Composite bulkhead fabrication development Final report
Composite bulkhead fabrication using vacuum or autoclave pressure concepts to hold preformed sandwich elements during age forming and adhesive bonding
SANDWICH CONSTRUCTION↗
SEARCH · Engineering Papers
Results for “vacuum processes”
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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Space processing applications of ion beam technology
Ion thruster engines for spacecraft propulsion can serve as ion beam sources for potential space processing applications. The advantages of space vacuum environments and the possible gravity effects on thruster ion beam materials operations such as thin film growth, ion milling, and surface texturing were investigated. The direct gravity effect on sputter deposition and vapor deposition processes are discussed as well as techniques for cold and warm welding.
Grodzka, P. G.↗
A study of plasma expansion phenomena in laboratory generated plasma wakes - Preliminary results
The plasma expansion into the wake of a large rectangular plate immersed in a single-ion, collisionless, streaming plasma has been investigated in the laboratory. Several characteristics of the process involved in 'plasma expansion into vacuum' that have been predicted theoretically were observed, including the creation and motion of a rarefaction wave disturbance; the creation and motion of an expansion front; and the acceleration of ions into the wake at speeds above the ion-acoustic speed. The expansion was limited to early times; i.e., a few ion plasma periods, by the combination of plasma drift speed and vacuum chamber size. This prevented detailed comparison with self-similar theory, but results are in good agreement with numerical simulations and other laboratory experiments for the early time expansion. The conclusion is that the plasma expansion process is the dominant wake filling mechanism in the near wake of a body, whose potential is approximately the plasma space potential.
Wright, K. H., Jr.↗
Development and Evaluation of Stitched Sandwich Panels
This study explored the feasibility and potential benefits provided by the addition of through-the-thickness reinforcement to sandwich structures. Through-the-thickness stitching is proposed to increase the interlaminar strength and damage tolerance of composite sandwich structures. A low-cost, out-of-autoclave processing method was developed to produce composite sandwich panels with carbon fiber face sheets, a closed-cell foam core, and through-the-thickness Kevlar stitching. The sandwich panels were stitched in a dry preform state, vacuum bagged, and infiltrated using Vacuum Assisted Resin Transfer Molding (VARTM) processing. For comparison purposes, unstitched sandwich panels were produced using the same materials and manufacturing methodology. Test panels were produced initially at the University of Utah and later at NASA Langley Research Center. Four types of mechanical tests were performed: flexural testing, flatwise tensile testing, core shear testing, and edgewise compression testing. Drop-weight impact testing followed by specimen sectioning was performed to characterize the damage resistance of stitched sandwich panels. Compression after impact (CAI) testing was performed to evaluate the damage tolerance of the sandwich panels. Results show significant increases in the flexural stiffness and strength, out-of-plane tensile strength, core shear strength, edgewise compression strength, and compression-after-impact strength of stitched sandwich structures.
Stanley, Larry E.↗
Deployment of salt sample extraction system at an engineering-scale electrorefiner
The goal of the salt sampling program at Argonne is to develop and deploy automated molten salt sampling approaches for interfacing relevant unit operations with salt analysis to improve the timeliness of sampling-based accountancy measurements. Two technologies under development in support of this goal are a vacuum sampling loop module and a high-throughput pneumatic sample generator module. Compared to traditional point sampling approaches (i.e., dip probes), the vacuum sampling loop facilitates the collection of a larger cross-section of the bulk salt in order to collect more representative samples. The vacuum sampling approach also eliminates the risk of dross contamination of samples and avoids the use of moving parts in the salt. The pneumatic sample generator module is used to facilitate high-throughput sample analysis to improve the measurement precision of any given analytical technique by averaging out random sampling and measurement errors. In FY21, two methods for integrating these two modules were tested including direct fluidic coupling and coupling using a solid salt transfer mechanism. Solid salt transfer was ultimately selected over fluidic coupling, primarily to enable the transport of samples over longer distances to support automated at-line integration with high-precision techniques (such as microcalorimetry) that cannot withstand the conditions near an electrorefining process. To facilitate rapid solid salt coupling, new mechanisms were developed for rapidly charging and discharging salt sample tubes at the vacuum sampling loop and pneumatic sample generator modules, respectively. While the charging mechanism will be deployed in FY22, the discharge mechanism was tested in FY21 and is described here. The solid salt tube transfer method was deployed at one of Argonne’s engineering-scale electrorefiners to implement at-line high-throughput pneumatic micro-sample generation capabilities. The approach was used to generate precise uranium- and lanthanide-bearing electrorefiner micro-samples with the specific dimensions requested by researchers at Los Alamos National Laboratory for use in testing their novel microcalorimeter x-ray techniques. The solid salt transfer mechanism proved not only to be an effective means of integrating the precision sample generator with vacuum sampling, but also improved the performance of the sampler generator. To discharge salt from the sample tubes at the sampler generator, tube segments were inserted directly into the sample generator’s Helmholtz chamber and pressure pulse actuations were used to generate precision molten salt samples directly from the tube segments. The direct insertion of sample tubes into the sample generator enabled rapid loading of the salt and prevented salt from contacting most of the interior surfaces of the sample generator, which eliminated cross-contamination between runs. The vacuum sampling-loop tube charging mechanism will support high-throughput tube sampling operations by employing a dynamic vacuum filling process to fill short charge tubes that are configured to be rapidly connected and disconnected from the loop. The dynamic vacuum sampling operation will be automated, and sample tube handling can be executed with simple overhead actuation. Because the modular sampling approach described here eliminates the need for new high-radiation sample handling capabilities, salt-wetted seals, salt-wetted moving parts, and heated transfer lines outside the electrorefiner, it will address most of the remaining technical challenges for the at-line deployment of high-precision analytical techniques which will enable significant reductions in the time delay for sampling-based high-precision accountancy measurements.
