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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
NASA NTRS2004

Vacuum Plasma Spray Forming of Tungsten Lorentz Force Accelerator Components

The Vacuum Plasma Spray (VPS) Laboratory at NASA's Marshall Space Flight Center, working with the Jet Propulsion Laboratory, has developed and demonstrated a fabrication technique using the VPS process to form anode and cathode sections for a Lorentz force accelerator made from tungsten. Lorentz force accelerators are an attractive form of electric propulsion that provides continuous, high-efficiency propulsion at useful power levels for such applications as orbit transfers or deep space missions. The VPS process is used to deposit refractory metals such as tungsten onto a graphite mandrel of the desired shape. Because tungsten is reactive at high temperatures, it is thermally sprayed in an inert environment where the plasma gun melts and deposits the molten metal powder onto a mandrel. A three-axis robot inside the chamber controls the motion of the plasma spray torch. A graphite mandrel acts as a male mold, forming the required contour and dimensions for the inside surface of the anode or cathode of the accelerator. This paper describes the processing techniques, design considerations, and process development associated with the VPS forming of Lorentz force accelerator components.

Zimmerman, Frank R.↗
NASA NTRS2004

Design of a Microgravity Spray Cooling Experiment

An analytical and experimental study was conducted for the application of spray cooling in a microgravity and high-g environment. Experiments were carried out aboard the NASA KC-135 reduced gravity aircraft, which provided the microgravity and high-g environments. In reduced gravity, surface tension flow was observed around the spray nozzle, due to unconstrained liquid in the test chamber and flow reversal at the heat source. A transient analytical model was developed to predict the temperature and the spray heat transfer coefficient within the heated region. Comparison of the experimental transient temperature variation with analytical results showed good agreement for low heat input values. The transient analysis also verified that thermal equilibrium within the heated region could be reached during the 20-25s reduced gravity portion of the flight profile.

Baysinger, Kerri M.↗
NASA NTRS1947

Effects of Variations in Forebody and Afterbody Dead Rise on the Resistance and Spray Characteristics of the 22ADR Class VPB Airplane: Langley Tank Model 207, TED No. NACA 2361

An investigation was made to determine the effects of changes in the amount and distribution of forebody and afterbody dead rise on the hydrodynamic resistance and spray characteristics of a 1/11-size model of the Bureau of Aeronautics design No. 22ADR class VPB airplane. The variations in dead rise within the range investigated had no significant effects on resistance or trim, free to trim, or on resistance or trimming moment, fixed in trim. The coordinates of the peaks of the bow-spray blisters, with reference to the model, were measured at low speeds, and it was found that the model with the low dead rise at the bow had the lowest blisters. The changes in position of the maximum dead rise of the afterbody had no effect on the bow-spray blister.

Clement, Eugene P.↗
NASA NTRS1946

Tank Tests of a 1/7-Size Powered Dynamic Model of the Grumman XJR2F-1 Amphibian: Spray Characteristics, Take-Off and Landing Stability in Smooth Water - Langley Tank Model 212, TED No. NACA 2378

Tests of a model of the XJR2F-Y amphibian were made in Langley tank no. to determine the spray characteristics and the take-off and landing stability. At a gross load of 22,000 pounds full size, spray entered the propeller disk only at a very narrow range of speeds. The spray striking the flaps was not excessive and no appreciable wetting of the tail surfaces was noted. The trim limits of stability appeared to be satisfactory and the upper-limit porpoising was not violent. The stable range of center-of-gravity locations with flaps set 20deg was well aft of the desired operating range. However, with flaps up, the forward limit was about 18 percent mean aerodynamic chord and the aft limit about 28.5 percent mean aerodynamic chord at a load of 26,000 pounds and with elevators deflected -10deg. Under these conditions the location of the step is considered satisfactory. Tests showed that the effect of water in the nose-wheel well would be to move the forward limit aft about 2-percent mean aerodynamic chord. Without ventilation of the main step, the model skipped during landing at most trims, but this skipping was not violent. With the ventilation, the model skipped lightly only at trims where the afterbody keel was approximately parallel to the water (around 7.5 deg).

Land, Norman S.↗
NASA NTRS1990

Development of HVOF Sprayed Erosion/Oxidation Resistant Coatings for Composite Structural Components in Propulsion Systems

Thermally sprayed coatings are being studied and developed as methods of enabling lightweight composites to be used more extensively as structural components in propulsion applications in order to reduce costs and improve efficiency through weight reductions. The primary goal of this work is the development of functionally graded material [FGM] polymer/metal matrix composite coatings to provide improved erosion/oxidation resistance to polyimide-based polymer matrix composite [PMC] substrates. The goal is to grade the coating composition from pure polyimide, similar to the PMC substrate matrix on one side, to 100% WC-Co on the other. Both step-wise and continuous gradation of the loading of the WC-Co reinforcing phase are being investigated, Details of the coating parameter development will be presented, specifically the high velocity oxy-fuel [HVOF] combustion spraying of pure PMR-I1 matrix material and layers of various composition PMR-II/WC-Co blends onto steel and PMR-15 composite substrates. Results of the HVOF process optimization, microstructural characterization, and analysis will be presented. The sprayed coatings were evaluated using standard metallographic techniques - optical and scanning electron microscopy [SEMI. An SEM + electron dispersive spectroscopy [EDS] technique has also been used to confirm retention of the PMR-I1 component. Results of peel/butt adhesion testing to determine adhesion will also be presented.

