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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Comparison of the Chromium Distribution in New Super Koropon Primer to 30 Year Old Super Koropon Using Focused Ion Beam/Scanning Electron Microscopy

Super Koropon primer (MB0125-055) plays a significant role in the corrosion protection of areas throughout the Orbiter. Because the Shuttle Program relies so heavily upon the performance of the Koropon primer, it is necessary to fully understand all aspects of the behavior of the coating. One area where little understanding of the Koropon primer still exists is the level of risk associated with age related degradation. Recently, efforts were undertaken to better understand the age life of the Koropon primer and to gain some insight into the aging process of this coating. In that study, an aluminum access panel from the Orbiter Enterprise was used to investigate the performance of the old Koropon film. A control panel was also used to study the performance of new Koropon coating. Preliminary investigations into the performance of aged Super Koropon primer indicated a significant decrease in corrosion protection. This investigation serves as an example of how Focused Ion Beam/Scanning Microscopy can be used to characterize the changes that occur as coatings age.

Lomness, Janice K.↗
NASA NTRS1993

Space Shuttle reaction control system thruster metal nitrate removal and characterization

The Space Shuttle hypergolic primary reaction control system (PRCS) thrusters continue to fail-leak or fail-off at a rate of approximately 1.5 per flight, attributed primarily to metal nitrate formation in the nitrogen tetroxide (N2O4) pilot operated valves (POV's). The failures have continued despite ground support equipment (GSE) and subsystem operational improvements. As a result, the Johnson Space Center (JSC) White Sands Test Facility (WSTF) performed a study to characterize the contamination in the N204 valves. This study prompted the development and implementation of a highly successful flushing technique using deionized (DI) water and gaseous nitrogen (GN2) to remove the contamination while minimizing Teflon seat damage. Following flushing a comprehensive acceptance test is performed before the thruster is deemed recovered. Between the time WSTF was certified to process flight thrusters (March 1992) and September 1993, a 68 percent thruster recovery rate was achieved. The contamination flushed from these thrusters was analyzed and has provided insight into the corrosion process, which is reported in this publication. Additionally, the long-term performance of 24 flushed thrusters installed in the WSTF Fleet Leader Shuttle reaction control subsystem (RCS) test articles is being assessed. WSTF continues to flush flight and test article thrusters and compile data to investigate metal nitrate formation characteristics in leaking and nonleaking valves.

Saulsberry, R. L.↗
NASA NTRS2007

Weathering of Thermal Control Coatings

Spacecraft radiators reject heat to their surroundings. Radiators can be deployable or mounted on the body of the spacecraft. NASA's Crew Exploration Vehicle is to use body mounted radiators. Coatings play an important role in heat rejection. The coatings provide the radiator surface with the desired optical properties of low solar absorptance and high infrared emittance. These specialized surfaces are applied to the radiator panel in a number of ways, including conventional spraying, plasma spraying, or as an applique. Not specifically designed for a weathering environment, little is known about the durability of conventional paints, coatings, and appliques upon exposure to weathering and subsequent exposure to solar wind and ultraviolet radiation exposure. In addition to maintaining their desired optical properties, the coatings must also continue to adhere to the underlying radiator panel. This is a challenge, as new composite radiator panels are being considered as replacements for the aluminum panels used previously. Various thermal control paints, coatings, and appliques were applied to aluminum and isocyanate ester composite coupons and were exposed for 30 days at the Atmospheric Exposure Site of the Kennedy Space Center s Beach Corrosion Facility for the purpose of identifying their durability to weathering. Selected coupons were subsequently exposed to simulated solar wind and vacuum ultraviolet radiation to identify the effect of a simulated space environment on the as-weathered surfaces. Optical properties and adhesion testing were used to document the durability of the paints and coatings. The purpose of this paper is to present the results of the weathering testing and to summarize the durability of several thermal control paints, coatings, and appliques to weathering and postweathering environments.

