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NASA NTRS1993

Turntable mechanism

In vacuum plasma spraying a turntable must be provided which not only makes it possible to rotate and tilt a heavy workpiece, but to operate at vacuum plasma temperatures to do so. In the vacuum plasma coating of large parts such as combustion chambers of rocket engines, the workpiece must not only be rotated, but it must be tilted. Hence, the turntable must be capable not only of supporting heavy parts, but of angulating such heavy workpieces. And this must be done without drive means failure due to extremely high temperatures under which the turntable mechanism is operated. A turntable mechanism is provided which is capable of operating under such conditions. For cooling the turntable drive mechanism, internal cooling means are included.

Myers, William Neill↗

DOE OSTI2024

Examining Graphite Degradation in Molten Salt Environments: A Chemical, Physical, and Material Analysis

Molten-salt reactors (MSRs) are Generation IV nuclear reactors that use liquid salt as a coolant and/or fuel. In several MSR designs, graphite serves as a moderator and/or reflector. However, due to limited experimental data and operational experience, our understanding of graphite behavior in molten salt environments remains incomplete. This report aims to identify the degradation mechanisms of nuclear graphite in MSRs, detail the mechanisms of each factor, and provide an initial assessment of their impact on the structural integrity of graphite components. This assessment is based on an extensive literature review and insights from subject matter experts. Furthermore, given the limited data, a modeling strategy using existing Grizzly software is proposed for a more thorough analysis where appropriate. Additionally, it presents mitigation strategies where applicable. The report covers physical degradation mechanisms such as infiltration, erosion, and abrasion, as well as chemical degradation mechanisms including fluorination, intercalation, corrosion, and oxidation. Molten salt can infiltrate the porous structure of graphite, leading to several detrimental effects. Entrapment of fissile products within the graphite pores can cause radiation damage and could pose challenges in the handling and disposal of contaminated components. The differential thermal expansion between the infiltrated salt and graphite, along with internal stress from pressurized molten salt and volumetric heating, can compromise the structural integrity of graphite. To mitigate these effects, employing ultra-fine graphite grades and applying sealants and coatings are effective strategies. A computational model based on coupled solid mechanics and heat transfer phenomena could be used to predict the internal stresses using Grizzly software. In pebble-bed MSRs, graphite fuel pebbles can cause abrasion against reactor components due to friction and wear. The severity of wear is influenced by various factors such as temperature, environment, and the presence of lubricants. Tribological studies reveal that higher temperatures and molten salt environments, such as FLiBe, significantly reduce wear rates compared to dry conditions. Additionally, the chemical composition of the salt can further optimize graphite's tribological performance. Long-term wear effects can be modeled by incorporating surface defects into the geometry and predict stresses under thermal and radiation effects using Grizzly software. Chemical degradation of graphite in a molten salt environment can occur through fluorination and intercalation. Fluorination can occur via replacement of hydrogen or oxygen atoms, or at the active sites, but does not cause structural degradation. Intercalation, on the other hand, can lead to exfoliation, where layers of graphite separate and peel away, damaging the graphite. Protective coatings can enhance graphite's resistance to intercalation. Graphite generally exhibits good chemical stability in molten salt environments, though it can corrode under specific conditions, particularly in the presence of impurities or oxidants. Studies have shown that protective coatings, such as plasma-sprayed partially stabilized zirconia (PSZ), can effectively prevent such degradation. Corrosion behavior varies significantly with different graphite grades and coating applications, underscoring the need for detailed studies on uncoated and coated graphite to understand and mitigate corrosion mechanisms in MSRs. Research indicates that the presence of oxidants and impurities can accelerate graphite degradation in molten salts, making it essential to explore acceptable impurity limits. Oxidation is another critical degradation mechanism, leading to weight loss and structural damage due to the formation of CO and CO 2 from the reaction of carbon atoms with oxygen. This process creates new porosity and compromises graphite's integrity. While extensive research on graphite oxidation has been conducted for gas-cooled reactors, studies specific to MSRs are limited. Findings from the coal industry suggest that molten alkali metal salts can significantly accelerate graphite oxidation, a hypothesis worth exploring for fluoride salts in MSRs. Understanding oxidation behavior in MSRs is vital for developing protective measures. The analysis of post-irradiated graphite from the MSRE experiment demonstrated exceptional chemical compatibility with molten fluoride salt, suggesting that the extent of chemical attack on graphite largely depends on the salt's infiltration capability. Therefore, the use of ultra-fine grade graphite could help mitigate chemical degradation effects. Existing oxidation modeling capabilities in Grizzly, which use reaction-diffusion equations to model graphite-air interactions, could be adapted to simulate the chemical degradation effects of graphite in molten salt environments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2014