Ivosevic, M.↗
NASA NTRS1999

High velocity pulsed wire-arc spray

Wire arc spraying using repetitively pulsed, high temperature gas jets, usually referred to as plasma jets, and generated by capillary discharges, substantially increases the velocity of atomized and entrained molten droplets. The quality of coatings produced is improved by increasing the velocity with which coating particles impact the coated surface. The effectiveness of wire-arc spraying is improved by replacing the usual atomizing air stream with a rapidly pulsed high velocity plasma jet. Pulsed power provides higher coating particle velocities leading to improved coatings. 50 micron aluminum droplets with velocities of 1500 m/s are produced. Pulsed plasma jet spraying provides the means to coat the insides of pipes, tubes, and engine block cylinders with very high velocity droplet impact.

Witherspoon, F. Douglas↗
NASA NTRS2008

Foam Spray Cooling Heat Transfer Performance Study

Previous studies have shown that spray cooling heat flux enhancement may be attained using enhanced surfaces. However, most enhanced surface spray cooling studies have been limited to extended and/or embedded surface structures. This study investigates the effect of foam on spray cooling heat flux. The foam used was graphite Poco Foam. The foam piece was attached to a copper block with a cross-sectional area of 2.0 cm(sup 2) using high thermal conductivity epoxy as the thermal interface material (TIM). Measurements were also obtained on a heater block with a flat surface for purposes of baseline comparison. A 2x2 nozzle array was used with PF-5060 as the working fluid. Thermal performance data was obtained under nominally degassed conditions (chamber pressure of 41.4 kPa). Results show that the highest heat flux (CHF) attained was 113 W/cm(sup 2) using the graphite Poco Foam.

Silk, E. A.↗
NASA NTRS2008

CFD Modeling of Superheated Fuel Sprays

An understanding of fuel atomization and vaporization behavior at superheat conditions is identified to be a topic of importance in the design of modern supersonic engines. As a part of the NASA aeronautics initiative, we have undertaken an assessment study to establish baseline accuracy of existing CFD models used in the evaluation of a ashing jet. In a first attempt towards attaining this goal, we have incorporated an existing superheat vaporization model into our spray solution procedure but made some improvements to combine the existing models valid at superheated conditions with the models valid at stable (non-superheat) evaporating conditions. Also, the paper reports some validation results based on the experimental data obtained from the literature for a superheated spray generated by the sudden release of pressurized R134A from a cylindrical nozzle. The predicted profiles for both gas and droplet velocities show a reasonable agreement with the measured data and exhibit a self-similar pattern similar to the correlation reported in the literature. Because of the uncertainty involved in the specification of the initial conditions, we have investigated the effect of initial droplet size distribution on the validation results. The predicted results were found to be sensitive to the initial conditions used for the droplet size specification. However, it was shown that decent droplet size comparisons could be achieved with properly selected initial conditions, For the case considered, it is reasonable to assume that the present vaporization models are capable of providing a reasonable qualitative description for the two-phase jet characteristics generated by a ashing jet. However, there remains some uncertainty with regard to the specification of certain initial spray conditions and there is a need for experimental data on separate gas and liquid temperatures in order to validate the vaporization models based on the Adachi correlation for a liquid involving R134A.

Raju, M. S.↗
NASA NTRS2008

Investigation of Pore Size Effect On Spray Cooling Heat Transfer With Porous Tunnels

Previous studies have shown that spray cooling heat flux enhancement may be attained by using enhanced surface structures. However, most enhanced surface spray cooling studies have been limited to extended surfaces relative to the base surface. In this study, experiments were conducted to study the effects of pore size on spray cooling heat flux when using porous tunnels. The porous tunnels where placed sub-surface relative to the top of the heater block. Pores of varying size were machined in the top of the heater block leading into the sub-surface tunnels. Pore diameters varied between 0.25 mm and 1.0 mm. Each copper block had a projected cross-sectional area of 2.0 cm(sup 2). Measurements were also obtained on a heater block with a flat surface for baseline comparison purposes. A 2x2 nozzle array was used with PF-5060 as the working fluid. Thermal performance data was obtained under nominally degassed (chamber pressure of 41.4 kPa) conditions with a bulk fluid temperature of 20.5 "C. Results for both the study show that the highest critical heat flux (CHF) attained was 141 w/cm2 using pores 1.0 mm in diameter. This gave an enhancement of 75% relative to the flat surface case under nominally degassed conditions.

