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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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The Heat Exchanger Method (HEM) is a promising low-cost ingot casting process for material used for solar cells. This is the only method that is capable of casting single crystal ingots with a square cross section using a directional solidification technique. This paper describes the chemical, mechanical and electrical properties of the HEM silicon material as a function of position within the ingot.
The Small Solar Probe Mission is designed to characterize the Solar Corona as close as three solar radii above the sun's surface. Until 1992 studies generated concepts with large spacecraft launched on large launch vehicles and requiring nearly a decade to reach their initial perihelion.
Recent results indicate that the specific damping capacity and resonant frequency measurements taken periodically during a component's lifetime is able to quantify the mechanical fatigue of CMCS. This gives hope for the potential of determining the actual and residual life of CMC materials using a combination of nondestructive techniques. If successful, then this new paradigm for life prediction of CMCs could revolutionize the approach for designing and servicing CMC components, thereby significantly reducing costs for design, development, health monitoring, and maintenance of CMC components and systems. The Nondestructive Characterization (NDC) life prediction approach would complement life prediction using micromechanics and continuum finite element models. This paper reports on the initial concept of NDC life prediction, a review of the C/SiC blisk damping data, and how changes in the specific damping capacity & ultrasonic elastic modulus data have established the concept as a possibility.
In the present study, a combination of high-throughput (HT) and low-throughput (LT) techniques was used to rapidly determine the processing window and generate processing maps for Selective Laser Melting (SLM) of 316L stainless steel. The HT method includes the fabrication of hundreds of hex nut-shaped specimens, each processed with a unique combination of laser power, scanning speed, and hatch spacing. An easily removable scaffolding permitted rapid sample extraction from the base plate, thus saving machining cost and time. Hardness and immersion density measurements were used for HT characterization to identify a processing window for maximum strength and density. Within the defined processing window, a low-throughput (LT) microstructural interrogation of specimens were performed. The microstructural analysis included quantification at various length scales (i.e., grains size and morphology, texture, primary dendrite arm spacing, and melt pool geometry analysis). Microstructure-based processing maps as a function of volumetric energy density were generated. The combination of HT and LT methods produced a predictive relationship between hardness and primary dendrite arm spacing using a Hall-Petch relationship. A model is proposed to explain the dependence of microstructure on the melt pool geometry. Here, the HT method can be applied for the microstructural design of SLM-fabricated components in other alloys.
Within virtually all reactor systems with heat exchangers, the thinnest barriers between primary and secondary fluids are the heat exchanger tubes. Consistent with light water reactor experience, the advanced reactor heat exchangers are the most susceptible regions for corrosion and leakage (NRC, 2019). Moreover, traditional inspections and repairs using robotics will be expensive or impractical. On-line structural health corrosion monitoring (OLSHM) is therefore desirable to detect tube degradation prior to leaks that may allow mixing of heat exchanger fluids. Rhetorically many molten salt reactor (MSR) designers plan for on-line monitoring of critical reactor components including heat exchangers but there are no proven OLSHM sensors or systems for MSR heat exchangers. Guided wave ultrasound from the tube-end or ID using conventional low-temperature piezoelectric sensors has been shown to be sensitive to pits and cracks less than 50% through-wall in long pipes and tubes (Narayanan M.M., 2019) . Mode and frequency selection are important for practical sensor design decisions and ultimate performance. The L-0 wave-mode is easily excited by L-mode transducers but they have surface normal wave motion that will be sensitive to and more attenuative because of fluid interaction with the tube surface (Rose J.L., 1994). Shear Horizontal (SH) wave modes have material motion parallel to the tube surface therefore are virtually unaffected by fluid interaction. For SH-0 to be nondispersive in steel, the frequency-thickness product (MHz-mm) must be less than approximately 1.5. SH mode transducers must be coupled by a material that can support shear stress; a thin layer of honey works well for temporary sensors and an adhesive or a brazed metallurgical bond for permanent sensors. If sensors are incorporated into the fabrication process, the same kinds of SH-0 waves can be generated from the stagnant flow area of the tube OD without compromising the heat-exchange tube function. Piezoelectric materials are also available that can withstand harsh temperatures of molten salt heat exchangers (Stevenson T., 2015) (Machura et al., 2008). Though they may not have as high-performance characteristics, their performance only needs to be good enough to detect flaws of interest. This project attempts to demonstrate feasibility to develop a sensor that can be sensitive to flaws of interest and perform long-term monitoring of a molten salt reactor heat exchanger. Benefits to the advanced reactor system include: • Minimizing the expense of a reactor shut down for periodic inspection—only shutdown for cause. • Reduce risk of unexpected tube rupture by detecting flaws before they grow to through-wall leaks. • Cost reduction by minimizing need to design for manual/robotic inspectability. Transducer design, characterization of the beam profile, wedges vs. direct application of piezoelectric sensors, and ultrasonic pulse-echo responses from a representative heat exchange tube with fabricated flaw types are discussed.