Development and Performance Evaluations of HfO2-Si and Rare Earth-Si Based Environmental Barrier Bond Coat Systems for SiC/SiC Ceramic Matrix Composites

Ceramic environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft propulsion systems because of their ability to significantly increase engine operating temperatures, improve component durability, reduce engine weight and cooling requirements. Advanced EBC systems for SiCSiC CMC turbine and combustor hot section components are currently being developed to meet future turbine engine emission and performance goals. One of the significant material development challenges for the high temperature CMC components is to develop prime-reliant, high strength and high temperature capable environmental barrier coating bond coat systems, since the current silicon bond coat cannot meet the advanced EBC-CMC temperature and stability requirements. In this paper, advanced NASA HfO2-Si based EBC bond coat systems for SiCSiC CMC combustor and turbine airfoil applications are investigated. The coating design approach and stability requirements are specifically emphasized, with the development and implementation focusing on Plasma Sprayed (PS) and Electron Beam-Physic Vapor Deposited (EB-PVD) coating systems and the composition optimizations. High temperature properties of the HfO2-Si based bond coat systems, including the strength, fracture toughness, creep resistance, and oxidation resistance were evaluated in the temperature range of 1200 to 1500 C. Thermal gradient heat flux low cycle fatigue and furnace cyclic oxidation durability tests were also performed at temperatures up to 1500 C. The coating strength improvements, degradation and failure modes of the environmental barrier coating bond coat systems on SiCSiC CMCs tested in simulated stress-environment interactions are briefly discussed and supported by modeling. The performance enhancements of the HfO2-Si bond coat systems with rare earth element dopants and rare earth-silicon based bond coats are also highlighted. The advanced bond coat systems, when integrated with advanced EBC top coats, showed promise to achieve 1500 C temperature capability, helping enable next generation turbine engines with significantly improved engine component temperature capability and long-term durability.

HfO2-Si bond coat↗

DOE OSTI2022

Journal paper

Laser technology is being widely studied for controlled energy deposition for a range of applications, including flow control, ignition, combustion, and diagnostics. The absorption and scattering of laser radiation by liquid droplets in aerosols affects propagation of the laser beam in the atmosphere, while the ignition and combustion characteristics in combustion chambers are influenced by the evaporation rate of the sprayed fuel. In this work, we present a mathematical model built on OpenFOAM for laser heating and evaporation of a single droplet in the diffusion-dominated regime taking into account absorption of the laser radiation, evaporation process, and vapor flow dynamics. The developed solver is validated against available experimental and numerical data for heating and evaporation of ethanol and water droplets. The two main regimes—continuous and pulsed laser heating—are explored. For continuous laser heating, the peak temperature is higher for larger droplets. For pulsed laser heating, when the peak irradiance is close to transition to the boiling regime, the temporal dynamics of the droplet temperature does not depend on the droplet size. With the empirical normalization of time, the dynamics of the droplet shrinkage and cooling are found to be independent of droplet sizes and peak laser intensities.

