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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Turbine nozzle and method of manufacture

Methods of fabricating a turbomachine component and turbomachine components are provided. The method includes irradiating a layer of powder in a powder bed to form a fused region. The powder is disposed on a build plate. The method further includes a step of providing a subsequent layer of powder over the powder bed by passing a recoater arm over the powder bed from a first side of the powder bed. The method further includes repeating the irradiating and providing steps until a turbine nozzle assembly is formed on the build plate. The turbine nozzle assembly includes the turbine nozzle and a plurality of heat fins disposed within the turbine nozzle. The plurality of heat fins transfer heat away from a thermally sensitive portion of the turbine nozzle.

Griffis, Clay Thomas↗
NASA NTRS2011

Nanoflare Evidence from Analysis of the X-Ray Variability of an Active Region Observed with Hinode/XRT

The investigation of the heating mechanisms of the confined coronal plasma is still under intense debate. It is widely believed that the energy source for coronal heating is the magnetic energy stored in the solar corona. An unsolved problem is how this magnetic energy is converted into thermal energy of the confined coronal plasma. As Parker proposed in 1988 rapid pulses called nanoflares are among the best candidate mechanisms of magnetic energy release. Nowadays a challenging problem is to obtain evidence that such nanoflares are really at work. If small energy discharges (nanoflares) contribute in some way to coronal heating, they could be too small and frequent to be resolved as independent events. In this case, we would need to search for indirect evidence. The idea of this work is that, if the solar corona emission is sustained by repeated nanoflares, locally the X-ray emission may not be entirely constant but may show variations around the mean intensity. So the nanoflares may leave their signature on the light curves. Many authors (Shimizu & Tsuneta 1997; Vekstein & Katsukawa 2000; Katsukawa & Tsuneta 2001; Katsukawa 2003; Sakamoto et al. 2008) pointed out that a detailed analysis of intensity fluctuations of the coronal X-ray emission could give us information on these smallest flares. Following this hint we use this approach for the first time on Hinode data, searching, with statistical analysis, for small but systematic variability in noisy background light curves and their link to coronal heating models.

Terzo, S.↗
DOE OSTI2021

A fast reduced model for a shell-and-tube based latent heat thermal energy storage heat exchanger and its application for cost optimal design by nonlinear programming

Numerical simulation of latent heat thermal energy storage (LHTES) systems plays a fundamental role in studying the physical process and guiding the engineering design. Discretization of the PDEs describing the nonlinear solidification/melting process of phase change materials (PCMs) leads to a large-scale complex dynamics system, where the system behavior depends on a set of parameters. In a design setting, repeated model evaluations are required over the set of parameters results in significant computational burden. In this paper, an explicit analytic solution was built for the propagation of the solidification front in a cylindrical coordinate. The analytic solution approach is further employed to develop a low computational reduced model (RM) as a module for a shell-and-tube based LHTES heat exchanger. The levelized Cost of Energy (LCOE) is used as a design metric and the RM model is used to apply system-level constraints in the nonlinear programming formulation that facilitates efficient global optimal design of the PCM properties, flow conditions and tube geometries. The use of LCOE as the design metric prevents over design of the heat transfer rate and also establishes a fair ground for evaluation of different thermal storage technologies and their integrated applications with other systems. Optimal results showed that a higher effectiveness results in a higher LCOE; the velocity of the HTF and the length of the channel are highly correlated with each other; both larger PCM latent energy and conductivity result in lower LCOE.

25 ENERGY STORAGE↗
DOE OSTI2022

Strong, thermo-reversible salogels with boronate ester bonds as thermal energy storage materials

