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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
NASA NTRS2013

Carbon nanotube vacuum gauges with wide-dynamic range and processes thereof

A miniature thermal conductivity gauge employs a carbon single-walled-nanotube. The gauge operates on the principle of thermal exchange between the voltage-biased nanotube and the surrounding gas at low levels of power and low temperatures to measure vacuum across a wide dynamic range. The gauge includes two terminals, a source of constant voltage to the terminals, a single-walled carbon nanotube between the terminals, a calibration of measured conductance of the nanotube to magnitudes of surrounding vacuum and a current meter in electrical communication with the source of constant voltage. Employment of the nanotube for measuring vacuum includes calibrating the electrical conductance of the nanotube to magnitudes of vacuum, exposing the nanotube to a vacuum, applying a constant voltage across the nanotube, measuring the electrical conductance of the nanotube in the vacuum with the constant voltage applied and converting the measured electrical conductance to the corresponding calibrated magnitude of vacuum using the calibration. The nanotube may be suspended to minimize heat dissipation through the substrate, increasing sensitivity at even tower pressures.

Manohara, Harish↗
DOE OSTI2024

Friction stir processing on a strontium modified, thin-wall, vacuum-assisted high-pressure die-cast Aural-5 alloy to improve tensile and fatigue performance

Here, this study explores the application of friction stir processing (FSP) to enhance the material properties of Sr-modified Aural-5 alloy, with a focus on improved tensile and fatigue properties. Aural-5 is a well-known vacuum-assisted high-pressure die-cast (HPDC) Al-Si7-Mg alloy used in the automotive industry to reduce vehicle weight, enhance fuel efficiency, and lower carbon emissions. This alloy modifies its material chemistry with Sr for fine fibrous networks of eutectic silicon and manganese (Mn) to reduce die soldering. It has significantly less iron (Fe) content resulting in the elimination of detrimental needle-shaped Fe-bearing ß-phase intermetallic and improving ductility. The initial microstructure of as-received HPDC Aural-5 exhibits shrinkage porosity in the middle section, a dendritic microstructure with fibrous Al-Si eutectic colonies, a shear-band structure beneath the die-wall, large dendritic externally solidified crystals (ESCs), needle-shaped Mg 2 Si phase and significant second-phase particulates. Some of those microstructural features, such as porosity, ESCs, needle-shaped Mg 2 Si phase, and large second-phase particles, serve as initiation sites for cracks under mechanical loading, resulting in adverse effects on tensile properties, particularly ductility. FSP effectively transforms the microstructure into a wrought configuration with uniform particle distribution by eliminating porosity and disintegrating dendrites, eutectic colonies, ESCs, second-phase particles, and shear-band structures. FSP-driven microstructure modification enhances yield strength and tensile ductility by ~30% and ~35%, respectively. The fatigue life of the material in a bending mode configuration (stress ratio R = 0.1) after FSP exhibits enhancements ranging from 2.0 to 3.9 times that of the original HPDC Aural-5 alloy, depending on the applied stress level.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Recent advances in the development of composites based on the NCNS resins

The NCNS resins, a new class of addition polymerized polyaromatic melamines, have undergone further development in the past year. Pilot plant quantities of resin NCNS-12M have been made available for evaluation. High solids laminating varnishes were prepared in alcohol/ethyl acetate and alcohol/chlorinated solvent mixtures. The prepregs had sufficient room temperature stability after three month storage to retain good processing characteristics and good bonded mechanical properties. Laminates were fabricated by vacuum bag-autoclave processing and by 5 minute press molding cycles. These laminates had low flame spread and low smoke emitting properties and retained good elevated temperature properties upon long-term oxidative aging. Humidity aging studies were carried out for 30 days at 95% R.H., 120 F. on NCNS/graphite fiber laminates. Initial results indicate that the NCNS resins, particularly those prepared from polymethylene polyphenylamines, are resistant to environmental degradation of elevated temperature mechanical strength.

Kray, R. J.↗
NASA NTRS1980

Development of simplified process for environmentally resistant cells

This report describes a program to develop a simple, foolproof, all vacuum solar cell manufacturing process which can be completely automated and which results in medium efficiency cells which are inherently environmentally resistant. All components of the completed cells are integrated into a monolithic structure with no material interfaces. The exposed materials (SI, Al2O3, Al, Ni) are all resistant to atmospheric attack and the junction, per se, is passivated to prevent long term degradation. Such cells are intended to be incorporated into a simple module consisting basically of a press formed metallic superstructure with a separated glass cover for missile, etc., protection.

