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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Chemical and Chemical-Mechanical Polishing of Surface Roughness on L-PBF/GRCop-42 Cu-Cr-Nb Additive Manufactured 10-GHz RF Structures

Laser-based powder bed fusion (L-PBF) allows additive manufacture (AM) of lower hybrid current drive (LHCD) radio-frequency (RF) launchers from Glenn Research Copper, a Cr 2 Nb precipitation-hardened alloy (GRCop-42) in configurations unachievable with conventional machining. Rough surfaces in AM components increase RF losses and lead to arcing in high-power vacuum RF applications. Chemical polishing, chemical-mechanical polishing, or a combination of both were utilized to planarize the internal surfaces of RF structures, resulting in surface roughness as low as R a = 0.2 µm. Refinement in polishing techniques now enables GRCop-42 alloys (4 at. % Cr, 2 at. % Nb) to achieve similar surface roughness to GRCop-84 (8 at. % Cr, 4 at. % Nb) and equivalent cavity losses to extruded oxygen-free copper waveguides at 10 GHz.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Predictive numerical modeling of plasma-induced surface roughness and wettability evolution in LM-PAEK/CF tape

Plasma surface modification effectively enhances adhesion in thermoplastic composites, yet its impacts on high-performance polymers like low-melting polyaryletherketone (LM-PAEK) remain inadequately quantified. Here, this study integrates experimental analysis and numerical modeling to characterize surface roughness and wettability changes in LM-PAEK/carbon fiber composites treated with atmospheric plasma. Atomic Force Microscopy quantified surface topography (n = 10 per condition for contact angles), while static contact-angle assessments measured wettability. Roughness rapidly increased from ∼0.2 nm to 1.6 nm, and contact angle reduced from ∼90° to 24°, both stabilizing after 25–30 s of exposure. A semi-empirical, physics-informed framework was calibrated to these data, coupling surface chemistry via the Owens–Wendt decomposition with topography via the Wenzel roughness factor, and evaluated using out-of-sample (cross-validated) tests, while static contact angle assessments measured wettability. Numerical predictions matched experimental results closely (RMSE <5%, R 2 > 0.95). Incorporating material-specific parameters, the calibrated model supports plasma-treatment optimization and provides quantitative guidance for improving interfacial adhesion in thermoplastic composite manufacturing.

Atomic Force Microscopy↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $ \$ $6B annually (at $ \$ $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year), and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE) missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

42 ENGINEERING↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $6B annually (at $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year),and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE)missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Mineral Deposition on the Rough Walls of a Fracture

Modeling carbonate growth in fractures and pores is important for understanding carbon sequestration in the environment or when supersaturated solutions are injected into rocks. Here, we study the simple but nontrivial problem of calcite growth on fractures with rough walls of the same mineral using kinetic Monte Carlo simulations of attachment and detachment of molecules and scaling approaches. First, we consider wedge-shaped fracture walls whose upper terraces are in the same low-energy planes and show that the valleys are slowly filled by the propagation of parallel monolayer steps in the wedge sides. The growth ceases when the walls reach these low-energy configurations so that a gap between the walls may not be filled. Second, we consider fracture walls with equally separated monolayer steps (vicinal surfaces with roughness below 1 nm) and show that growth by step propagation will eventually clog the fracture gap. In both cases, scaling approaches predict the times to attain the final configurations as a function of the initial geometry and the step-propagation velocity, which is set by the saturation index. The same reasoning applied to a random wall geometry shows that step propagation leads to lateral filling of surface valleys until the wall reaches the low-energy crystalline plane that has the smallest initial density of molecules. Thus, the final configurations of the fracture walls are much more sensitive to the crystallography than to the roughness or the local curvature. The framework developed here may be used to determine those configurations, the times to reach them, and the mass of deposited mineral. Effects of transport limitations are discussed when the fracture gap is significantly narrowed.

calcite↗
NASA NTRS1971

Effects of surface roughness on the photometric properties of Mars

Starting with a macroscopically flat surface, which at each point scatters according to the Minnaert law with exponent k, the photometric effects of increasing the large-scale roughness of the Martian surface were investigated. The photometric properties of macroscopically rough surfaces can still be described by the Minnaert law, but with an exponent k star, in general not equal to k. Therefore observed values of the Minnaert exponent cannot be used to infer the small-scale surface properties of Mars (or of any planet) unless proper allowance is made for the photometric effects of large-scale roughness. The azimuthal dependence of k star provides a sensitive test for the importance of these effects.