Inorganic salt hydrates are promising phase change materials (PCMs) but suffer from low viscosity at temperatures above their melting point resulting in leakage problems during thermal storage applications. To achieve shape stabilization of one type of molten inorganic PCM – calcium nitrate tetrahydrate (CNH) – this work explored gelation of polyvinyl alcohol (PVA) in this solvent and the effect of dynamic boronate ester bonds on salogel strength. The occurrence of gelation of PVA in molten CNH but not in water is rationalized by the extremely high salt content and scarcity of hydration water in CNH, enabling intermolecular hydrogen bonding between PVA chains. While neat PVA salogels in CNH were weak, with a gel-to-sol transition temperature (T gel ) below room temperature, the addition of small amounts of borax (<~0.3 wt%) introduced dynamic covalent crosslinks and yielded salogels with T gel tunable over a wide temperature range from 7 to 70 °C. Here, the PVA/borax salogels were about one order of magnitude stronger than their well-known PVA/borax hydrogel counterparts, and, unlike PVA/borax hydrogels, were capable of retaining their shape and preventing leakage of molten CNH. Moreover, the salogels exhibited reversible and repeatable temperature-triggered gel-to-sol transitions and the ability to self-heal. The low polymer and crosslinker concentration also ensured that more than 95% of the heat of fusion of neat CNH was maintained in the salogels and was retained after twenty cycles of melting and crystallization, demonstrating the robust nature of these energy storage materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1977

Radiative metallic thermal protection systems - A status report

During the early stages of the space shuttle program there were a number of technological uncertainties concerning the applicability of metallic thermal protection systems (TPS) to the multimission environment of the shuttle. To resolve the uncertainties and to advance the state-of-the-art, the NASA-Langley Research Center initiated a broad-based technology program to develop metallic TPS over the temperature range from 810 K to 1590 K. Wind tunnel tests conducted to assess the influence of surface/stream interaction of wavy surfaces on the design of metallic TPS indicate small increases in heat flux and surface drag for flow angles less than 20 deg. Analytical and experimental investigations, recently completed, have significantly improved prediction methods for cyclic creep behavior of TPS components repeatedly exposed to complex mission cycles. Thermal/structural concept optimization studies to minimize mass while maintaining structural integrity have led to advanced designs with unit masses which are competitive with those for shuttle RSI. In addition, the durability and reusability of metallic TPS have been repeatedly demonstrated in tests of full-scale systems. The current state-of-the-art strongly suggests that radiative metallic TPS have come of age.

Bohon, H. L.↗
NASA NTRS1980

An all-plated, low cost contact system for silicon solar cells

The plating sequences Pd-Cr-Cu and Pd-Ni-Cu are demonstrated. The surface was sensitized with a 50 A-thick Pd layer obtained from an immersion bath. After 15 min heating at 400 C in N2, a thin barrier layer of either Cr or Ni was deposited from electroless baths operated at temperatures around 90 C. The sintering process was repeated, and a thin copper layer of 500 A was deposited by electroless means. An electrolytic copper bath was used to build the copper layer to 3-4 micron thicknesses. Cells with good I-V curves were obtained, and the all-plated contacts had good adhesion. Preliminary cost estimates show that the process costs approximately 12 cents per watt excluding the cost of the masking procedure.

Tanner, D. P.↗
NASA NTRS1991

Test program, helium II orbital resupply coupling

The full scope of this program was to have included development tests, design and production of custom test equipment and acceptance and qualification testing of prototype and protoflight coupling hardware. This program was performed by Ball Aerospace Systems Division, Boulder, Colorado until its premature termination in May 1991. Development tests were performed on cryogenic face seals and flow control devices at superfluid helium (He II) conditions. Special equipment was developed to allow quantified leak detection at large leak rates up to 8.4 x 10(exp -4) SCCS. Two major fixtures were developed and characterized: The Cryogenic Test Fixture (CTF) and the Thermal Mismatch Fixture (Glovebox). The CTF allows the coupling hardware to be filled with liquid nitrogen (LN2), liquid helium (LHe) or sub-cooled liquid helium when hardware flow control valves are either open or closed. Heat leak measurements, internal and external helium leakage measurements, cryogenic proof pressure tests and external load applications are performed in this fixture. Special reusable MLI closures were developed to provide repeatable installations in the CTF. The Thermal Mismatch Fixture allows all design configurations of coupling hardware to be engaged and disengaged while measuring applied forces and torques. Any two hardware components may be individually thermally preconditioned within the range of 117 deg K to 350 deg K prior to engage/disengage cycling. This verifies dimensional compatibility and operation when thermally mismatched. A clean, dry GN2 atmosphere is maintained in the fixture at all times. The first shipset of hardware was received, inspected and cycled at room temperature just prior to program termination.

