oven and cooled to a Tom temperature under dry nitrogen. The flow of the powder was studied from 2 to 100 percent relative humidity (RH) The results suggest that the feedstock flow is slightly degraded with increasing humidity below 66 percent RH and is more affected above 66 percent RH. There was no flow above 88 percent RH. Narrower particle size distributions of the angular fluorides allowed flow up to 95 percent RH. These results offer guidance that enhances the commercial potential for this material system.

Stanford, Malcolm K.↗
NASA NTRS1989

Analysis and test of insulated components for rotary engine

The direct-injection stratified-charge (DISC) rotary engine, while attractive for aviation applications due to its light weight, multifuel capability, and potentially low fuel consumption, has until now required a bulky and heavy liquid-cooling system. NASA-Lewis has undertaken the development of a cooling system-obviating, thermodynamically superior adiabatic rotary engine employing state-of-the-art thermal barrier coatings to thermally insulate engine components. The thermal barrier coating material for the cast aluminum, stainless steel, and ductile cast iron components was plasma-sprayed zirconia. DISC engine tests indicate effective thermal barrier-based heat loss reduction, but call for superior coefficient-of-thermal-expansion matching of materials and better tribological properties in the coatings used.

Badgley, Patrick R.↗
NASA NTRS1999

Zero Gravity Cryogenic Vent System Concepts for Upper Stages

The capability to vent in zero gravity without resettling is a technology need that involves practically all uses of sub-critical cryogenics in space. Venting without resettling would extend cryogenic orbital transfer vehicle capabilities. However, the lack of definition regarding liquid/ullage orientation coupled with the somewhat random nature of the thermal stratification and resulting pressure rise rates, lead to significant technical challenges. Typically a zero gravity vent concept, termed a thermodynamic vent system (TVS), consists of a tank mixer to destratify the propellant, combined with a Joule-Thomson (J-T) valve to extract thermal energy from the propellant. Marshall Space Flight Center's (MSFC's) Multipurpose Hydrogen Test Bed (MHTB) was used to test both spray bar and axial jet TVS concepts. The axial jet system consists of a recirculation pump heat exchanger unit. The spray bar system consists of a recirculation pump, a parallel flow concentric tube, heat exchanger, and a spray bar positioned close to the longitudinal axis of the tank. The operation of both concepts is similar. In the mixing mode, the recirculation pump withdraws liquid from the tank and sprays it into the tank liquid, ullage, and exposed tank surfaces. When energy is required. a small portion of the recirculated liquid is passed sequentially through the J-T expansion valve, the heat exchanger, and is vented overboard. The vented vapor cools the circulated bulk fluid, thereby removing thermal energy and reducing tank pressure. The pump operates alone, cycling on and off, to destratify the tank liquid and ullage until the liquid vapor pressure reaches the lower set point. At that point. the J-T valve begins to cycle on and off with the pump. Thus, for short duration missions, only the mixer may operate, thus minimizing or even eliminating, boil-off losses.

Flachbart, Robin H.↗
NASA NTRS1986

Thermal barrier coating life prediction model development

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology with both performance and durability benefits. The foremost TBC benefit is the reduction of heat transferred into air-cooled components, which yields performance and durability benefits. This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY (or CoNiCrAlY) bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by Chromalloy, Klock, and Union Carbide. The second type of TBC is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal.