Veverka, J.↗
NASA NTRS1971

Lunar terrain mapping and relative-roughness analysis

Terrain maps of the equatorial zone were prepared at scales of 1:2,000,000 and 1:1,000,000 to classify lunar terrain with respect to roughness and to provide a basis for selecting sites for Surveyor and Apollo landings, as well as for Ranger and Lunar Orbiter photographs. Lunar terrain was described by qualitative and quantitative methods and divided into four fundamental classes: maria, terrae, craters, and linear features. Some 35 subdivisions were defined and mapped throughout the equatorial zone, and, in addition, most of the map units were illustrated by photographs. The terrain types were analyzed quantitatively to characterize and order their relative roughness characteristics. For some morphologically homogeneous mare areas, relative roughness can be extrapolated to the large scales from measurements at small scales.

Rowan, L. C.↗
NASA NTRS1972

Surface roughness effects on equilibrium temperature.

An analysis is presented for evaluation of equilibrium temperature distribution on radiatively adiabatic, adjoint planes which are uniformly irradiated by a collimated solar flux. The analysis employs a semigrey spectral model. Radiation properties for surface emitted radiation are obtained from the expressions of electromagnetic theory for smooth surfaces. Rough surface properties for solar radiation are given by the Beckmann bidirectional reflectance model. Numerical solutions to the governing equations yield equilibrium temperature distributions for a range of the influencing parameters. Surface roughness has little influence on equilibrium temperature for materials with high values for solar absorptance. However, for low or intermediate values of solar absorptance, roughness effects on the spatial distribution of reflected solar radiation can significantly alter equilibrium temperature particularly at surface elements where radiant interaction is small.

Houchens, A. F.↗
NASA NTRS1972

Effects of surface roughness on the photometric properties of Mars.

Starting with a macroscopically flat surface which at each point scatters according to the Minnaert law with exponent k, we investigate the photometric effects of increasing the large scale roughness of the surface. It is found that the photometric properties of macroscopically rough surfaces can still be described by the Minnaert law, but with an exponent k1, in general not equal to k. In fact, examples are given where k1 differs considerably from k. Therefore observed values of the Minnaert exponent cannot be used to infer the small scale surface properties of Mars (or of any planet) unless proper allowance is made for the photometric effects of large scale roughness. The azimuthal dependence of k1 provides a sensitive test for the importance of these effects.

Veverka, J.↗
NASA NTRS1970

A rough earth scattering model for multipath prediction

The most important phenomena to be considered in a model of radio wave communication between earth satellites are scattering from the surface of the earth. A model is derived and implemented on a computer to predict the field received after reflection from a rough, spherical earth. The scattering integrals are computed numerically; the domain of integration is the appropriate region on the surface of the earth. Calculations have been performed at VHF frequencies and for terrain which could be described as marshy land. Rough surface scattering calculations must be performed over a spherical earth when satellites are involved. There is a definite dependence on the values of the roughness, and the correlation length.

Page, L. J.↗
NASA NTRS1973

Numerical comparisons of a modified Rayleigh approach with other rough surface EM scattering solutions.

A modification of the classical Rayleigh technique utilizing the fast Fourier transform, developed into the so-called Rayleigh-FFT method for electromagnetic scattering, is shown to obtain valid scattering results from arbitrary irregular periodic structures composed of a rough layer over a rough half-space. The considerable usefulness of the Rayleigh approach is thus established, and Beckmann's (1968) contention (that the convergence of the method is reasonably rapid only if the roughness is very slight) is refuted.

Jiracek, G. R.↗
NASA NTRS1974

Lubricant pressure rippling in dynamic Hertzian contacts induced by surface roughness

A numerical analysis of the pressure distribution of a lubricant in contact with a rough surface was conducted. The magnitude of the pressures was determined by their root mean square value for the contact of two dimensional cylinders. The pressure was found to vary in the following manner: (1) the location in the contact, (2) the spectrum or frequency content of the surface roughness, (3) the mean plateau film thickness, and (4) the root mean square value of the surface roughness. Mathematical models are developed to show the relationships of the parameters.