King, W. J.↗
DOE OSTI2025

Hierarchically Structured Vitrimer Biocomposites for Sustainable Manufacturing

Polymers containing dynamic covalent bonds (DCBs) exhibit thermoplastic-like flow above their topology freezing temperature (T v ) while maintaining thermoset-like properties below it, making them promising for sustainable manufacturing. However, their large-scale adoption remains limited due to challenges in accurately determining T v and achieving efficient fiber-matrix bonding in composite applications. Here, hierarchically structured epoxy-anhydride-based polyester vitrimer composites reinforced with cellulosic filaments is demonstrated, where hydroxyl groups on fiber surfaces participate directly in transesterification with the matrix. Further, this dynamic interfacial bonding delivers exceptional mechanical properties, including ≈70 MPa shear strength and >10% strain-to-failure, while enabling thermal malleability. Using a combination of nuclear magnetic resonance and nano-infrared spectroscopies, direct evidence is provided that chemical bond exchange begins well below the conventionally measured T v , supporting the hypothesis that rheologically determined T v reflects a combination of chemical exchange and frictional dynamics rather than a discrete transition. The composites demonstrate excellent processability through vacuum-assisted resin transfer molding and maintain >90% of their mechanical properties after multiple thermal reforming cycles. These findings advance both the fundamental understanding of vitrimeric transitions and the practical development of sustainable, high-performance composite materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Process-informed adsorbent design guidelines for direct air capture

Direct air capture using solid adsorbents is a proven technology critical to reducing our net greenhouse gas emissions to zero and beyond. Currently, academic research into the technology mainly focuses on the development of new adsorbents. However, there is a discord between the adsorbent design and process performance. Many materials scientists focus on maximising metrics such as the CO 2 capacity of their adsorbent. Here, we combine detailed process modelling, machine learning, and extensive global sensitivity analysis, which entails varying all of the model parameters together, on a direct air capture process to show that the dry CO 2 adsorption capacity does not influence process performance for an amine-functionalised adsorbent operating in a temperature vacuum swing adsorption (TVSA) process, while it is important in a steam-assisted TVSA (S-TVSA) process. In fact, adsorption kinetics, density, and thermal conductivity are all critical attributes to obtaining a low energy penalty and reduced costs. The analysis also highlights the importance of heat transfer, directing process engineers to (alternative) adsorber designs that maximise this. By an in-depth evaluation of how process performance indicators are affected by materials properties and process operating parameters, this work provides guidance to both material scientists and process engineers towards the design of a “unicorn adsorbent” and intensified DAC processes. This will improve the performance of solid adsorbent direct air capture and help drive down the costs of this vital technology to avert the worst impacts of climate change.

42 ENGINEERING↗
DOE OSTI2024

Black-hole powered quantum coherent amplifier

Abstract Atoms falling into a black hole (BH) through a cavity are shown to enable coherent amplification of light quanta powered by the BH-gravitational vacuum energy. This process can harness the BH energy towards useful purposes, such as propelling a spaceship trapped by the BH. The process can occur via transient amplification of a signal field by falling atoms that are partly excited by Hawking radiation reflected by an orbiting mirror. In the steady-state regime of thermally equilibrated atoms that weakly couple to the field, this amplifier constitutes a BH-powered quantum heat engine. The envisaged effects substantiate the thermodynamic approach to BH acceleration radiation.

Physics↗
DOE OSTI2024

Time reflection of light from a quantum perspective and vacuum entanglement

If a boundary between two static media is moving with a constant superluminal velocity, or there is a sudden change of the refractive index with time, this yields generation of entangled pairs of photons out of vacuum propagating in the opposite directions. Here we show that during this process, entanglement of Minkowski vacuum is transferred to the entanglement of the generated photon pairs. If initially an electromagnetic pulse is present in the medium the photon generation is stimulated into the pulse mode, and since photons are created as entangled pairs the counter-propagating photon partners produce a pulse moving in the opposite direction, which is known as time reflection. Thus, time reflection occurs due to stimulated generation of the entangled photon pairs out of entangled vacuum and no photons in the original pulse are in fact being reflected. This is different from the mechanism of light reflection from spatial inhomogeneities for which no photons are generated.