Within virtually all reactor systems with heat exchangers, the thinnest barriers between primary and secondary fluids are the heat exchanger tubes. Consistent with light water reactor experience, the advanced reactor heat exchangers are the most susceptible regions for corrosion and leakage (NRC, 2019). Moreover, traditional inspections and repairs using robotics will be expensive or impractical. On-line structural health corrosion monitoring (OLSHM) is therefore desirable to detect tube degradation prior to leaks that may allow mixing of heat exchanger fluids. Rhetorically many molten salt reactor (MSR) designers plan for on-line monitoring of critical reactor components including heat exchangers but there are no proven OLSHM sensors or systems for MSR heat exchangers. Guided wave ultrasound from the tube-end or ID using conventional low-temperature piezoelectric sensors has been shown to be sensitive to pits and cracks less than 50% through-wall in long pipes and tubes (Narayanan M.M., 2019) . Mode and frequency selection are important for practical sensor design decisions and ultimate performance. The L-0 wave-mode is easily excited by L-mode transducers but they have surface normal wave motion that will be sensitive to and more attenuative because of fluid interaction with the tube surface (Rose J.L., 1994). Shear Horizontal (SH) wave modes have material motion parallel to the tube surface therefore are virtually unaffected by fluid interaction. For SH-0 to be nondispersive in steel, the frequency-thickness product (MHz-mm) must be less than approximately 1.5. SH mode transducers must be coupled by a material that can support shear stress; a thin layer of honey works well for temporary sensors and an adhesive or a brazed metallurgical bond for permanent sensors. If sensors are incorporated into the fabrication process, the same kinds of SH-0 waves can be generated from the stagnant flow area of the tube OD without compromising the heat-exchange tube function. Piezoelectric materials are also available that can withstand harsh temperatures of molten salt heat exchangers (Stevenson T., 2015) (Machura et al., 2008). Though they may not have as high-performance characteristics, their performance only needs to be good enough to detect flaws of interest. This project attempts to demonstrate feasibility to develop a sensor that can be sensitive to flaws of interest and perform long-term monitoring of a molten salt reactor heat exchanger. Benefits to the advanced reactor system include: • Minimizing the expense of a reactor shut down for periodic inspection—only shutdown for cause. • Reduce risk of unexpected tube rupture by detecting flaws before they grow to through-wall leaks. • Cost reduction by minimizing need to design for manual/robotic inspectability. Transducer design, characterization of the beam profile, and ultrasonic pulse-echo responses from a representative heat exchange tube with fabricated flaw types are discussed.
