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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗
NASA NTRS2010

Advanced Welding Applications

Some of the applications of advanced welding techniques are shown in this poster presentation. Included are brief explanations of the use on the Ares I and Ares V launch vehicle and on the Space Shuttle Launch vehicle. Also included are microstructural views from four advanced welding techniques: Variable Polarity Plasma Arc (VPPA) weld (fusion), self-reacting friction stir welding (SR-FSW), conventional FSW, and Tube Socket Weld (TSW) on aluminum.

Ding, Robert J.↗
NASA NTRS2012

Regolith-Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication

In this paper we will discuss a new mass-efficient and innovative way of protecting high-mass spacecraft during planetary Entry, Descent & Landing (EDL). Heat shields fabricated in situ can provide a thermal-protection system (TPS) for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from regolith materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Two regolith processing and manufacturing methods will be discussed: 1) Compression and sintering of the regolith to yield low density materials; 2) Formulations of a High-temperature silicone RTV (Room Temperature Vulcanizing) compound are used to bind regolith particles together. The overall positive results of torch flame impingement tests and plasma arc jet testing on the resulting samples will also be discussed.

Hogue, Michael D.↗
DOE OSTI2017

Use of Nuclear Divers in Decommissioning of Spent Fuel Pools/Ponds in the United Kingdom - 17431

Magnox Ltd. (Operated by the Cavendish Fluor Partnership) has initiated decommissioning of spent fuel pools/ponds utilizing divers. This decommissioning technique is being employed to disassemble and size reduce underwater equipment and furniture, as well as the collection of sludge and debris prior to draining of the pool. This technique has proven to be highly effective at reducing the radiological exposure to the workforce over previously implemented methods and is expected to significantly reduce overall decommissioning durations and costs. The decommissioning of the UK Nuclear Decommissioning Authority's (NDA) Dungeness A power station spent fuel ponds was initiated in 2015 to eliminate the mobile hazards and prepare the facilities for entry into a Care and Maintenance period. This dual reactor site has two spent fuel ponds each containing 1000 m{sup 3} of water, with the fuel removed since April 2012, which will utilize divers to remove solid wastes from the ponds prior to drain down. This technique has overcome many challenges to implementation including regulatory approval and high airborne contamination. The use of divers for decommissioning was a new technique for the Magnox Sites and required early engagement with the UK Office for Nuclear Regulation (ONR) and the Health and Safety Executive (HSE). The use of plasma arc cutting underwater required the pond area to be classified as an airborne contamination area. The implementation of local ventilation has controlled this hazard. The initial demonstration dives at Dungeness A were completed in April 2016 and the decommissioning dives are expected to be completed in March 2017. This is a substantial improvement to the project schedule and will allow the project completion 5 1/2 years ahead of the Licence Condition milestone. This technique is planned to be implemented at two further NDA Magnox power stations over the next three years. This paper provides the accomplishments and lessons learned to date. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1972

Pressure and current effects on the thermal efficiency of an MPD arc used as a plasma source

Measurements of arc voltage and energy loss to the cooled electrodes of a magnetoplasmadynamic (MPD) arc, operating without an applied magnetic field, were made at chamber pressures of 26 to 950 torr, argon mass flow rates of 0.08 to 44 g/s and current of 200 to 2000 A. The resulting arc thermal efficiency varied from 22% at a chamber pressure of 26 torr to 88% at 950 torr. Thermal efficiency was only weakly dependent on arc current. It is concluded that the MPD arc operating without an applied magnetic field and at higher pressure than normally used in thruster applications is a reliable and efficient steady-state plasma source.