Tallian, T. E.↗
NASA NTRS1974

Dual frequency microwave radiometer measurements of soil moisture for bare and vegetated rough surfaces

Controlled ground-based passive microwave radiometric measurements on soil moisture were conducted to determine the effects of terrain surface roughness and vegetation on microwave emission. Theoretical predictions were compared with the experimental results and with some recent airborne radiometric measurements. The relationship of soil moisture to the permittivity for the soil was obtained in the laboratory. A dual frequency radiometer, 1.41356 GHz and 10.69 GHz, took measurements at angles between 0 and 50 degrees from an altitude of about fifty feet. Distinct surface roughnesses were studied. With the roughness undisturbed, oats were later planted and vegetated and bare field measurements were compared. The 1.4 GHz radiometer was less affected than the 10.6 GHz radiometer, which under vegetated conditions was incapable of detecting soil moisture. The bare surface theoretical model was inadequate, although the vegetation model appeared to be valid. Moisture parameters to correlate apparent temperature with soil moisture were compared.

Lee, S. L.↗
NASA NTRS1975

Rough-to-smooth transition of an equilibrium neutral constant stress layer

A model is proposed for low-level atmospheric flows over terrains of changing roughness length, such as those found at the windward end of landing strips adjoining rough terrain. The proposed model is used to develop a prediction technique for calculating transition wind and shear-stress profiles in the region following surface roughness discontinuity. The model for the transition region comprises two layers: a logarithmic layer and a buffer layer. The flow is assumed to be steady, two-dimensional, and incompressible, with neutral hydrostatic stability. A diagram is presented for a typical wind profile in the transition region, obtained from the logarithmic and velocity defect profiles using shear stress calculated by relevant equations.

Logan, E., Jr.↗
NASA NTRS1975

Rough-to-smooth transition of an equilibrium neutral constant stress layer

Purpose of research on rough-to-smooth transition of an equilibrium neutral constant stress layer is to develop a model for low-level atmospheric flow over terrains of abruptly changing roughness, such as those occurring near the windward end of a landing strip, and to use the model to derive functions which define the extent of the region affected by the roughness change and allow adequate prediction of wind and shear stress profiles at all points within the region. A model consisting of two bounding logarithmic layers and an intermediate velocity defect layer is assumed, and dimensionless velocity and stress distribution functions which meet all boundary and matching conditions are hypothesized. The functions are used in an asymptotic form of the equation of motion to derive a relation which governs the growth of the internal boundary layer. The growth relation is used to predict variation of surface shear stress.

Logan, E., Jr.↗
NASA NTRS1976

Selection of remote sensing techniques - Surface roughness information from 3 cm wavelength SLAR images

The value of SLAR (Side-Looking Airborne Radar) image data for detecting and measuring small-scale surface roughness is examined, using as an example the Cottonball Basin in Death Valley National Monument, California. The SLAR image was obtained by an X-band (3 cm wavelength) synthetic aperture radar system operated at an altitude of 10,732 m above sea level. The polarization of the transmitted and received signals was horizontal. Film density values were used to produce color hypsometric maps of small-scale surface irregularities. It is shown that semi-quantitative surface roughness information, from uniquely flat surfaces such as the Cottonball Basin, can be obtained by analysis of 3 cm wavelength SLAR images calibrated by limited field measurements. Quantitative roughness data could be obtained with proper consideration of modifying surface and radar system parameters.

Schaber, G. G.↗
NASA NTRS1976

Effects of load, speed, and surface roughness on sliding EHD contact temperatures

An infrared technique has been used to determine the effects of load, speed and surface roughness on temperature in a sliding elastohydrodynamic (EHD) point contact. Ball surface temperatures are reported for sliding speeds of 0.35 to 5.08 m/s at 0.52 to 2.03 GN/per sq m maximum pressure with surface roughness in the range 0.01 to 0.38 micron c.l.a. The relationship between asperity interaction, as measured by relocation surface profilimetry and high frequency temperature measurements, and the ratio of film thickness to surface roughness has also been studied.

Nagaraj, H. S.↗
NASA NTRS1977

Effect of surface cooling and roughness on transition for the Shuttle Orbiter

An analysis of roughness-induced boundary-layer transition examines the sensitivity of the Orbiter boundary-layer transition criteria to surface cooling, to surface roughness, and to the assumed flow-field model. The experimental data were obtained using a 0.0175-scale Orbiter with surface roughness represented by misaligned heat-shield tiles for surface temperatures from 0.12 stagnation temperature (a value typical of entry conditions) to 0.42 stagnation temperature (a value typical of continuous-flow wind-tunnels). Tile misalignment had only a slight effect on the heat transfer and on the trasition locations for wall temperature = 0.42 stagnation temperature. Cooling the boundary layer caused the tile-induced disturbances to increase significantly, promoting premature transition. Correlation of the effects of the misalignment height and of surface cooling in promoting transition are presented and predictions are made for typical Orbiter entry conditions.

Bertin, J. J.↗