42 ENGINEERING↗
Cascade Distillation Subsystem Development: Progress Toward a Distillation Comparison Test
Recovery of potable water from wastewater is essential for the success of long-duration manned missions to the Moon and Mars. Honeywell International and a team from NASA Johnson Space Center (JSC) are developing a wastewater processing subsystem that is based on centrifugal vacuum distillation. The wastewater processor, referred to as the Cascade Distillation Subsystem (CDS), utilizes an innovative and efficient multistage thermodynamic process to produce purified water. The rotary centrifugal design of the system also provides gas/liquid phase separation and liquid transport under microgravity conditions. A five-stage subsystem unit has been designed, built, delivered and integrated into the NASA JSC Advanced Water Recovery Systems Development Facility for performance testing. A major test objective of the project is to demonstrate the advancement of the CDS technology from the breadboard level to a subsystem level unit. An initial round of CDS performance testing was completed in fiscal year (FY) 2008. Based on FY08 testing, the system is now in development to support an Exploration Life Support (ELS) Project distillation comparison test expected to begin in early 2009. As part of the project objectives planned for FY09, the system will be reconfigured to support the ELS comparison test. The CDS will then be challenged with a series of human-gene-rated waste streams representative of those anticipated for a lunar outpost. This paper provides a description of the CDS technology, a status of the current project activities, and data on the system s performance to date.
Callahan, M. R.↗
Electron Beam Brazing of Titanium for Construction in Space
An extended presence of humans in space requires an in-situ capability to construct various permanent structures to support scientific research, power generation, communication, radiation shielding and other functions. Electron Beam (EB) vacuum brazing has been identified as one of the best joining processes for in-space joining, particular for making a large quantity of permanent joints as required for construction of the sizeable truss structures. Thin wall titanium tubes are perhaps the best choice because of their high stiffness, excellent strength-to-weight ratio and great metal forming and joining ability. An innovative EB vacuum spot brazing process is being developed at Goddard Space Flight Center to be used for robotic as well as human-assisted construction in space. This paper describes experimental results obtained during the initial effort of EB brazing of titanium tubes with the special emphasis on low temperature aluminum filler metals.
Flom, Yury↗
RHETT/EPDM Performance Characterization
The 0.6 kW Electric Propulsion Demonstration Module (EPDM) flight thruster system was tested in a large vacuum facility for performance measurements and functional checkout. The thruster was operated at a xenon flow rate of 3.01 mg/s, which was supplied through a self-contained propellant system. All power was provided through a flight-packaged power processing unit, which was mounted in vacuum on a cold plate. The thruster was cycled through 34 individual startup and shutdown sequences. Operating periods ranged from 3 to 3600 seconds. The system responded promptly to each command sequence and there were no involuntary shutdowns. Direct thrust measurements indicated that steady state thrust was temperature sensitive, and varied from a high of 41.7 mN at 16 C, to a low of 34.8 mN at 110 C. Short duration thruster firings showed rapid response and good repeatability.
Haag, T.↗
Vacuum mechatronics
The discipline of vacuum mechatronics is defined as the design and development of vacuum-compatible computer-controlled mechanisms for manipulating, sensing and testing in a vacuum environment. The importance of vacuum mechatronics is growing with an increased application of vacuum in space studies and in manufacturing for material processing, medicine, microelectronics, emission studies, lyophylisation, freeze drying and packaging. The quickly developing field of vacuum mechatronics will also be the driving force for the realization of an advanced era of totally enclosed clean manufacturing cells. High technology manufacturing has increasingly demanding requirements for precision manipulation, in situ process monitoring and contamination-free environments. To remove the contamination problems associated with human workers, the tendency in many manufacturing processes is to move towards total automation. This will become a requirement in the near future for e.g., microelectronics manufacturing. Automation in ultra-clean manufacturing environments is evolving into the concept of self-contained and fully enclosed manufacturing. A Self Contained Automated Robotic Factory (SCARF) is being developed as a flexible research facility for totally enclosed manufacturing. The construction and successful operation of a SCARF will provide a novel, flexible, self-contained, clean, vacuum manufacturing environment. SCARF also requires very high reliability and intelligent control. The trends in vacuum mechatronics and some of the key research issues are reviewed.