42 ENGINEERING↗

DOE OSTI2022

Numerical Modeling of Laser Heating and Evaporation of a Single Droplet

42 ENGINEERING↗

NASA NTRS2009

Aerojet - AJ10-137 Apollo Service Module Engine

The general configuration of the SPS engine was 20,000 pounds of thrust, with a chamber pressure of 100 psi and specific impulse (Isp) of 314.5. The very large nozzle had an area ratio of 62.5:1 (exit area to throat area). The propellants were nitrogen tetroxide (also known as N2O4 and nitrous oxide) and A-50. A-50 was a hydrazine family fuel. Aerojet developed it for the Titan Missile Program when they went with Titan II, to store it in the launch silos. They wanted the highest performance they could get. N2H4 was just pure hydrazine, which doesn't take low temperature very well. In fact, it freezes about like water. We started adding unsymmetrical-dimethylhydrazine (UDMH) to the hydrazine until such time as it would meet the environmental specifications the Air Force needed for Titan II. It turned out it s roughly a fifty-fifty mix. We still had to be careful with that fuel because the two fluids didn't mix very well chemically. We had to spray the two fluids through some special nozzles to get them to emulsify with each other into a single fluid. If we ever got it too cold or froze it, the hydrazine separated back out. Then, if we tried to run the engine, things could go boom in the night. The inlet pressure was only 165 pounds per square inch absolute (psia), but we needed at least forty psi pressure drop across the injector just to get some kind of stable flow. It was a whole new game for some of us. We didn't have much supply pressure to work with. It had the aluminum injector to keep the weight down. That was a couple feet in diameter, and we didn't have a lot of propellant to cool it. In fact, we had to use both propellants to keep the injector cool. There were twenty-two ring channels in the injector. Specification required 750 seconds duration, or fifty engine restarts during a flight. There were several first flight things we accomplished with the engine. It was the first ablative thrust chamber of any size to fly. (See Slide 6, Appendix G) There were no liners in it. It was just straight ablative material. It took us a while to figure that out. It was a throat-gimbaled engine, and it was the first engine to fly with columbium (also known as niobium, used as an alloying element in steels and superalloys) in the nozzle.

Boyce, Clay↗

NASA NTRSDate not supplied

Numerical Modeling of No Vent Filling of a Cryogenic Tank with Thermo-dynamic Vent System Assisted Injector

This paper presents a multi-node finite volume model of No Vent Filling (NVF) of a cryogenic tank with Thermo-dynamic Vent System (TVS) assisted injector, using the Generalized Fluid System Simulation Program (GFSSP), a general purpose flow network code. NVF tests were conducted in a CRYOgenic Orbital Testbed (CRYOTE) tank which was filled by liquid nitrogen using a TVS assisted injector with vent valve closed during the entire filling process. In TVS assisted injector, the liquid flow splits into two streams: one stream is routed to a Joule-Thomson (J-T) orifice where the flow immediately flashes from liquid to vapor or two phase mixture because the downstream to J-T leg is maintained at vacuum level.; the other stream is injected into the tank after being cooled by cold vapor of J-T leg in a heat exchanger. The flow through J-T leg is also used to cool the outer metal matrix of the injector which in turn cools the vapor in the tank ullage. The cooling of vapor in the ullage by cold injector surface reduces ullage pressure that allows liquid to enter and fill the tank. An integrated numerical model of the test set up was developed. The model included the dual lines of TVS assisted injector, tank and tank wall. The tank was discretized into multiple fluid nodes and branches to represent the ullage and liquid nitrogen and multiple solid nodes to represent the tank wall and structure. The heat transfer between solid to fluid was calculated from pool boiling correlations which include film, transition, and nucleate boiling, as well as natural convection during pre- and post-boiling. The model also accounts for the condensation of vapor at ullage-injector interface and when it comes in contact with the liquid spray. The predicted pressure, resident mass, wall temperature in the tank were compared with the test data.