Optics↗
DOE OSTI2023

Recent Beam Stability Analysis for the EIC

This document summarizes work done in WBS 6.02.02 during FY23. Additional details can be found in the EIC overview paper presented at IPAC’23 [1], and the references therein. Progress has been made in the ESR and HSR lattice design, dynamic aperture optimization, and the RCS lattice design. The impedance and Collective effects are progressing and include the impedance optimization process of the vacuum systems for RCS, HSR, and ESR; collective effects studies; collective effects and beam-beam interaction; coupled bunch instabilities and the crab cavities; low-level RF feedback system design and beam-ion instability. The reversed phasing RF system has been numerically studied for the ESR to mitigate Robinson instability and demonstrate reliable stable beam operation. Various codes, including C++, SPACE [2], ELEGANT [3], and Mbtrack2 [4] have been employed to benchmark the results. The simulation of HSR bunch splitting with beam loading has been performed at 275 GeV energy. The evaluation of Beam Position Monitors aimed to validate their expected performance, with the primary objective being to verify their accuracy. Calculations of Electron Polarization in the ESR, RCS, and HSR are showing good progress. In the RCS, preliminary studies indicate excellent polarization transmission over intrinsic spin resonances, achieving over 90% transmission with improved performance compared to the previous lattice. Preliminary simulations in the ESR indicate encouraging results in minimizing depolarization and improving equilibrium polarization.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Logical Approach to Tritium Vacuum Pump Selection

Introduction Vacuum pumps are essential to the operation of tritium purification and recovery processes. However, not all vacuum pumps sold meet the requirements for tritium service. Manufacturers routinely do not fully appreciate the hazards associated with tritium, or the complex materials interactions. Therefore, a decision tree was established detailing which pump types, and certain manufacturers, are either fully compatible, limited use, or to avoid at all costs to establish a more structured and uniform approach to tritium vacuum pumps.

ANGELETTE, LUCAS↗
DOE OSTI2025

Characterization of Performance Degradation Mechanisms in Low-Cost High Throughput DI-O3 Layer for Passivated Contact Silicon Solar Cells

Characterization and mitigating performance limiting defects in Silicon (Si) PV is one of key areas to be addressed to improve PV hardware costs and energy yield in order to lower the levelized cost of energy (LCOE) of installed PV cost to $0.02/kWh. As Si PV cells efficiencies have surpassed 22% and approaching 23%, the recombination at the metal contacts have become the focus point to be addressed. Passivated contact technologies—having a heterojunction with a band-gap larger than silicon between the metal and silicon—have emerged as a great potential for future highand ultrahigh-efficiency solar cells, as it concurrently reduces recombination and increases carrier selectivity, by incorporating thin films within the contact structure. Passivated contact Si solar cell technologies use a wide variety of tunnel layers—playing a crucial role to passivate metal contacts and tunnel charge carriers—including stoichiometric silicon oxide (SiO 2 ) grown by thermal oxidation and Low-Pressure Chemical Vapor Deposition (LPCVD) technique and silicon oxide (SiO x ) by hot nitric acid. However, thorough investigations on understanding the failure and performance degradation mechanisms associated with tunnel layers are still limited to date. Unlocking those degradation characteristics in crucial tunnel layers could improve the reliability and energy yield of passivated contact Si solar cells. Besides, the technique of growing aforementioned tunneling layers are low throughput, and requires high temperature processes and/or a vacuum environment. In this project, we investigated the performance degradation mechanisms of a low-cost high-throughput ozonated oxide (DI-O 3 ) tunnel layer for the passivated contact Si solar cells.

14 SOLAR ENERGY↗
DOE OSTI2021

FEED Study of Carbon Capture Inc. DAC and CarbonCure Utilization Using United States Steel's Gary Works Waste Plant