Pivirotto, T. J.↗
DOE OSTI2019

Simulation of an Ultrahigh-Pressure Short-Arc Xenon Discharge Plasma

We have studied a high- (ultrahigh-) pressure short-arc discharge in xenon with thoriated tungsten cathodes. A system of equations formulated based on earlier experimental data indicating possible emission of cathode material (thorium) into the discharge gap has made it possible to determine the electric field strength, plasma temperature, and concentration of thorium atoms as well as thorium and xenon ions in the plasma. The problem has been solved for a model discharge between planar electrodes. The results indicate the key role of thorium atoms in the cathode region. Thorium atoms determine the ionization balance and other electrokinetic properties of plasma. Emission of thorium atoms reduces the plasma temperature at the cathode, which turns out to be noticeably lower than the plasma temperature near the anode; this is a new result that agrees with experimental data. Other electrokinetic characteristics of the plasma (in particular, charged particle concentration and electric field strength) are also in good agreement with the experiment.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2015

Study of the feasibility of distributed cathodic arc as a plasma source for development of the technology for plasma separation of SNF and radioactive wastes

One of the key problems in the development of plasma separation technology is designing a plasma source which uses condensed spent nuclear fuel (SNF) or nuclear wastes as a raw material. This paper covers the experimental study of the evaporation and ionization of model materials (gadolinium, niobium oxide, and titanium oxide). For these purposes, a vacuum arc with a heated cathode on the studied material was initiated and its parameters in different regimes were studied. During the experiment, the cathode temperature, arc current, arc voltage, and plasma radiation spectra were measured, and also probe measurements were carried out. It was found that the increase in the cathode heating power leads to the decrease in the arc voltage (to 3 V). This fact makes it possible to reduce the electron energy and achieve singly ionized plasma with a high degree of ionization to fulfill one of the requirements for plasma separation of SNF. This finding is supported by the analysis of the plasma radiation spectrum and the results of the probe diagnostics.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS2001

Optical Plasma Control During ARC Carbon Nanotube Growth

To improve nanotube production, we developed a novel optical control technique, based on the shape of the visible plasma zone created between the anode and the cathode in the direct current (DC) arc process. For a given inert gas, we adjust the anode to cathode distance (ACD) in order to obtain strong visible vortices around the cathode. This enhance anode vaporization, which improve nanotubes formation. In light of our experimental results, we focus our discussion on the relationship between plasma parameters and nanotube growth. Plasma temperature control during arc process is achieved using argon, helium, and their mixtures as a buffer gases. The variation of the gas mixture from pure argon to pure helium changes plasma temperature. As a consequence, the microscopic characteristics of nanotubes as diameter distribution is changed moving from smaller values for argon to higher diameters for helium. We also observe a dependence of the macroscopic characteristics of the final products as Brunauer-Emmett-Teller (BET) surface area.

Hinkov, I.↗
NASA NTRS1978

Comparative characteristics of electron energy spectrum in PIG and arc type discharge plasmas

The electron distribution functions relative to the velocity component directed along the magnetic field are compared for PIG and arc type discharges. The identity of these functions for the plasma region pierced by the primary electron beam and their difference in the peripheral part of the discharge are shown. It is concluded that the electron distribution function in the PIG type discharge is formed during one transit of the primary electron through the discharge gap. The mechanisms of electron energy spectrum formation in both the axis region and the peripheral region of the discharge are discussed.

Romanyuk, L. I.↗
NASA NTRS1984

The effect of plasma on solar cell array arc characteristics

The influence from the ambient plasma on the arc characteristics of a negatively biased solar cell array was investigated. The arc characteristics examined were the peak current during an arc, the decay time as the arc terminates, and the charge lost during the arc. These arc characteristics were examined in a nitrogen plasma with charge densities ranging from 15,000 to 45,000 cu cm. Background gas pressures ranged from 8x1,000,000 to 6x100,000 torr. Over these ranges of parameters no significant effect on the arc characteristics were seen. Arc characteristics were also examined for three gas species: helium, nitrogen and argon. The helium arcs have higher peak currents and shorter decay times than nitrogen and argon arcs. There are slight differences in the arc characteristics between nitrogen and argon. These differences may be caused by the differences in mass of the respective species. Also, evidence is presented for an electron emission mechanism appearing as a precursor to solar array arcs. Occassionally the plasma generator could be turned off, and currents could still be detected in the vacuum system. When these currents are presented, arcs may occur.