Alok Majumdar↗

NASA NTRS1984

Experimental and theoretical deposition rates from salt-seeded combustion gases of a Mach 0.3 burner rig

Deposition rates on platinum-rhodium cylindrical collectors rotating in the cross streams of the combustion gases of a salt-seeded Mach 0.3 burner rig were determined. The collectors were internally air cooled so that their surface temperatures could be widely varied while they were exposed to constant combustion gas temperatures. The deposition rates were compared with those predicted by the chemically frozen boundary layer (CFBL) computer program, which is based on multicomponent vapor transport through the boundary layer. Excellent agreement was obtained between theory and experiment for the NaCl-seeded case, but the agreement lessened as the seed was changed to synthetic sea salt, NaNO3, and K2SO4, respectively, and was particularly poor in the case of Na2SO4. However, when inertial impaction was assumed to be the deposition mechanism for the Na2SO4 case, the predicted rates agreed well with the experimental rates. The former were calculated from a mean particle diameter that was derived from the measured intial droplet size distribution of the solution spray. Critical experiments showed that liquid phase deposits were blown off the smooth surface of the platinum-rhodium collectors by the aerodynamic shear forces of the high-velocity combustion gases but that rough or porous surfaces retained their liquid deposits.

Santoro, G. J.↗

NASA NTRSDate not supplied

Summary of Testing Results for the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER)

Testing was completed on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) between August 2019 and January 2020. SHIIVER was designed to be a test bed for the scaling of cryogenic fluid management technologies as applied to large upper stages and long duration in-space stages. The baseline SHIIVER design consists of uninsulated structural skirts attached to a propellant tank insulated with polyurethane Spray-On Foam Insulation (SOFI). The initial testing of the SHIIVER hardware was with liquid hydrogen and sought to demonstrate the use of boil-off vapor to intercept heat on a structural skirt, multilayer insulation (MLI) on the tank domes, and the radio frequency mass gauge (RFMG). Testing was completed in four stages: a baseline thermal vacuum test prior to installation of the MLI on the tank domes, a thermal vacuum test after the MLI installation, a reverberant acoustic test, and a subsequent thermal vacuum test to verify that no damage occurred during the reverberant acoustic testing. Each thermal vacuum test with chamber wall at ambient temperature and vacuum level in the 10-6 torr range was conducted continuously between approximately 90% full and 25% full. Test results showed that the vapor cooling reduced the heat load to the tank by approximately 10%, but the boil-off by less than 3% at 50% full, with and without MLI installed on the domes. The MLI installed on the domes reduced the heat load to the tank by approximately 40% at all fill levels, but the boil-off by approximately 25% at 90% full and 45% below 65% full. The RFMG performed well over all fill ranges, and several RF tank modes were used to gauge the mass of fluid in the tank. SHIIVER was then exposed to an acoustic environment of 147 dB OASPL (overall sound pressure level) in a reverberant chamber. The acoustic environment envelopes the upper stage internal acoustic level of several different modern launch vehicles. No structural or thermal performance changes were observed after exposure to the acoustic environment. Final thermal vacuum testing after the acoustic testing showed no degradation to the MLI due to the acoustic environment as measured via system heat loads

SHIIVER↗

NASA NTRS1997

Enhancement of Nucleate Boiling Heat Flux on Macro/Micro-Structured Surfaces Cooled by Multiple Impinging Jets