Hackwood, Susan↗
Vapor-Gas Bubble Evolution and Growth in Extremely Viscous Fluids Under Vacuum
Formation of vapor and gas bubbles and voids is normal and expected in flow processes involving extremely viscous fluids in normal gravity. Practical examples of extremely viscous fluids are epoxy-like filler materials before the epoxy fluids cure to their permanent form to create a mechanical bond between two substrates. When these fluids flow with a free liquid interface exposed to vacuum, rapid bubble expansion process may ensue. Bubble expansion might compromise the mechanical bond strength. The potential sources for the origin of the gases might be incomplete out-gassing process prior to filler application; regasification due to seal leakage in the filler applicator; and/or volatiles evolved from cure reaction products formed in the hardening process. We embarked on a study that involved conducting laboratory experiments with imaging diagnostics in order to deduce the seriousness of bubbling caused by entrained air and volatile fluids under space vacuum and low gravity environment. We used clear fluids with the similar physical properties as the epoxy-like filler material to mimic the dynamics of bubbles. Another aspect of the present study was to determine the likelihood of bubbling resulting from dissolved gases nucleating from solution. These experimental studies of the bubble expansion are compared with predictions using a modified Rayleigh- Plesset equation, which models the bubble expansion.
Kizito, John↗
Sensor-model prediction, monitoring and in-situ control of liquid RTM advanced fiber architecture composite processing
In-situ frequency dependent electromagnetic sensors (FDEMS) and the Loos resin transfer model have been used to select and control the processing properties of an epoxy resin during liquid pressure RTM impregnation and cure. Once correlated with viscosity and degree of cure the FDEMS sensor monitors and the RTM processing model predicts the reaction advancement of the resin, viscosity and the impregnation of the fabric. This provides a direct means for predicting, monitoring, and controlling the liquid RTM process in-situ in the mold throughout the fabrication process and the effects of time, temperature, vacuum and pressure. Most importantly, the FDEMS-sensor model system has been developed to make intelligent decisions, thereby automating the liquid RTM process and removing the need for operator direction.
Kranbuehl, D.↗
Powder metallurgy processing of high strength turbine disk alloys
Using vacuum-atomized AF2-1DA and Mar-M432 powders, full-scale gas turbine engine disks were fabricated by hot isostatically pressing (HIP) billets which were then isothermally forged using the Pratt & Whitney Aircraft GATORIZING forging process. While a sound forging was produced in the AF2-1DA, a container leak had occurred in the Mar-M432 billet during HIP. This resulted in billet cracking during forging. In-process control procedures were developed to identify such leaks. The AF2-1DA forging was heat treated and metallographic and mechanical property evaluation was performed. Mechanical properties exceeded those of Astroloy, one of the highest temperature capability turbine disk alloys presently used.
Evans, D. J.↗
Feedstock and Catalyst Impact on Bio-Oil Production and FCC Co-Processing to Fuels
NREL’s thermochemical biomass conversion research is focused on ex-situ upgrading of biomass fast-pyrolysis (FP) vapors as an efficient and economical route to completely biogenic pyrolysis-based fuel precursors, potential fuels, and value-added chemicals depending on catalyst choice and process conditions. In this approach, biomass vapors are generated via fast pyrolysis with destabilizing vapor components (char, inorganics, tar aerosols) removed by hot gas filtration to produce conditioned vapors more responsive to catalytic upgrading. A Davison Circulating Riser (DCR), a petroleum industry standard for fluidized catalytic cracking (FCC) catalyst evaluation, was coupled with a custom pyrolyzer system designed to produce consistent composition pyrolysis vapors as feed to the DCR. The coupled system is shown below (Figure 1). Pyrolysis vapors, derived from pure hardwood and softwood, were upgraded using commercially available and laboratory modified zeolite-based catalysts. Upgraded oils were analyzed via 31P and 13C NMR spectroscopy, GCxGC-TOF/MS, carbonyl and ultimate analysis (CHNO), and micro distillation to assess both oil chemistry and distillation behavior as they relate to catalyst and feedstock type for producing fungible hydrocarbon product liquids. Measured process parameters identified from technoeconomic process analysis included achieving oil oxygenate contents of 20% or less, carbon-conversion efficiencies of 30% or more, and catalyst coking rates of 10% or less. A proprietary modified zeolite catalyst from Johnson Matthey produced oils that met these requirements. Using the DCR equipped with a proprietary nozzle system, a second approach focused on reducing the carbon intensity of petroleum-derived hydrocarbon fuels by FCC co-processing these CFP oils with petroleum vacuum gas oil (VGO) to produce biogenic carbon containing fuels. The vapor-phase upgrading results demonstrated for the first time the feasibility of producing refinery-compatible hydrocarbon fuel intermediates entirely from biomass-derived fast-pyrolysis vapors using an industry-accepted DCR system for catalytic upgrading. The co-processing results demonstrated the feasibility of using CFP oils with VGO feeds in FCC refinery operations to produce biogenic carbon containing fuels.
bio-oil↗
Handbook of Materials and Techniques for Vacuum Devices.