Jaworske, Donald A.↗
DOE OSTI2024

DECOVALEX-2023: Task B Final Report

In all repository concepts for the geological disposal of radioactive waste, an engineered barrier system (EBS) is used to encapsulate the waste canister, or, to act as borehole or gallery seals. These systems are often based on bentonite clays due to their low permeability and high swelling capacity enabling the closure of engineering voids. However, in all repository concepts gases will be generated through the corrosion of metallic materials (under anoxic conditions), the radioactive decay of waste and the radiolysis of water. Thus, understanding the processes and mechanisms controlling the advective movement of gas (as a discrete phase) in clay-based materials is a key aspect when assessing the impact of gas flow in a repository safety case.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1999

The Mars Environmental Compatibility Assessment (MECA) Wet Chemistry Experiment on the Mars 2001 Lander

The Mars Environmental Compatibility Assessment (MECA) is an instrument suite that will fly on the Mars Surveyor 2001 Lander Spacecraft. MECA is sponsored by the Human Exploration and Development of Space (HEDS) program and will evaluate potential hazards that the dust and soil of Mars might present to astronauts and their equipment on a future human mission to Mars. Four elements constitute the integrated MECA payload: a microscopy station, patch plates, an electrometer, and the wet chemistry laboratory (WCL). The WCL consists of four identical cells, each of which will evaluate a sample of Martian soil in water to determine conductivity, pH, redox potential, dissolved C02 and 02 levels, and concentrations of many soluble ions including sodium, potassium, magnesium, calcium and the halides. In addition, cyclic voltammetry will be used to evaluate reversible and irreversible oxidants present in the water/soil solution. Anodic stripping voltammetry will be used to measure concentrations of trace metals including lead, copper, and cadmium at ppb levels. Voltammetry is a general electrochemical technique that involves controlling the potential of an electrode while simultaneously measuring the current flowing at that electrode. The WCL experiments will provide information on the corrosivity and reactivity of the Martian soil, as well as on soluble components of the soil which might be toxic to human explorers. They will also guide HEDS scientists in the development of high fidelity Martian soil simulants. In the process of acquiring information relevant to HEDS, the WCL will assess the chemical composition and properties of the salts present in the Martian soil.

Grannan, S. M.↗
DOE OSTI2020

Analysis of the Impurity MgOHCl in Molten Chloride Salts Toward its Electrochemical Removal from CSP Plants During Operation

The work presented here is a study of the impurity MgOHCl in molten chloride salts, toward the eventual goal of electrochemically removing it from operational molten-chloride-based concentrating solar power (CSP) plants.1,2 Implementation of molten chloride salts as a heat transfer fluid is among the most promising pathways for decreasing the levelized cost of energy (LCOE) of CSP systems because its high thermal stability allows higher operating temperatures, and thus, greater efficiency. However, this impurity - formed when MgCl2 salts are exposed to air and moisture - cause significant corrosion of containment alloys.1 Therefore, we have developed and validated in a laboratory setting: 1) a method for the formation of MgOHCl for controlled impurity spike in molten salt for its further sensing, evaluation, and reduction; 2) evaluated its diffusion in the molten salt, and 3) began assessing its electrochemical properties. Our findings allow us to propose solutions for efficiently and instantly removing MgOHCl from an operational CSP plant.

concentrated solar power↗
DOE OSTI2022

Rethinking PCMI Failures Under Transient Conditions

Under PCMI conditions, the cladding strain is driven by either pellet swelling during normal operation or pellet thermal expansion in transients. The loading in PCMI is displacement controlled because friction between the pellet and the cladding results in a strain compatibility at the pellet/cladding interface. Failure is known to occur under PCMI loading conditions during operation when normal power changes result in release of iodine (and other fission products) causing stress corrosion cracking where the crack-propagation rate is dependent upon the cladding stress but slow relative to strictly mechanical failures. Failures after normal power changes are often referred to as failure by pellet-cladding interaction or PCI to distinguish it from PCMI. Such failures are considered displacement-controlled failures, as noted above, and occur with limited plastic strain. This is different to what is typically thought of as PCMI failure under transient conditions, either Anticipated Operational Occurrences (AOOs) or Reactivity Insertion Accidents (RIAs), which is generally assumed to occur once the cladding reaches a mechanical strain limit. But there are two features in the typical PCMI failure in an RIA that are not consistent with the PCMI assumptions. The first is the ductile shear failure feature in cross section and the second is a large crack opening post failure (e.g., see OI-11 failure in NSRR program). The ductile feature is indicative of a plastic instability that requires very large local strains, and the large crack opening must be the result of a release of energy, both of which are not expected if stress in the cladding was only driven by thermal expansion in the pellet. It is concluded that there must be a mechanism (likely related to rod internal pressure) that eliminates strain compatibility between the pellet and cladding – allowing strain localization to occur in what are known as PCMI transient failures. In some sense, these PCMI failures may actually be early burst failures that occur when thermal expansion causes uniform strains greater than a defined limit and fission gas pressure eliminate the strain compatibility