An experimental investigation of nucleate boiling heat transfer from modified surfaces cooled by multiple in-line impinging circular jets is reported and found to agree with single jet results. A copper block is heated from the back by two electrical arcs, and cooled on the opposite side by three identical liquid jets of distilled water at subcoolings of 25 C 50 C and 77 C and Freon 113 at 24 C subcooling. Liquid flow rates are held constant at 5, 10, and 15 GPH for each of the three jets with jet velocities ranging from 1.4 m/s to 1 1.2 m/s and jet diameters from 0.95 mm to 2.2 mm. To increase the maximum heat flux (CHF) and heat removal rate, the boiling surface was modified by both macro and micro enhancements. Macro modification consists of machined radial grooves in the boiling surface arranged in an optimally designed pattern to allow better liquid distribution along the surface. These grooves also reduce splashing of liquid droplets, and provide 'channels' to sweep away bubbles. Micro modification was achieved by flame spraying metal powder on the boiling surface, creating a porous, sintered surface. With the addition of both micro and macro structured enhancements, maximum heat flux and nucleate boiling can be enhanced by more than 200%. Examination of each surface modification separately and together indicates that at lower superheats, the micro structure provides the enhanced heat transfer by providing more nucleation sites, while for higher superheats the macro structure allows better liquid distribution and bubble removal. A correlation is presented to account for liquid subcoolings and surface enhancements, in addition to the geometrical and fluid properties previously reported in the literature.

Kugler, Scott Lee↗

DOE OSTI2026

Flame stabilization in DME spray flames under engine-relevant conditions characterized by OH* chemiluminescence and formaldehyde laser-induced fluorescence

The transient and quasi-steady flame structures of Dimethyl Ether (DME) fuel sprays, produced by a single-hole injector (Spray D), were investigated using Planar Laser-Induced Fluorescence (PLIF) and chemiluminescence imaging in a constant-volume chamber under Engine Combustion Network (ECN) Spray A conditions (900 K ambient temperature, 60 bar ambient pressure, 1500 bar injection pressure, and 22.8 kg/m 3 ambient density). Low-temperature chemical reaction zones were visualized using formaldehyde (CH 2 O) PLIF with 355 nm excitation, while high-temperature flame regions were captured via chemiluminescence imaging of excited-state hydroxyl radicals (OH*). Both transient and quasi-steady flame structures clearly show the transition from CH 2 O to OH*, highlighting the progression from low- to high-temperature combustion, while the position of the flame is displaced for DME compared to reference hydrocarbon n-dodecane. Homogeneous reactor calculations with detailed chemistry and using adiabatic mixing for initial temperature show that CH 2 O peaks are significantly higher for DME at the same equivalence ratio, with a higher heat-release during the cool-flame regime with respect to the fuel heating value. Thus, the cool-flame dynamic as a precursor to high-temperature combustion and flame stabilization exhibit distinct behavior for DME relative to conventional hydrocarbons, and these phenomena are effectively resolved through the soot-free nature of DME and the high-speed, time-resolved diagnostics.

CH2O laser-induced fluorescence↗

NASA NTRS1986

De-icing of the altitude wind tunnel turning vanes by electro-magnetic impulse

The Altitude Wind Tunnel at the NASA-Lewis facility is being proposed for a refurbishment and moderization. Two major changes are: (1) the increasing of the test section Mach number to 0.90, and (2) the addition of spray nozzles to provide simulation of flight in icing clouds. Features to be retained are the simulation of atmospheric temperature and pressure to 50,000 foot altitude and provision for full-scale aircraft engine operation by the exhausting of the aircraft combustion gases and ingestion of air to replace that used in combustion. The first change required a re-design of the turning vanes in the two corners downstream of the test section due to the higher Mach number at the corners. The second change threatens the operation of the turning vanes by the expected ice build-up, particulary on the first-corner vanes. De-icing by heat has two drawbacks: (1) an extremely large amount of heat is required, and (2) the melted ice would tend to collect as ice on some other surfaces in the tunnel, namely, the tunnel propellers and the cooling coils. An alternate de-icing method had been under development for three years under NASA-Lewis grants to the Wichita State University. This report describes the electro-impulse de-icing (EIDI) method and the testing work done to assess its applicability to wind tunnel turning vane de-icing. Tests were conducted in the structural dynamics laboratory and in the NASA Icing Research Tunnel. Good ice protection was achieved at lower power consumption and at a wide range of tunnel operations conditions. Recommendations for design and construction of the system for this application of the EIDI method are given.