Silk, Eric A.↗
NASA NTRS2008

The Effect of Spray Initial Conditions on Heat Release and Emissions in LDI CFD Calculations

The mass and velocity distribution of liquid spray has a primary effect on the combustion heat release process. This heat release process then affects emissions like nitrogen oxides (NOx) and carbon monoxide (CO). Computational Fluid Dynamics gives the engineer insight into these processes, but various setup options exist (number of droplet groups, and initial droplet temperature) for spray initial conditions. This paper studies these spray initial condition options using the National Combustion Code (NCC) on a single swirler lean direct injection (LDI) flame tube. Using laminar finite rate chemistry, comparisons are made against experimental data for velocity measurements, temperature, and emissions (NOx, CO).

Iannetti, Anthony C.↗
NASA NTRS2009

Young's Moduli of Cold and Vacuum Plasma Sprayed Metallic Coatings

Monolithic metallic copper alloy and NiCrAlY coatings were fabricated by either the cold spray (CS) or the vacuum plasma spray (VPS) deposition processes. Dynamic elastic modulus property measurements were conducted on these monolithic coating specimens between 300 K and 1273 K using the impulse excitation technique. The Young's moduli decreased almost linearly with increasing temperature at all temperatures except in the case of the CS Cu-23%Cr-5%Al and VPS NiCrAlY, where deviations from linearity were observed above a critical temperature. It was observed that the Young's moduli for VPS Cu-8%Cr were larger than literature data compiled for Cu. The addition of 1%Al to Cu- 8%Cr significantly increased its Young's modulus by 12 to 17% presumably due to a solid solution effect. Comparisons of the Young s moduli data between two different measurements on the same CS Cu- 23%Cr-5%Al specimen revealed that the values measured in the first run were about 10% higher than those in the second run. It is suggested that this observation is due to annealing of the initial cold work microstructure resulting form the cold spray deposition process.

Raj, S. V.↗
NASA NTRS2010

Comparing Spray Characteristics from Reynolds Averaged Navier-Stokes (RANS) National Combustion Code (NCC) Calculations Against Experimental Data for a Turbulent Reacting Flow

Developing physics-based tools to aid in reducing harmful combustion emissions, like Nitrogen Oxides (NOx), Carbon Monoxide (CO), Unburnt Hydrocarbons (UHC s), and Sulfur Dioxides (SOx), is an important goal of aeronautics research at NASA. As part of that effort, NASA Glenn Research Center is performing a detailed assessment and validation of an in-house combustion CFD code known as the National Combustion Code (NCC) for turbulent reacting flows. To assess the current capabilities of NCC for simulating turbulent reacting flows with liquid jet fuel injection, a set of Single Swirler Lean Direct Injection (LDI) experiments performed at the University of Cincinnati was chosen as an initial validation data set. This Jet-A/air combustion experiment operates at a lean equivalence ratio of 0.75 at atmospheric pressure and has a 4 percent static pressure drop across the swirler. Detailed comparisons of NCC predictions for gas temperature and gaseous emissions (CO and NOx) against this experiment are considered in a previous work. The current paper is focused on detailed comparisons of the spray characteristics (radial profiles of drop size distribution and at several radial rakes) from NCC simulations against the experimental data. Comparisons against experimental data show that the use of the correlation for primary spray break-up implemented by Raju in the NCC produces most realistic results, but this result needs to be improved. Given the single or ten step chemical kinetics models, use of a spray size correlation gives similar, acceptable results

Iannetti, Anthony C.↗
NASA NTRS2011

Assessment of Some Atomization Models Used in Spray Calculations

The paper presents the results from a validation study undertaken as a part of the NASA s fundamental aeronautics initiative on high altitude emissions in order to assess the accuracy of several atomization models used in both non-superheat and superheat spray calculations. As a part of this investigation we have undertaken the validation based on four different cases to investigate the spray characteristics of (1) a flashing jet generated by the sudden release of pressurized R134A from cylindrical nozzle, (2) a liquid jet atomizing in a subsonic cross flow, (3) a Parker-Hannifin pressure swirl atomizer, and (4) a single-element Lean Direct Injector (LDI) combustor experiment. These cases were chosen because of their importance in some aerospace applications. The validation is based on some 3D and axisymmetric calculations involving both reacting and non-reacting sprays. In general, the predicted results provide reasonable agreement for both mean droplet sizes (D32) and average droplet velocities but mostly underestimate the droplets sizes in the inner radial region of a cylindrical jet.