The increasing demand for renewable and low‐cost energy has triggered a vast amount of research aimed at developing, characterizing and optimizing materials that can efficiently convert sun light into useful chemical energy in the form of electricity or chemical fuels. So‐ called quantum dot sensitized solar cell (QDSC) materials have gained much attention in recent years based on the advantageous physicochemical properties of semiconducting quantum dots (QDs) as sensitizers, as well as their promising potential to increase the conversion efficiency beyond the Shockley‐Queisser limit of ∼33% by making use of hot‐electron transfer (HET) routes and multiple exciton generation (MEG). By finely tuning the size of the QDs, the band gap can be carefully aligned to the metal oxide (MO) conduction band such that charge transfer from the photoexcited QD is thermodynamically favorable.
The ceramic microstructure strongly influences its properties. During manufacturing, the online monitoring of microstructure is critical to ensure the desired material properties. So far, the microstructure on the relevant scale is usually characterized offline using scanning electron microscopy (SEM), which is time and cost-consuming. In this work, we demonstrate a cost-effective, machine learning (ML)-based approach to simulate the SEM micrographs in real-time from the laser spot brightness. We experimentally observed a strong correlation between the laser spot brightness and the corresponding microstructure at the exact locations. The brightness values obtained from thermal emission images and the corresponding SEM micrographs were used in the training datasets. The ML algorithm was a style-based conditional generative adversarial network (CGAN). After training, the ML model could generate high-fidelity microstructure images within 0.1 seconds based on in-situ captured brightness at the laser sintering spot. We used the average grain sizes as the metric to evaluate the accuracy of the ML-predicted micrographs. Here, the ML-predicted microstructures were in good agreement, with less than 5% in difference from the real SEM images. In conclusion, we demonstrate the cost-effective, online microstructure estimation during laser sintering with a simple setup (a camera, a regular computer, and the ML model).
This report documents the progress achieved over the past 6 to 12 months on four graduate student projects conducted within the NASA-UVA Light Aerospace Alloy and Structures Technology Program. These studies were aimed specifically at light metallic alloy issues relevant to the High Speed Civil Transport. Research on Hydrogen-Enhanced Fracture of High-Strength Titanium Alloy Sheet refined successfully the high resolution R-curve method necessary to characterize initiation and growth fracture toughnesses. For solution treated and aged Low Cost Beta without hydrogen precharging, fracture is by ductile transgranular processes at 25 C, but standardized initiation toughnesses are somewhat low and crack extension is resolved at still lower K-levels. This fracture resistance is degraded substantially, by between 700 and 1000 wppm of dissolved hydrogen, and a fracture mode change is affected. The surface oxide on P-titanium alloys hinders hydrogen uptake and complicates the electrochemical introduction of low hydrogen concentrations that are critical to applications of these alloys. Ti-15-3 sheet was obtained for study during the next reporting period. Research on Mechanisms of deformation and Fracture in High-Strength Titanium Alloys is examining the microstructure and fatigue resistance of very thin sheet. Aging experiments on 0. 14 mm thick (0.0055 inch) foil show microstructural agility that may be used to enhance fatigue performance. Fatigue testing of Ti-15-3 sheet has begun. The effects of various thermo-mechanical processing regimens on mechanical properties will be examined and deformation modes identified. Research on the Effect of Texture and Precipitates on Mechanical Property Anisotropy of Al-Cu-Mg-X and Al-Cu alloys demonstrated that models predict a minor influence of stress-induced alignment of Phi, caused by the application of a tensile stress during aging, on the yield stress anisotropy of both modified AA2519 and a model Al-Cu binary alloy. This project is no longer included in the NASA-UVA LAST program. Research on the Creep Behavior and Microstructural stability of Al-Cu-Mg-Ag and Al-Cu-Li-Mg-Ag showed that the creep resistance of three candidate aluminum alloys (C415, C416 and ML377) was much superior compared to that of the current Concorde alloy, AA2618. Creep induced change in precipitates at grain boundaries was observed in the alloy which exhibits the highest creep strain of the three examined. The other two alloys developed no detectable microstructural changes at grain boundaries under the creep conditions tested.