Zumwalt, G. W.↗

NASA NTRS2001

Detailed Studies on Flame Extinction by Inert Particles in Normal- and Micro-gravity

The combustion of dusty flows has been studied to lesser extent than pure gas phase flows and sprays. Particles can have a strong effect by modifying the dynamic response and detailed structure of flames through the dynamic, thermal, and chemical couplings between the two phases. A rigorous understanding of the dynamics and structure of two-phase flows can be attained in stagnation flow configurations, which have been used by others to study spray combustion as well as reacting dusty flows. In earlier studies on reacting dusty flows, the thermal coupling between the two phases as well as the effect of gravity on the flame response were not considered. However, in Ref. 6, the thermal coupling between chemically inert particles and the gas was addressed in premixed flames. The effects of gravity was also studied showing that it can substantially affect the profiles of the particle velocity, number density, mass flux, and temperature. The results showed a strong dynamic and thermal dependence of reacting dusty flows to particle number density. However, the work was only numerical and limited to twin-flames, stagnation, premixed flames. In Ref. 7 the effects of chemically inert particle clouds on the extinction of strained premixed and non-premixed flames were studied both experimentally and numerically at 1-g. It was shown and explained that large particles can cause more effective flame cooling compared to smaller particles. The effects of flame configuration and particle injection orientation were also addressed. The complexity of the coupling between the various parameters in such flows was demonstrated and it was shown that it was impossible to obtain a simple and still meaningful scaling that captured all the pertinent physics.

Andac, M. G.↗

NASA NTRS2016

Rapid Fabrication Techniques for Liquid Rocket Channel Wall Nozzles

The functions of a regeneratively-cooled nozzle are to (1) expand combustion gases to increase exhaust gas velocity while, (2) maintaining adequate wall temperatures to prevent structural failure, and (3) transfer heat from the hot gases to the coolant fluid to promote injector performance and stability. Regeneratively-cooled nozzles are grouped into two categories: tube-wall nozzles and channel wall nozzles. A channel wall nozzle is designed with an internal liner containing a series of integral coolant channels that are closed out with an external jacket. Manifolds are attached at each end of the nozzle to distribute coolant to and away from the channels. A variety of manufacturing techniques have been explored for channel wall nozzles, including state of the art laser-welded closeouts and pressure-assisted braze closeouts. This paper discusses techniques that NASA MSFC is evaluating for rapid fabrication of channel wall nozzles that address liner fabrication, slotting techniques and liner closeout techniques. Techniques being evaluated for liner fabrication include large-scale additive manufacturing of freeform-deposition structures to create the liner blanks. Abrasive water jet milling is being evaluated for cutting the complex coolant channel geometries. Techniques being considered for rapid closeout of the slotted liners include freeform deposition, explosive bonding and Cold Spray. Each of these techniques, development work and results are discussed in further detail in this paper.

Gradl, Paul R.↗

DOE OSTI2021

Energy Efficient Waste Heat Coupled Forward Osmosis for Effluent Water Management at Coal-Fired Power Plants