Hyatt, William S.↗
DOE OSTI2022

Initial Design and Experimental Results of a Novel Near-Isothermal Compressor for Heat Pump Applications

In efforts to increase the efficiency of residential and commercial air conditioners and heat pumps, it is found that the compressor has the highest electrical energy usage of the system. Therefore, it is appropriate to try to increase the efficiency of this component to reduce its energy usage. Another challenge with heat pump design is that some compressor types have drawbacks that make modulation difficult. To answer these challenges, we are developing an isothermal liquid compressor. The compressor uses propylene glycol to compress carbon dioxide. In the compression chamber the propylene glycol can enter either from the bottom to create a liquid piston for compression or it can enter through a spray nozzle at the top of the chamber. In the latter case, heat transfer from the gas to be compressed to the liquid droplets is high. This allows near isothermal operation of the compressor, which increases the efficiency by 17% to 30%, compared to adiabatic compression. In addition, the isothermal liquid compressor enables very efficient and simple part load modulation.Experimental results demonstrating the operation of the liquid compressor are presented. Initial data demonstrated a temperature rise of 7 K at pressure ratios of almost 4. For comparison at the same initial pressure, temperature, and pressure ratio, adiabatic compression would result in a temperature increase of approximately 70 K. Plotting data on a P-h diagram demonstrates that the compression started at superheated state and ended in supercritical state. Testing was later performed with repeated compressions in the superheated region of the P-h diagram at liquid flow rates of 2 x 10-3 m3/min and 2 x 10-3 m3/min to understand the limitations of the prototype for use with an actual heat pump system. This work demonstrated a novel cycle on a T-s diagram. Results from this work will be used to develop a second-generation prototype where more rapid cycling is possible.

Kowalski, Steve↗
DOE OSTI2023

A comparative study of cerium oxides formed by pulsed laser ablation and continuous wave laser heating

Abstract The formation of Ce 2 O 3 from cerium metal requires complex reducing conditions. Alternatively, we show that different stoichiometries and structures of cerium oxides can be generated in high‐temperature laser experiments by varying the availability of oxygen and the use of either pulsed laser ablation (PLA) or continuous wave (CW) laser heating of cerium metal. X‐ray diffraction and Raman spectroscopy suggest that a low structural order Ce 2 O 3 /CeO 2 mixed structure is formed in a 1% O 2 atmosphere with PLA. For CW heating in a 1% O 2 environment, Raman measurements show the formation of crystalline A‐type Ce 2 O 3 in proximity to the point of laser impingement. These experiments were repeated in 18 O 2 and allowed us to report for the first time the corresponding Raman spectrum of Ce 2 18 O 3 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

A User’s Guide to the PLTEMP/ANL Code (V.4.3)

PLTEMP/ANL V4.3 is a program that obtains a steady-state flow and temperature solution for a nuclear reactor core, or for a single fuel assembly. It is based on an evolutionary sequence of codes originally used for plate temperatures, hence “PLTEMP”, developed at Argonne National Laboratory over several decades. Fueled and non-fueled regions are modeled. Each fuel assembly consists of one or more plates or tubes separated by coolant channels. The fuel plates may have one to five layers of different materials, each with heat generation. The width of a fuel plate may be divided into multiple longitudinal stripes, each with its own axial power shape. Depending upon the heat transfer method selected, the temperature solution is effectively 2-dimensional or 3-dimensional (Appendix XV). It should be noted that for a 3-dimensional solution the axial power shape is modeled without accounting for axial heat conduction. It begins with a solution across all coolant channels and fuel plates or tubes within a given fuel assembly, at the entrance to the assembly. The temperature solution is repeated for each axial node along the length of the fuel assembly. The geometry may be either slab or radial, corresponding to fuel assemblies made of a series of flat (or slightly curved) plates, or of nested tubes. A variety of thermal-hydraulic correlations are available to determine safety margins such as onset-of-nucleate boiling ratio(ONBR), departure from nucleate boiling ratio (DNBR), and onset of flow instability ratio (OFIR). Coolant properties for either light or heavy water are obtained from FORTRAN functions rather than from tables. The code is intended for thermal-hydraulic analysis of research reactor performance in the sub-cooled boiling regime. Both turbulent and laminar flow regimes can be modeled. Options to calculate both forced flow and natural circulation are available. A general search capability is available (Appendix XII) to greatly reduce the reactor analyst’s time.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1989