The development of NDE techniques has always been driven by the ongoing need for low-cost, rapid, user-friendly, reliable and efficient methods of detecting and characterizing flaws as well as determining material properties.
This working paper provides an overview of the Future Communication Study (FCS) technology investigation progress. It includes a description of the methodology applied to technology evaluation; evaluation criteria; and technology screening (down select) results. A comparison of screening results with other similar technology screening activities is provided. Additional information included in this working paper is a description of in-depth studies (including characterization of the L-band aeronautical channel; L-band deployment cost assessment; and performance assessments of candidate technologies in the applicable aeronautical channel) that have been conducted to support technology evaluations. The paper concludes with a description on-going activities leading to conclusion of the technology investigation and the development of technology recommendations.
A facility that includes a probe station and a scanning open-ended waveguide probe for measuring near electromagnetic fields has been added to Glenn Research Center's suite of antenna-testing facilities, at a small fraction of the cost of the other facilities. This facility is designed specifically for nondestructive characterization of the radiation patterns of miniaturized microwave antennas fabricated on semiconductor and dielectric wafer substrates, including active antennas that are difficult to test in traditional antenna-testing ranges because of fragility, smallness, or severity of DC-bias or test-fixture requirements. By virtue of the simple fact that a greater fraction of radiated power can be captured in a near-field measurement than in a conventional far-field measurement, this near-field facility is convenient for testing miniaturized antennas with low gains.
During the course of closing nuclear testing release sites at the Nevada National Security Site (NNSS) under the Federal Facility Agreement and Consent Order (FFACO) using the Risk-Based Corrective Action (RBCA) evaluation process, conservative assumptions and estimates were used in many phases of the work. These assumptions and estimates were agreed to during Data Quality Objective (DQO) meetings and published in the FFACO documents. However, the potential cumulative effect of these multiple sources of conservatism was not evaluated. The RBCA process ensures that corrective action decisions minimize the risk of making Type I errors (not applying corrective action to areas that exceed action levels) at the expense of making Type II errors (applying corrective action to areas that do not exceed action levels). Rather than fully characterizing the spatial distribution of contaminants throughout each site, the RBCA process uses a bounding methodology that conservatively estimates spatial boundaries beyond which contamination is not present that exceed corrective action levels. This process accepts that these boundaries may encompass areas that do not exceed corrective action levels and, therefore, may be somewhat larger than for fully characterized sites. This is justified at sites where the reduction in investigation costs are more than any potential increase in corrective action costs. To minimize the risk of making Type I errors, conservatism was used throughout the process. This study documents the many sources of conservatism used in the RBCA process. Conservatism was used in the RBCA process in determining potential receptors, determining action levels, collecting samples, converting sample results into receptor dose, and accounting for uncertainty. This provides decision-makers with a high level of confidence that unacceptable risk to receptors will not result from exposure to residual contamination outside the corrective action boundaries. However, it does not provide an estimate of the actual extent of areas exceeding action levels. This study provides an evaluation of the effects of compounding conservatism on RBCA process decisions. (authors)
We present a preliminary methodology for including geothermal resource uncertainty into the Renewable Energy Potential model, which estimates potential capacity and costs on a gridded surface at the national scale. The uncertainty outputs characterize the 10th, 50th and 90th percentile for geothermal resources using two energy capacity estimation equations. We then present a method and results that demonstrate how other geologic data layers, which may be indicative of permeability, can be used to inform the mean and standard deviation of the geothermal capacity. We demonstrate how the mean and standard deviation can be defined or partially informed by using collocated regression estimates and estimate errors, respectively . These regression results are from 36 observed geothermal power plants in the Great Basin region and are also used to benchmark the P10-P90 calculations.