Handbook of materials and techniques for vacuum devices covering high temperature properties, materials selection, joining processes, etc
ELECTRONIC EQUIPMENT↗
Tracking renewable carbon in bio-oil/crude co-processing with VGO through 13C/12C ratio analysis
Not Available
Li, Zheng-Hua (ORCID:000000030946500X)↗
Design and Operation of a Multi-Bed Catalytic Micro-Reactor for the Study of Co-Processing of Bio-Oils with VGO
An industry wide shift from fossil-based fuel to renewable fuel sources including biomass, municipal waste, and plastics will require new process monitoring methods to minimize transitional risks including off specification product formation and catalyst deactivation. This project aims to provide a machine learning based process monitoring tool composed of online, slipstream mass spectra for use in biomass refineries and co-processing in existing refineries allowing operators to monitor product qualities and adjust process conditions accordingly. In order to maximize the robustness of the tool, large volumes of data must be collected to fine tune model parameters which consists of both micro and pilot scale mass spectral data. Micro-scale data is collected with a multi-tube micro-reactor housing up to six catalysts in horizontal beds, coupled with a molecular beam mass spectrometer. A pyrolizer equipped with an auto-sampler streamlines the micro-scale data collection process. This type of pyrolizer/micro-reactor configuration does not exist on the market, and therefore had to be created for the purposes of this project. The design and commissioning of this reactor will be presented in detail. This reactor set-up is highly flexible and increases throughput of analysis. For catalyst testing, each bed can be individually selected simply by turning valves. For catalyst reduction and regeneration, simultaneous flow through all six beds is used. The reproducibility of the system was first assessed with whole biomass pyrolysis along with pyrolysis of calibration standards. Initial work on this system evaluated two FCC catalysts, equilibrium catalyst (E-cat), and a proprietary catalyst from Johnson Matthey specifically design for co-processing of bio-oil with vacuum gas oil (VGO). This work used model compounds and VGO which illuminated differences in products produced by the catalysts.
biomass↗
Relativistic plasma physics in supercritical fields
Since the invention of chirped pulse amplification, which was recognized by a Nobel Prize in physics in 2018, there has been a continuing increase in available laser intensity. Combined with advances in our understanding of the kinetics of relativistic plasma, studies of laser-plasma interactions are entering a new regime where the physics of relativistic plasmas is strongly affected by strong-field quantum electrodynamics (QED) processes, including hard photon emission and electron-positron (e⁻-e⁺) pair production. Additionally, this coupling of quantum emission processes and relativistic collective particle dynamics can result in dramatically new plasma physics phenomena, such as the generation of dense e⁻-e⁺ pair plasma from near vacuum, complete laser energy absorption by QED processes, or the stopping of an ultra-relativistic electron beam, which could penetrate a cm of lead, by a hair's breadth of laser light. In addition to being of fundamental interest, it is crucial to study this new regime to understand the next generation of ultra-high intensity laser-matter experiments and their resulting applications, such as high energy ion, electron, positron, and photon sources for fundamental physics studies, medical radiotherapy, and next generation radiography for homeland security and industry.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Quantitation of olefins in sustainable aviation fuel intermediates using principal component analysis coupled with vacuum ultraviolet spectroscopy
Olefins, a common intermediate from biomass conversion processes, are undesirable in jet fuel because of their poor thermal stability. This paper presents an approach for olefin quantitation using 2D gas chromatography coupled with vacuum ultraviolet spectroscopy. Principal component analysis was used to reduce the dimensionality of the spectroscopic data from a highly olefinic fuel intermediate. A principal component template was created that enabled olefin quantitation, which was compared to the existing GCxGC-VUV approach from the literature. The principal component method was able to identify and quantify trace amounts of cyclodienes, which were present at only 0.01 wt% in the fuel sample. The principal component approach also identifies species that fall outside of the GCxGC template. For instance, quantitation with the literature method resulted in an olefin concentration of 0.95 times that of the principal component method due to olefins falling outside of the expected GCxGC regions. The principal component results were compared with 13 C and 1 H NMR data, which confirmed that the fuel had a high concentration of olefins and alkanes with little aromatic content.
Kosir, Shane↗