Elasto-plastic finite element analyses of two-dimensional rolling and sliding contact deformation of bearing steel

An elastoplastic finite element analysis of repeated rolling-plus-sliding contact is presented for the elastic-linear-kinematic hardening-plastic properties of hardened bearing steel at room temperature. Contacts in the absence of frictional heating are found to produce peak cyclic strain ranges and residual stresses that are similar to the values obtained for pure rolling. For the cases considered, the energy dissipated as heat by plastic deformation is found to be 3-15 percent of the energy dissipated at the surface by friction.

Kumar, A. M.↗
NASA NTRS1997

Regolith Evolved Gas Analyzer (REGA)

The instrument consists of five subsystems: (1) a programmable furnace which can be loaded with samples of regolith, (2) a mass spectrometer which detects and measures atmospheric gases or gases evolved during heating, (3) a tank of pressurized gas which can be introduced to the regolith material while detecting and measuring volatile reaction products, (4) a mechanism for dumping the regolith sample and repeating the experiment on a fresh sample, and (5) a data system which controls and monitors the furnace, gas system, and mass spectrometer.

Allen, Carlton C.↗
NASA NTRS1959

Engine Operating Conditions that Cause Thermal-Fatigue Cracks in Turbojet-Engine Buckets

Five engine tests were conducted to definitely establish the failure mechanism of leading-edge cracking and to determine which conditions of engine operation cause the failures. Five groups of S-616 and M-252 buckets from master lots were run consecutively in the same J47-25 engine. The tests included a steady-state run at full-power conditions, rapid cycling between idle and rated speed, and three different start-stop tests. The first start-stop test consisted of cycles of start and stop with 5 minutes of idle speed before each stop; the second included cycles of start and stop but with 15 minutes of rated speed before each stop; the third consisted of cycles of gradual starts and normal stops with 5 minutes at idle speed before each stop. The test results demonstrated that the primary cause of leading-edge cracking was thermal fatigue produced by repeated engine starts. The leading edge of the bucket experiences plastic flow in compression during starts and consequently is subjected to a tensile stress when the remainder of the bucket becomes heated and expands. Crack initiation was accelerated when rated-speed operation was added to each normal start-stop cycle. This acceleration of crack formation was attributed to localized creep damage and perhaps to embrittlement resulting from overaging. It was demonstrated that leading-edge cracking can be prevented simply by starting the engine gradually.

Johnston, James R.↗
NASA NTRS2000

Durability Evaluation of a Thin Film Sensor System With Enhanced Lead Wire Attachments on SiC/SiC Ceramic Matrix Composites

An advanced thin film sensor system instrumented on silicon carbide (SiC) fiber reinforced SiC matrix ceramic matrix composites (SiC/SiC CMCs), was evaluated in a Mach 0.3 burner rig in order to determine its durability to monitor material/component surface temperature in harsh environments. The sensor system included thermocouples in a thin film form (5 microns thick), fine lead wires (75 microns diameter), and the bonds between these wires and the thin films. Other critical components of the overall system were the heavy, swaged lead wire cable (500 microns diameter) that contained the fine lead wires and was connected to the temperature readout, and ceramic attachments which were bonded onto the CMCs for the purpose of securing the lead wire cables, The newly developed ceramic attachment features a combination of hoops made of monolithic SiC or SiC/SiC CMC (which are joined to the test article) and high temperature ceramic cement. Two instrumented CMC panels were tested in a burner rig for a total of 40 cycles to 1150 C (2100 F). A cycle consisted of rapid heating to 1150 C (2100 F), a 5 minute hold at 1150 C (2100 F), and then cooling down to room temperature in 2 minutes. The thin film sensor systems provided repeatable temperature measurements for a maximum of 25 thermal cycles. Two of the monolithic SiC hoops debonded during the sensor fabrication process and two of the SiC/SiC CMC hoops failed during testing. The hoops filled with ceramic cement, however, showed no sign of detachment after 40 thermal cycle test. The primary failure mechanism of this sensor system was the loss of the fine lead wire-to-thin film connection, which either due to detachment of the fine lead wires from the thin film thermocouples or breakage of the fine wire.