Damping measurements have been taken on ceramic matrix composite (CMC) turbopump blisks in the as fabricated, post proof testing, and post turbopump testing conditions. These results indicate that damping is able to quantify fatigue of the CMC blisk. This gives hope for the potential of determining the actual and residual life of CMC materials using a combination of nondestructive techniques. If successful, then this new paradigm for life prediction of CMCs could revolutionize the approach for designing and servicing CMC components, thereby significantly reducing costs for design, development, health monitoring, and maintenance of CMC components and systems. The Nondestructive Characterization (NDC) life prediction approach would complement life prediction using micromechanics and continuum finite element models. This paper reports on the initial concept of NDC life prediction and how changes in damping and ultrasonic elastic modulus data have established the concept as a possibility.
Direct-drive laser-fusion targets may include low-cost plastic ablator material. Here, this work describes a tabletop experimental system designed to enable the investigation of the interaction of such ablator material as a function of the laser wavelength and the associated excitation mechanism. This experimental system offers time-resolved imaging of the material response with subpicosecond temporal resolution and ≈1-μm spatial resolution. The system involves synchronized femtosecond and picosecond lasers to initiate and characterize the dynamics of polystyrene planar targets irradiated by conditions similar to a “picket” prepulse from a direct-drive pulse shape. Ultrafast imaging of the initial excitation process followed by the resulting critical plasma formation, shock-wave propagation, and blowoff plasma expansion is used to compare the impact of excitation wavelength, 355 nm or 266 nm, on the ensuing dynamics. This work aims to investigate fundamental laser material interactions to help advance physics models that can inform the development of laser driver and target designs.
When a new, better-formulated physical parameterization is introduced into a global atmospheric model, aspects of the global model solutions are sometimes degraded. Then, in order to use the new global model to address science questions, there is an incentive to restore its accuracy. Oftentimes this restoration is achieved by tuning of model parameter values. Unfortunately, the retuning process is expensive because characterizing the parameter dependence requires numerous time-consuming global simulations. To reduce the cost of tuning, this manuscript introduces a “poor man's” model tuner, “QuadTune”. QuadTune carves the globe into regions and approximates the model parameter dependence through the use of an uncorrelated quadratic emulator (i.e., response surface). The simplicity of the emulator reduces the required number of global model simulations and aids explainability of tuner behavior. Tuning removes parametric error but leaves behind model structural error. Structural error manifests itself as regional residual biases, such as stubborn biases and tuning trade-offs. To visualize these residual biases, QuadTune's software includes a set of diagnostic plots. This paper illustrates the use of the plots for characterizing residual biases with an example tuning problem.
Abstract The eddy covariance method is widely used to investigate fluxes of energy, water, and carbon dioxide at landscape scales, providing important information on how ecological systems function. Flux measurements quantify ecosystem responses to environmental perturbations and management strategies, including nature‐based climate‐change mitigation measures. However, due to the high cost of conventional instrumentation, most eddy covariance studies employ a single system, limiting spatial representation to the flux footprint. Insufficient replication may be limiting our understanding of ecosystem behavior. To address this limitation, we deployed eight lower‐cost eddy covariance systems in two clusters around two conventional eddy covariance systems in the Chihuahuan Desert of North America for a period of 2 years. These dryland settings characterized by large temperature variations and relatively low carbon dioxide fluxes represented a challenging setting for eddy covariance. We found very good closure of energy and water balance across all systems (within ±9% of unity). We found very good correspondence between the lower‐cost and conventional systems' fluxes of sensible heat (with concordance correlation coefficient (CCC) of ≥0.87), latent energy (evapotranspiration; CCC ≥ 0.89), and useful correspondence in the net ecosystem exchange ((NEE); with CCC ≥ 0.4) at the daily temporal resolution. Relative to the conventional systems, the low‐frequency systems were characterized by a higher level of random error, particularly in the NEE fluxes. Lower‐cost systems can enable wider deployment affording better replication and sampling of spatiotemporal variability at the expense of greater measurement noise that might be limiting for certain applications. Replicated eddy covariance observations may be useful when addressing gaps in the existing monitoring of critical and underrepresented ecosystems and for measuring areas larger than a single flux footprint.