This project sought to evaluate the technical and economic viability of the Aquapod©, a transformational low energy (<200 kJ/kg water) waste heat coupled forward osmosis (FO) technology, to manage effluents, meet cooling water demands, and achieve water conservation in a coal-fired power plant environment. The Aquapod© process is innovative because it is heat-driven, avoids the evaporation of water, and uses no toxic chemicals such as ammonia or amines. The Aquapod© process accomplishes this using an aqueous two-phase system (ATPS) coupled FO process. The evaluation revealed that the Aquapod© process offers a pathway to exploit waste heat resources within a power plant to achieve flue-gas desulfurization (FGD) wastewater volume reduction and water recovery with minimal pretreatment. Water recovery of 80% from FGD wastewater was achieved with minimal pretreatment, exceeding the project target of 50%. The estimated electrical energy of 2.16 kWh/m 3 of water produced for the Aquapod© process met the project target of < 3.6 kWh/m 3 . The heat required for the process operation was approximately 186 kJ/kg of produced water, which was slightly lower than the project target of 200 kJ/kg. The estimated treatment cost for installing and operating the Aquapod© process in conjunction with a spray dryer evaporator to achieve zero-liquid discharge (ZLD) of the 100 gpm FGD wastewater was $13.24/m 3 over a 30-year lifetime. As a point of reference, this study’s host power plant currently incurs a cost of $3.70/m 3 – $8.87/m3 on a discharged volume basis to discharge its wastewater into the publicly owned treatment works (POTW) after physical-chemical treatment. Therefore, the Illinois power plant would incur an incremental cost increase of $4.37/m 3 – 9.54/m 3 to achieve ZLD using the Aquapod© and spray dryer combination. Ample opportunities exist to further lower the ZLD capital and operating costs in the next design iteration to attain pipe parity at the higher end of the site treatment costs.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS2005

High-Temperature, Thin-Film Strain Gages Improved

Conventional resistance strain gage technology uses "bonded" strain gages. These foil or wire gages are bonded onto the surface of the test article with glue, ceramic cements, or flame-sprayed ceramics. These bonding agents can, in some instances, limit both the degree of strain transmission from the test structure to the gage and the maximum working temperature of the gage. Also, the bulky, bonded gage normally disrupts aerodynamic gas flow on the surface of the test structure because of its intrusive character. To respond to the urgent needs in aeronautic and aerospace research where stress and temperature gradients are high, aerodynamic effects need to be minimized, and higher operational temperatures are required, the NASA Lewis Research Center developed a thin film strain gage. This gage, a vacuum-deposited thin film formed directly on the surface of a test structure, operates at much higher temperatures than commercially available gages do and with minimal disruption of the aerodynamic flow. The gage uses an alloy, palladium-13 wt % chromium (hereafter, PdCr), which was developed by United Technologies Research Center under a NASA contract. PdCr is structurally stable and oxidation resistant up to at least 1100 C (2000 F); its temperature-induced resistance change is linear, repeatable, and not sensitive to the rates of heating and cooling. An early strain gage, which was made of 25-micrometer-diameter PdCr wire and demonstrated to be useable to 800 C, won an R&D 100 award in 1991. By further improving the purity of the material and by developing gage fabrication techniques that use sputter-deposition, photolithography patterning, and chemical etching, we have made an 8- to 10-m PdCr thin-film strain gage that can measure dynamic and static strain to at least 1100 C. For static strain measurements, a 5-m-thick Pt element serves as a temperature compensator to further minimize the temperature effect of the gage. These thin-film gages provide the advantage of minimally intrusive surface strain measurements and give highly repeatable readings with low drift at temperatures from ambient to 1100 C. This is a 300 C advance in operating temperature over the PdCr wire gage and a 500 C advance over commercially available gages made of other materials.

Source record↗

DOE OSTI2024

Measurement report: A comparison of ground-level ice-nucleating-particle abundance and aerosol properties during autumn at contrasting marine and terrestrial locations