Lei, Jih-Fen↗
NASA NTRS2016

Vented Chill / No-Vent Fill of Cryogenic Propellant Tanks

Architectures for extended duration missions often include an on-orbit replenishment of the space vehicle's cryogenic liquid propellants. Such a replenishment could be accomplished via a tank-to-tank transfer from a dedicated tanker or a more permanent propellant depot storage tank. Minimizing the propellant loss associated with transfer line and receiver propellant tank thermal conditioning is essential for mass savings. A new methodology for conducting tank-to-tank transfer while minimizing such losses has been demonstrated. Charge-Hold-Vent is the traditional methodology for conducting a tank-to-tank propellant transfer. A small amount of cryogenic liquid is introduced to chill the transfer line and propellant tank. As the propellant absorbs heat and undergoes a phase change, the tank internal pressure increases. The tank is then vented to relieve pressure prior to another charge of cryogenic liquid being introduced. This cycle is repeated until the transfer lines and tank are sufficiently chilled and the replenishment of the propellant tank is complete. This method suffers inefficiencies due to multiple chill and vent cycles within the transfer lines and associated feed system components. Additionally, this system requires precise measuring of cryogenic fluid delivery for each transfer, multiple valve cycling events, and other complexities associated with cycled operations. To minimize propellant loss and greatly simplify on-orbit operations, an alternate methodology has been designed and demonstrated. The Vented Chill / No Vent Fill method is a simpler, constant flow approach in which the propellant tank and transfer lines are only chilled once. The receiver tank is continuously vented as cryogenic liquid chills the transfer lines, tank mass and ullage space. Once chilled sufficiently, the receiver tank valve is closed and the tank is completely filled. Interestingly, the vent valve can be closed prior to receiver tank components reaching liquid saturation temperature. An incomplete fill results if insufficient energy is removed from the tank's thermal mass and ullage space. The key to successfully conducting the no vent fill is to assure that sufficient energy is removed from the system prior to closing the receiver tank vent valve. This paper will provide a description of the transfer methodology and test article, and will provide a discussion of test results.

Rhys, Noah O.↗
NASA NTRS1986

Active hold-down for heat treating

The object of the disclosure is to provide a vacuum hold-down for holding thin sheets to a support surface, which permits the thin sheet to change dimensions as it is held down. The hold-down includes numerous holes in the support surface, through which a vacuum is applied from a vacuum source. The holes are arranged in zones. The vacuum is repeatedly interrupted at only one or a few zones, while it continues to be applied to other zones, to allow the workpiece to creep along that interrupted zone. The vacuum to different zones is interrupted at different times, as by a slowly turning valve number, to allow each zone of the workpiece to creep. A positive pressure may be applied from a pressured air source to a zone when the vacuum is interrupted there, to help lift the corresponding workpiece zone off the surface to aid in creeping. The workpiece may undergo dimensional changes because of heating, cooling, drying, or other procedure.