T E Strangman↗
NASA NTRS2001

Zero Gravity Cryogenic Vent System Concepts for Upper Stages

The capability to vent in zero gravity without resettling is a technology need that involves practically all uses of sub-critical cryogenics in space, and would extend cryogenic orbital transfer vehicle capabilities. However, the lack of definition regarding liquid/ullage orientation coupled with the somewhat random nature of the thermal stratification and resulting pressure rise rates, lead to significant technical challenges. Typically a zero gravity vent concept, termed a thermodynamic vent system (TVS), consists of a tank mixer to destratify the propellant, combined with a Joule-Thomson (J-T) valve to extract thermal energy from the propellant. Marshall Space Flight Center's (MSFC's) Multipurpose Hydrogen Test Bed (MHTB) was used to test both spray-bar and axial jet TVS concepts. The axial jet system consists of a recirculation pump heat exchanger unit. The spray-bar system consists of a recirculation pump, a parallel flow concentric tube heat exchanger, and a spray-bar positioned close to the longitudinal axis of the tank. The operation of both concepts is similar. In the mixing mode, the recirculation pump withdraws liquid from the tank and sprays it into the tank liquid, ullage, and exposed tank surfaces. When energy extraction is required, a small portion of the recirculated liquid is passed sequentially through the J-T expansion valve, the heat exchanger, and is vented overboard. The vented vapor cools the circulated bulk fluid, thereby removing thermal energy and reducing tank pressure. The pump operates alone, cycling on and off, to destratify the tank liquid and ullage until the liquid vapor pressure reaches the lower set point. At that point, the J-T valve begins to cycle on and off with the pump. Thus, for short duration missions, only the mixer may operate, thus minimizing or even eliminating boil-off losses.

Flachbart, Robin H.↗
NASA NTRS1959

Crash-Fire Protection System for T-56 Turbopropeller Engine Using Water as Cooling and Inerting Agent

A crash-fire protection system to suppress the ignition of crash-spilled fuel that may be ingested by a T-56 turbopropeller engine is described. This system includes means for rapidly extinguishing the combustor flame and means for cooling and inerting with water the hot engine parts likely to ignite engine-ingested fuel. Combustion-chamber flames were extinguished in 0.07 second at the engine fuel manifold. Hot engine parts were inerted and cooled by 52 pounds of water discharged at ten engine stations. Performance trials of the crash-fire prevention system were conducted by bringing the engine up to takeoff temperature, stopping the normal fuel flow to the engine, starting the water discharge, and then spraying fuel into the engine to simulate crash-ingested fuel. No fires occurred during these trials, although fuel was sprayed into the engine from 0.3 second to 15 minutes after actuating the crash-fire protection system.

Busch, Arthur M.↗
NASA NTRS2016

Update on the NASA Glenn Propulsion Systems Lab Ice Crystal Cloud Characterization (2015, 2016)

NASA Glenn's Propulsion Systems Lab, an altitude engine test facility, was outfitted with a spray system to generate ice crystals in 2011. Turbine engines and driven rigs can experience ice crystal icing at flight altitudes, temperatures and Mach numbers. To support these tests, four ice crystal characterizations have been conducted in two different facility configurations. In addition, super-cooled liquid and mixed phase clouds have also been generated. This paper represents a work in progress. It will describe some of the 11-parameter calibration space, and how those parameters interact with each other, the instrumentation used to characterize the cloud and present a sample of the cloud characterization results.

Engine Icing↗
NASA NTRS2016

Radio Frequency Plasma Synthesis of Boron Nitride Nanotubes (BNNTs) for Structural Applications

Boron nitride nanotubes (BNNTs) are more thermally and chemically compatible with metal- and ceramic-matrix composites than carbon nanotubes (CNTs). The lack of an abundant supply of defect-free, high-aspect-ratio BNNTs has hindered development as reinforcing agents in structural materials. Recent activities at the National Research Council - Canada (NRC-C) and the University of California - Berkeley (UC-B) have resulted in bulk synthesis of few-walled, small diameter BNNTs. Both processes employ induction plasma technology to create boron vapor and highly reactive nitrogen species at temperatures in excess of 8000 K. Subsequent recombination under controlled cooling conditions results in the formation of BNNTs at a rate of 20 g/hr and 35 g/hr, respectively. The end product tends to consist of tangled masses of fibril-, sheet-, and cotton candy-like materials, which accumulate within the processing equipment. The radio frequency plasma spray (RFPS) facility at NASA Langley (LaRC), developed for metallic materials deposition, has been re-tooled for in-situ synthesis of BNNTs. The NRC-C and UC-B facilities comprise a 60 kW RF torch, a reactor with a stove pipe geometry, and a filtration system. In contrast, the LaRC facility has a 100 kW torch mounted atop an expansive reaction chamber coupled with a cyclone separator. The intent is to take advantage of both the extra power and the equipment configuration to simultaneously produce and gather BNNTs in a macroscopic form amenable to structural material applications.