Raju, M. S.↗
NASA NTRS2011

Gas Dynamic Spray Technology Demonstration

Zinc primer systems are currently used across NASA and AFSPC for corrosion protection of steel. AFSPC and NASA have approved the use of Thermal Spray Coatings (TSCs) as an environmentally preferable alternative. TSCs are approved in NASA-STD-5008 and AFSPC and KSC is currently looking for additional applications in which TSC can be used. Gas Dynamic Spray (GDS, also known as Cold Spray) is being evaluated as a means of repairing TSCs and for areas such as corners and edges where TSCs do not work as well. Other applications could include spot repair/maintenance of steel on structures, facilities, and ground support equipment.

Burford, Pattie Lewis↗
NASA NTRS2011

Radiation-Spray Coupling for Realistic Flow Configurations

Three Large Eddy Simulations (LES) for a lean-direct injection (LDI) combustor are performed and compared. In addition to the cold flow simulation, the effect of radiation coupling with the multi-physics reactive flow is analyzed. The flame let progress variable approach is used as a subgrid combustion model combined with a stochastic subgrid model for spray atomization and an optically thin radiation model. For accurate chemistry modeling, a detailed Jet-A surrogate mechanism is utilized. To achieve realistic inflow, a simple recycling technique is performed at the inflow section upstream of the swirler. Good comparison is shown with the experimental data mean and root mean square profiles. The effect of combustion is found to change the shape and size of the central recirculation zone. Radiation is found to change the spray dynamics and atomization by changing the heat release distribution and the local temperature values impacting the evaporation process. The simulation with radiation modeling shows wider range of droplet size distribution by altering the evaporation rate. The current study proves the importance of radiation modeling for accurate prediction in realistic spray combustion configurations, even for low pressure systems.

El-Asrag, Hossam↗
NASA NTRS2009

Gas-Liquid Supersonic Cleaning and Cleaning Verification Spray System

NASA Kennedy Space Center (KSC) recently entered into a nonexclusive license agreement with Applied Cryogenic Solutions (ACS), Inc. (Galveston, TX) to commercialize its Gas-Liquid Supersonic Cleaning and Cleaning Verification Spray System technology. This technology, developed by KSC, is a critical component of processes being developed and commercialized by ACS to replace current mechanical and chemical cleaning and descaling methods used by numerous industries. Pilot trials on heat exchanger tubing components have shown that the ACS technology provides for: Superior cleaning in a much shorter period of time. Lower energy and labor requirements for cleaning and de-scaling uper.ninih. Significant reductions in waste volumes by not using water, acidic or basic solutions, organic solvents, or nonvolatile solid abrasives as components in the cleaning process. Improved energy efficiency in post-cleaning heat exchanger operations. The ACS process consists of a spray head containing supersonic converging/diverging nozzles, a source of liquid gas; a novel, proprietary pumping system that permits pumping liquid nitrogen, liquid air, or supercritical carbon dioxide to pressures in the range of 20,000 to 60,000 psi; and various hoses, fittings, valves, and gauges. The size and number of nozzles can be varied so the system can be built in configurations ranging from small hand-held spray heads to large multinozzle cleaners. The system also can be used to verify if a part has been adequately cleaned.

Parrish, Lewis M.↗
NASA NTRS2014

High Temperature Multilayer Environmental Barrier Coatings Deposited Via Plasma Spray-Physical Vapor Deposition

Si-based ceramic matrix composites (CMCs) require environmental barrier coatings (EBCs) in combustion environments to avoid rapid material loss. Candidate EBC materials have use temperatures only marginally above current technology, but the addition of a columnar oxide topcoat can substantially increase the durability. Plasma Spray-Physical Vapor Deposition (PS-PVD) allows application of these multilayer EBCs in a single process. The PS-PVD technique is a unique method that combines conventional thermal spray and vapor phase methods, allowing for tailoring of thin, dense layers or columnar microstructures by varying deposition conditions. Multilayer coatings were deposited on CMC specimens and assessed for durability under high heat flux and load. Coated samples with surface temperatures ranging from 2400-2700F and 10 ksi loads using the high heat flux laser rigs at NASA Glenn. Coating morphology was characterized in the as-sprayed condition and after thermomechanical loading using electron microscopy and the phase structure was tracked using X-ray diffraction.

Plasma↗
NASA NTRS2026

In-Space Demonstration of Spray-on Solar White Paint

Discs coated with spray-on solar white and two similar thermal control coatings were flown in low earth orbit for roughly five hours. While in orbit, the coated discs were exposed to direct sunlight and to deep space for short intervals. Measurements of disc temperatures showed that the spray-on solar white coating had the lowest absorption of sunlight. Numerical modeling was used to infer that spray-on solar white had a solar absorptance between 0.02 and 0.04 and a thermal emittance between 0.93 and 0.99, both of which are consistent with terrestrial laboratory measurements.

Solar White↗