Direct Air Capture (DAC) has been proposed as a means of reducing atmospheric concentrations of CO2. While DAC has been evaluated through lab-scale, bench-scale, and small-scale pilot units, large-scale deployment has not been achieved. Feasibility studies are one tool to understand the potential design, operation, performance, and impact of commercial-scale DAC. This paper presents the results of a feasibility study for a passive DAC system deployed at >100,000 tpy scale in three different regions across the U.S. and awarded to Carbon Collect by the U.S. Department of Energy National Energy Technology Laboratory (DOE NETL). The MechanicalTree™technology has been designed and engineered by Carbon Collect based on the concept initially developed at Arizona State University Center for Negative Carbon Emissions. It uses a tower of stacked, sorbentcontaining disks supported by a lifting mechanism, exposed to the air to capture CO2 during the adsorption phase. The disks are then lowered into a regeneration chamber for vacuum and steam regeneration to produce CO2 product during the desorption step. The modular tree design allows large installations with repeatable, mass-manufactured units connected to common utilities such as steam supply, vacuum, and CO2 processing for compression and geologic storage. The passive DAC system eliminates the equipment and energy of forced air fans by using natural air circulation to contact the sorbent with the CO2 in the air. Because of this, the performance is dependent on the wind speed in addition to the temperature and relative humidity. Performance and flow rate fluctuations were incorporated into equipment and facility design with considerations for turndown to 10% of maximum rated flow to allow operation in all seasons. The feasibility study was undertaken to evaluate the technology in different regions and climates. Three locations were selected for this study representing different climates: Alabama (hot and humid), California (hot and arid), and Wyoming (continental). For each region, the adsorption/desorption cycle was optimized including tuning the heat integration and cycle timings. The performance of individual trees was then scaled to the full facility with the same design of more than 20,000 trees common between all regions. The installations had expected average CO2 capture rates of between 330,000 and 485,000 tonnes of CO2 per year depending on the climate. The initial engineering design for the facility at each location was performed with cost and performance estimates for the trees, carbon purification and compression, and the balance of plant. To supply thermal and electrical energy for the facility, carbon-free or low-carbon power must be considered. Options for low-carbon, continuous thermal and electrical energy were considered. The best-performing option from those considered was identified to be an electrically-heated molten salt energy storage system, powered by an on-site photovoltaic field. During molten salt thermal discharge, steam is produced from heat exchange with the molten salt and used to generate power in a steam turbine as well as steam for regenerating the DAC carbon trees. The thermal and electrical supply and analysis is presented in the context of low-carbon power for carbon removal. Modelling and economics of transportation and geologic storage of the CO2 is considered and presented for each location. The results of the feasibility study are incorporated into the presented techno-economic and life-cycle assessments. This work is intended to provide an understanding of the performance, cost, and impact of capturing CO2 at the commercial scale and the impact of climate and regional siting on the considered passive DAC system.

42 ENGINEERING↗
NASA NTRS1972

Brazing of refractory, superalloy, and composite materials for Space Shuttle applications.

Research work concerning the metallic portion of the shuttle-orbiter heat shield (expected to experience temperatures up to 2500 F) is described. The five metals being evaluated are TD-Ni-Cr, Cb-C129Y, Cb752, Hayes 188, and Inconel 625. Brazing techniques whereby pairs of these materials are joined into thin-membered assemblies for heat shield applications are described. Results obtained with the vacuum-furnace brazing process are examined. In addition, the use of brazed aluminum-boron metal-matrix-contoured composite structures for heat shield applications is evaluated.

Beuyukian, C. S.↗
NASA NTRS1974

Development and flight tests of a gyro-less wing leveler and directional autopilot

A gyro-less wing leveler and directional autopilot were developed and flight tested in a single-engine light airplane. The primary purpose of the project was to develop a simple, reliable, low-cost stability augmentation and autopilot system for light aircraft. The wing leveler used a fluidic inertial rate sensor, electronic signal processing circuitry, and vacuum operated servos. A strap-down magnetic heading reference of simple design provided the wing leveler with directional autopilot capability. Flight tests indicated that the performance of the gyro-less wing leveler was equal to that of a commercial wing leveler using a gyroscopic rate sensor. Drift-free, long-term, heading-hold capability of the magnetic heading reference was demonstrated.

Garner, H. D.↗
NASA NTRS1983

Materials processing in space program tasks

Crystal growth; solidification of metals, alloys, and composites; fluids, transports, and chemical processes; and ultrahigh vacuum and containerless technologies are discussed.

Pentecost, E.↗
NASA NTRS1985

Vacuum plasma coatings for turbine blades

Turbine blades, vacuum plasma spray coated with NiCrAlY, CoCrAlY or NiCrAlY/Cr2O3, were evaluated and rated superior to standard space shuttle main engine (SSME) coated blades. Ratings were based primarily on 25 thermal cycles in the MSFC Burner Rig Tester, cycling between 1700 F (gaseous H2) and -423 F (liquid H2). These tests showed no spalling on blades with improved vacuum plasma coatings, while standard blades spalled. Thermal barrier coatings of ZrO2, while superior to standard coatings, lacked the overall performance desired. Fatigue and tensile specimens, machined from MAR-M-246(Hf) test bars identical to the blades were vacuum plasma spray coated, diffusion bond treated, and tested to qualify the vacuum plasma spray process for flight hardware testing and application. While NiCrAlY/Cr2O3 offers significant improvement over standard coatings in durability and thermal protection, studies continue with an objective to develop coatings offering even greater improvements.

Holmes, R. R.↗
NASA NTRS1986

Pseudolog Digital-to-Analog Converter

Sensitivity decreases by 10 at beginning of each input decade. Method conceived to convert binary-coded data to suitable linear form for stripchart recording. Strip-chart recordings obtained from typical pressure readings in a vacuum system during pumpdown. In reading curve, BCD digital vacuum-gage output processed by analog-to-digital converter in such way that only reading digits (but not range) appear in output. In range and reading, range also converted to analog and placed as most significant digit.

Gooder, S. T.↗