Collins, E. R., Jr.↗
NASA NTRS2018

Establishing and Monitoring an Aseptic Workspace

When are aseptic operations necessary? In order to meet certain bioburden requirements, some components must undergo dry heat microbial reduction (DHMR) or other sterilizing procedures. If sensitive surfaces must be re-exposed after DHMR, this could compromise the bioburden levels. Recontaminating sterilized surfaces could be costly both in time by requiring repeated DHMR and risk to the hardware, which may not be compatible with repeated high temperature bakes. In order to prevent recontamination of the sensitive surfaces, an aseptic environment and sterile technique must be employed. Aseptic environments mean working in a space with almost no detectable bioburden in the air or on surfaces. Ideally, DHMR happens as late as possible to avoid requiring aseptic operations, as it can be considered a high-risk operations. Preparing the cleanroom for aseptic operations Establishing an ISO (International Organization for Standardization) class 5 space to minimize airborne particles. Maintain low bioburden in the cleanroom by using biocidal cleaners. Using multiple biocidal techniques decreases the likelihood of selecting for resistant microorganisms. 70% Isopropyl Alcohol (IPA) denatures the proteins in a microorganism (note: 70% IPA is better at killing microorganisms than 100% IPA) 7% hydrogen peroxide: damages DNA and proteins through oxygen radical damage. Ultraviolet-C (UV-C) lamps: causes crosslinking in DNA which prevents replication. Monitor cleanroom regularly for bioburden trending: Standard bioassay: Swab or wipe samples of cleanroom surfaces processed for colony forming unity (viable or spore selected); Rapid bioassay: Adenosine triphosphate (ATP) or Limulus amebocyte lysate (LAL) for a bioburden snapshot. High levels can signal an immediate re-cleaning before standard bioassay samples are taken. Airborne monitoring: Active (pulling air through a filter) or passive (particle fallout) for bioburden. Verify bioburden levels just before aseptic operation. Test hardware and cleanroom surfaces and air 3 days before the planned aseptic operation. Rapid bioburden just before aseptic operation to ensure room was not re-contaminated. Preparing personnel and tools: Personnel training. Everyone in the cleanroom: Standard cleanroom certification Everyone on the team: 1 day Planetary Protection overview. Aseptic operators only: Half-day aseptic operations training. Covers sterile garmenting/gloves, Sterile handling with a focus on contact transfer risk, tool/GSE preparation, and two-operator system for opening sterilized tools/components. Tool sterilization: All tools to be used during an aseptic operation need to be identified. Compatible tools are sterilized by DHMR or Autoclave. Double wrapped so that the exterior bag can be handled by a non-sterile operator, and the sterile. Tools that are not compatible with high heat do not come in contact with sensitive surfaces: either substitutes are found, or tools are isolated by wrapping in sterile foil. During an aseptic operation. Pre-task to make sure everyone understands the operations, who is handling what, and when the most critical surfaces will be exposed. Monitoring during the operation. Bioburden: active and passive airborne bioburden sampling, glove-tip dabs onto a plate after completion of operation (3 days for results). Particles: real time particle counter constantly running, with alarm for exceeding ISO 5 conditions.

aseptic processing↗
NASA NTRS2001

Safer Aviation Materials Tested

A series of thermally stable polymer samples were tested. These materials are called low heat release materials and are designed for aircraft interior decorative materials. The materials are designed to give off a minimum amount of noxious gases when heated, which increases the possibility that people can escape from a burning aircraft. New cabin materials have suitably low heat release so that fire does not spread, toxic chemicals are not given off, and the fire-emergency escape time for crew and passengers is lengthened. These low heat-release materials have a variety of advantages and applications: interiors for ground-based facilities, interiors of space vehicles, and many commercial fire-protection environments. A microscale combustion calorimeter at the Federal Aviation Administration's (FAA) Technical Center tested NASA Langley Research Center materials samples. The calorimeter is shown. A sharp, quantitative, and reproducible heat-release-rate peak is obtained in the microscale heat-release-rate test. The newly tested NASA materials significantly reduced the heat release capacity and total heat release. The thermal stability and flammability behavior of the samples was very good. The new materials demonstrated a factor of 4 reduction in total heat release over ULTEM (a currently used material). This information is provided in the following barchart. In other tests, the materials showed greater than a factor 9 reduction in heat-release capacity over ULTEM. The newly tested materials were developed for low dielectric constant, low color, and good solubility. A scale up of the material samples is needed to determine the repeatability of the performance in larger samples. Larger panels composed of the best candidate materials will be tested in a larger scale FAA Technical Center fire facility. The NASA Glenn Research Center, Langley (Jeff Hinkley), and the FAA Technical Center (Richard Lyon) cooperatively tested these materials for the Accident Mitigation aspects of Fire Prevention under NASA's Aviation Safety Program.

Palaszewski, Bryan A.↗