Hales, Stephen J.↗
NASA NTRSDate not supplied

Development of an Additive Manufactured Cryogenic TVS Augmented Injector

Cryogenic fluid transfer is critical in ground and space systems. Transfer typically requires venting a receiver vessel during the chill and fill process to maintain a pressure favorable to fluid flow. Venting in space is problematic due to low-gravity where fluid position is indeterminate; possibly allowing fluid to flow out the vent. To control receiver tank venting the vented chill/no-vent fill methodology is attractive. An additively manufactured Injector coupled with a Thermodynamic Venting System (TVS) augmentation can enable the vented chill/no-vent fill approach with simplified operations. The TVS augmented injector includes an internal heat exchanger, fluid injector spray head, and external surface condensation heat exchange; combined with integrated flow paths in one part. Operations using the injector allow the tank vent to be closed very early in the transfer and not reopened. The TVS circuit eliminates the potential for stalled fill by maintaining cooling flow on the injector and condenser elements, reducing tank pressure. The injector can also be employed for long-term cryo fluid storage as a means of controlling tank pressure if integrated with a recirculation pump. A cryo-cooler can be used in place of/or augmenting the TVS flow circuit for a zero loss pressure control system. The Injector was developed using the principles of design for additive manufacture and printed as one part, resulting in part count reduction, improved reproducibility, shorter lead times, and reduced cost. The TVS augmented injector is compact and highly adaptable simplifying its integration. A key benefit is that this methodology enables simplified operations in reaching 100% fill conditions.

Omar Mireles↗
NASA NTRS1971

Exploratory screening tests of several alloys and coatings for automobile thermal reactors

A total of 23 materials (including uncoated ferritic and austenitic iron-base alloys, uncoated nickel and cobalt-base superalloys, and several different coatings on AISI 304 stainless steel) were screened as test coupons on a rack in an automobile thermal reactor. Test exposures were generally 51 hours including 142 thermal cycles of 10 minutes at 1010 + or - 30 C test coupon temperature and 7-minutes cool-down to about 510 C. Materials that exhibited corrosion resistance better than that of Hastelloy X include: a ferritic iron alloy with 6 weight percent aluminum; three nickel-base superalloys; two diffused-aluminum coatings on AISI 304; and a Ni-Cr slurry-sprayed coating on AISI 304. Preliminary comparison is made on the performance of the directly impinged coupons and a reactor core of the same material.

Oldrieve, R. E.↗
NASA NTRS1975

Development and parametric evaluation of the prototype 2 and 3 flash evaporators

Development of the Prototype 2 and 3 flash evaporator heat sinks which vaporize an expendable fluid to cool a heat transport fluid loop is reported. The units utilize Freon 21 as the heat transport fluid and water as the expendable fluid to meet the projected performance requirements of the space shuttle for both on-orbit and ascent/reentry operations. The evaporant is pulse-sprayed by on-off control onto heat transfer surfaces containing the transport fluid and exhausted to the vacuum environment through fixed area exhaust ducts.

Hixon, C. W.↗
NASA NTRS1978

Investigation of the effect of ceramic coatings on rocket thrust chamber life

Two cylindrical rocket thrust chamber cylinders were coated with a 0.203 mm layer of zirconium oxide using a process that employed electrodeposition of metal to a spray-coated mandrel. The cylinders were cyclically tested using hydrogen-oxygen propellants at a nominal chamber pressure of 4.14 MN/sq m to show the effect of the coating on life. Both cylinders failed prematurely due to causes unrelated to the coatings. Post destructive analysis showed no cooling passage wall deformation. Where erosion of the coating occurred, the coating thickness stabilized at 0.061 mm within 80 cycles and remained well adhered throughout the tests. The hot-gas-side metal wall temperature and the theoretical maximum effective strain were reduced by 80 and 92%, respectively, where the coating was 0.203 mm thick and by 40 and 50%, respectively, where the coating was 0.061 mm thick compared to an uncoated cylinder. The 50 and 92% reductions in maximum effective strain resulted in theoretical lives of 1900 cycles and greater than 10,000 cycles, respectively, compared to 300 cycles for the uncoated cylinder.