Abstract. Ice-nucleating particles (INPs) are an essential class of aerosols found worldwide that have far-reaching but poorly quantified climate feedback mechanisms through interaction with clouds and impacts on precipitation. These particles can have highly variable physicochemical properties in the atmosphere, and it is crucial to continuously monitor their long-term concentration relative to total ambient aerosol populations at a wide variety of sites to comprehensively understand aerosol–cloud interactions in the atmosphere. Hence, our study applied an in situ forced expansion cooling device to measure ambient INP concentrations and test its automated continuous measurements at atmospheric observatories, where complementary aerosol instruments are heavily equipped. Using collocated aerosol size, number, and composition measurements from these sites, we analyzed the correlation between sources and abundance of INPs in different environments. Toward this aim, we have measured ground-level INP concentrations at two contrasting sites, one in the Southern Great Plains (SGP) region of the United States with a substantial terrestrially influenced aerosol population and one in the Eastern North Atlantic Ocean (ENA) region with a primarily marine-influenced aerosol population. These measurements examined INPs mainly formed through immersion freezing and were performed at a ≤ 12 min resolution and with a wide range of heterogeneous freezing temperatures (Ts above −31 °C) for at least 45 d at each site. The associated INP data analysis was conducted in a consistent manner. We also explored the additional offline characterization of ambient aerosol particle samples from both locations in comparison to in situ data. From our ENA data, on average, INP abundance ranges from ≈ 1 to ≈ 20 L−1 (−30 °C ≤ T ≤ −20 °C) during October–November 2020. Backward air mass trajectories reveal a strong marine influence at ENA with 75.7 % of air masses originating over the Atlantic Ocean and 96.6 % of air masses traveling over open water, but analysis of particle chemistry suggests an additional INP source besides maritime aerosols (e.g., sea spray aerosols) at ENA. In contrast, 90.8 % of air masses at the SGP location originated from the North American continent, and 96.1 % of the time, these air masses traveled over land. As a result, organic-rich SGP aerosols from terrestrial sources exhibited notably high INP abundance from ≈ 1 to ≈ 100 L−1 (−30 °C ≤ T ≤ −15 °C) during October–November 2019. The probability density function of aerosol surface area-scaled immersion freezing efficiency (ice nucleation active surface site density; ns) was assessed for selected freezing temperatures. While the INP concentrations measured at SGP are higher than those of ENA, the ns(T) values of SGP (≈ 105 to ≈ 107 m−2 for −30 °C ≤ T ≤ −15 °C) are reciprocally lower than ENA for approximately 2 orders of magnitude (≈ 107 to ≈ 109 m−2 for −30 °C ≤ T ≤ −15 °C). The observed difference in ns(T) mainly stems from varied available aerosol surface areas, Saer, from two sites (Saer,SGP > Saer,ENA). INP parameterizations were developed as a function of examined freezing temperatures from SGP and ENA for our study periods.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2017

An Initial Study of the Fundamentals of Ice Crystal Icing Physics in the Nasa Propulsion Systems Laboratory

This paper presents results from an initial study of the fundamental physics of ice-crystal ice accretion using the NASA Propulsion Systems Lab (PSL). Ice accretion due to the ingestion of ice-crystals is being attributed to numerous jet-engine power-loss events. The NASA PSL is an altitude jet-engine test facility which has recently added a capability to inject ice particles into the flow. NASA is evaluating whether this facility, in addition to full-engine and motor-driven-rig tests, can be used for more fundamental ice-accretion studies that simulate the different mixed-phase icing conditions along the core flow passage of a turbo-fan engine compressor. The data from such fundamental accretion tests will be used to help develop and validate models of the accretion process. The present study utilized a NACA0012 airfoil. The mixed-phase conditions were generated by partially freezing the liquid-water droplets ejected from the spray bars. This paper presents data regarding (1) the freeze out characteristics of the cloud, (2) changes in aerothermal conditions due to the presence of the cloud, and (3) the ice accretion characteristics observed on the airfoil model. The primary variable in this test was the PSL plenum humidity which was systematically varied for two duct-exit-plane velocities (85 and 135 ms) as well as two particle size clouds (15 and 50 m MVDi). The observed clouds ranged from fully glaciated to fully liquid, where the liquid clouds were at least partially supercooled. The air total temperature decreased at the test section when the cloud was activated due to evaporation. The ice accretions observed ranged from sharp arrow-like accretions, characteristic of ice-crystal erosion, to cases with double-horn shapes, characteristic of supercooled water accretions.

Evaporative Cooling↗