Snyder, D. B.↗
NASA NTRS1985

The effect of plasma on solar cell array arc characteristics

The influence from the ambient plasma on the arc characteristics of a negatively biased solar cell array was investigated. The arc characteristics examined were the peak current during an arc, the decay time as the arc terminates, and the charge lost during the arc. These arc characteristics were examined in a nitrogen plasma with charge densities ranging from 15,000 to 45,000 cu cm. Background gas pressures ranged from 8x1,000,000 to 6x100,000 torr. Over these ranges of parameters no significant effect on the arc characteristics were seen. Arc characteristics were also examined for three gas species: helium, nitrogen and argon. The helium arcs have higher peak currents and shorter decay times than nitrogen and argon arcs. There are slight differences in the arc characteristics between nitrogen and argon. These differences may be caused by the differences in mass of the respective species. Also, evidence is presented for an electron emission mechanism appearing as a precursor to solar array arcs. Occasionally the plasma generator could be turned off, and currents could still be detected in the vacuum system. When these currents are presented, arcs may occur.

Snyder, D. B.↗
DOE OSTI2022

Non-Intrusive Measurements Using Femtosecond Laser in Atmospheric Pressure Plasma Jet

Femto-second (fs) lasers offer state-of-the art non-intrusive diagnostic capabilities in plasma flow environments. The diagnostics in plasma flows using a fs-laser that are relevant to this proposal include Two-photon Absorption Laser Induced Fluorescence (TALIF) for measuring the number density of an atomic species, and Femto-second Laser Electronic Excitation Tagging (FLEET) for performing velocity measurements in plasma flows. Various aspects of these diagnostics using fs-lasers are still an active domain of research. The TALIF technique has been used to measure the number density of atomic species in various plasma flow environments like atmospheric pressure plasma jet (APPJ) and arc-jet flows. This technique utilizes a fs-laser to excite an atomic species and the subsequent relaxation process through fluorescence is recorded to make measurements. A narrow band-pass filter is used to isolate the fluorescence signal that is in the infra-red regime. However, broad-band background emissions can potentially pass through the filter and induce noise in the TALIF signal. Particularly, arc-jet plasma flows inherently contain background emissions. In such plasma flow environments, in addition to the filter, the background-subtraction technique will play an important role in reducing the noise that is induced in the number density measurements using TALIF. The proposed research focuses on evaluating the effectiveness of a background-subtraction technique by measuring atomic oxygen using a femtosecond (fs) TALIF in APPJ with induced background emissions and comparing measurements obtained without inducing the emissions. Therefore, by quantifying the changes in the signal-to-noise ratio caused by a background-subtraction technique applied for APPJ, it will enable a better understanding of the uncertainties in the background subtracted fs-TALIF measurements for arc-jet plasma flows. In addition to this, FLEET will be used to obtain velocity in the APPJ, and the impact of background emissions will be analyzed. Under this effort, the experimenters and research personnel will gain the technical know-how in the operational and theoretical aspects of the advanced fs-laser-based diagnostic techniques. The knowledge gained in this process will then also directly be applied to a separate ONR funded project at the Aerodynamics Research Center (ARC), UT Arlington, related to arc-jet flow characterization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2003

Ceramic Foams for TPS Applications

Ceramic foams have potential in many areas of Thermal Protection Systems (TPS) including acreage and tile leading edges as well as being suitable as a repair approach for re-entry vehicles. NASA Ames is conducting ongoing research in developing lower-density foams from pre-ceramic polymer routes. One of the key factors to investigate, when developing new materials for re-entry applications, is their oxidation behavior in the appropriate re-entry environment which can be simulated using ground based arc jet (plasma jet) testing. Arc jet testing is required to provide the appropriate conditions (stagnation pressures, heat fluxes, enthalpies, heat loads and atmospheres) encountered during flight. This work looks at the response of ceramic foams (Si systems) exposed to simulated reentry environments and investigates the influence of microstructure and composition on the material? response. Other foam properties (mechanical and thermal) will also be presented.

Stockpoole, Mairead↗