Quentmeyer, R. J.↗
NASA NTRS1978

Investigation of the effect of ceramic coatings on rocket thrust chamber life

Cylindrical rocket thrust chamber cylinders were coated with a 0.203 mm (0.008 in.) layer of zirconium oxide using a process that employed electrodeposition of metal to a spray coated mandrel. The cylinders were cyclically tested using hydrogen oxygen propellants at a nominal chamber pressure of 4.14 MN/sq m (600 psia) to show the effect of the coating on life. Both cylinders failed prematurely due to causes unrelated to the coatings. Post destructive analysis showed no cooling passage wall deformation. Where erosion of the coating occurred, the coating thickness stabilized at 0.061 mm (0.0024 in.) within 80 cycles and remained well adhered throughout the tests.

Quentmeyer, R. J.↗
NASA NTRS1985

Fabrication of ceramic substrate-reinforced and free forms

Components fabricated of, or coated with, ceramics have lower parasitic cooling requirements. Techniques are discussed for fabricating thin-shell ceramic components and ceramic coatings for applications in rocket or jet engine environments. Thin ceramic shells with complex geometric forms involving convolutions and reentrant surfaces were fabricated by mandrel removal. Mandrel removal was combined with electroplating or plasma spraying and isostatic pressing to form a metal support for the ceramic. Rocket engine thrust chambers coated with 0.08 mm (3 mil) of ZrO2-8Y2O3 had no failures and a tenfold increase in engine life. Some measured mechanical properties of the plasma-sprayed ceramic are presented.

Quentmeyer, R. J.↗
NASA NTRS1986

Making High-Porosity Alloy Spheroids

Noncontact process yields low-density, porous microstructure. Small spheroids of porous alloys with large surface area per unit volume produced by containerless processing method. Without container walls to serve as nucleation sites, alloy cools to well below normal freezing point without solidifying. Solidification then proceeds rapidly; interdendritic liquid pulled out by growing crystals, resulting in porous microstructure. The more rapid the cooling rate, the faster crystals grow and more porous solid becomes. Drop-tube method useful in creating porous microstructures from other materials including oxides, carbides, and organic materials. Other means of containerless processing - acoustic or air-jet levitation, low-gravity float melting, melt spinning, or jet spraying, adapted to process.

Ethridge, E. C.↗
NASA NTRS1985

Microstructural aspects of zirconia thermal barrier coatings

Various combination of plasma-sprayed bond coatings and zirconia ceramic coatings on a nickel-based superalloy substrate were tested by static thermal exposure at 1200 C and cyclic thermal exposure to 1000 C. The bond coats were based on Ni-Cr-Al alloys with additions of rare earth elements and Si. The ceramic coats were various ZrO2-Y2O3 compositions, of which the optimum was found to be ZrO2-8.9 wt percent Y2O3. Microstructural analysis showed that resistance to cracking during thermal exposure is strongly related to deleterious phase changes. Zones depleted of Al formed at the bond coat/ceramic coat interface due to oxidation and at the bond coat/substrate interface due to interdiffusion, leading eventually to breakdown of the bond coat. The 8.9 percent Y2O3 coating performed best because the as-sprayed metastable tetragonal phase converted slowly into the low-Y2O3 tetragonal plus high-Y2O3 cubic-phase mixture, so that the deleterious monoclinic phase was inhibited from forming. Failure appeared to start with the formation of circumferential cracks in the zirconia, probably due to compressive stresses during cooling, followed by the formation of radial cracks due to tensile stresses during heating. Cracks appeared to initiate at the Al2O3 scale/bond coat interface and propagate through the zirconia coating. Comparisons were made with the behavior of bulk ZrO2-Y2O3 and the relationship between the microstructure of the tetragonal phase and the phase diagram. A separate investigation was also made of the ZrO2-Al2O3 interface.

Mitchell, T. E.↗