Cantonwine, Paul↗
NASA NTRS1989

Sodium sulfate - Deposition and dissolution of silica

The hot-corrosion process for SiO2-protected materials involves deposition of Na2SO4 and dissolution of the protective SiO2 scale. Dew points for Na2SO4 deposition are calculated as a function of pressure, sodium content, and sulfur content. Expected dissolution regimes for SiO2 are calculated as a function of Na2SO4 basicity. Controlled-condition burner-rig tests on quartz verify some of these predicted dissolution regimes. The basicity of Na2SO4 is not always a simple function of P(SO3). Electrochemical measurements of an (Na2O) show that carbon creates basic conditions in Na2SO4, which explains the extensive corrosion of SiO2-protected materials containing carbon, such as SiC.

Jacobson, Nathan S.↗
NASA NTRS2016

Engineering Model Propellant Feed System Development for an Iodine Hall Thruster Demonstration Mission

CUBESATS are relatively new spacecraft platforms that are typically deployed from a launch vehicle as a secondary payload, providing low-cost access to space for a wide range of end-users. These satellites are comprised of building blocks having dimensions of 10x10x10 cu cm and a mass of 1.33 kg (a 1-U size). While providing low-cost access to space, a major operational limitation is the lack of a propulsion system that can fit within a CubeSat and is capable of executing high (Delta)v maneuvers. This makes it difficult to use CubeSats on missions requiring certain types of maneuvers (i.e. formation flying, spacecraft rendezvous). Recently, work has been performed investigating the use of iodine as a propellant for Hall-effect thrusters (HETs) 2 that could subsequently be used to provide a high specific impulse path to CubeSat propulsion. 3, 4 Iodine stores as a dense solid at very low pressures, making it acceptable as a propellant on a secondary payload. It has exceptionally high ρIsp (density times specific impulse), making it an enabling technology for small satellite near-term applications and providing the potential for systems-level advantages over mid-term high power electric propulsion options. Iodine flow can also be thermally regulated, subliming at relatively low temperature (< 100 C) to yield I2 vapor at or below 50 torr. At low power, the measured performance of an iodine-fed HET is very similar to that of a state-of-the-art xenon-fed thruster. Just as importantly, the current-voltage discharge characteristics of low power iodine-fed and xenon-fed thrusters are remarkably similar, potentially reducing development and qualifications costs by making it possible to use an already-qualified xenon-HET PPU in an iodine-fed system. Finally, a cold surface can be installed in a vacuum test chamber on which expended iodine propellant can deposit. In addition, the temperature doesn't have to be extremely cold to maintain a low vapor pressure in the vacuum chamber (it is under 10(exp −6) torr at −75 C), making it possible to 'cryopump' the propellant with lower-cost recirculating refrigerant-based systems as opposed to using liquid nitrogen or low temperature gaseous helium cryopanels. In the present paper, we describe the design and testing of the engineering model propellant feed system for iSAT (see Fig. 1). The feed system is based around an iodine propellant reservoir and two proportional control valves (PFCVs) that meter the iodine flow to the cathode and anode. The flow is split upstream of the PFCVs to both components can be fed from a common reservoir. Testing of the reservoir is reported to demonstrate that the design is capable of delivering the required propellant flow rates to operate the thruster. The tubing and reservoir are fabricated from hastelloy to resist corrosion by the heated gaseous iodine propellant. The reservoir, tubing, and PFCVs are heated to ensure the sublimed propellant will not re-deposit within the feed system. Heating is accomplished through a number of individual zones to control the overall power expended on heating the system and insulation is employed to minimize the amount of power used to heat the system prior to thruster operation.

Polzin, Kurt A.↗
DOE OSTI2021

High-temperature corrosion of a nickel-based alloy in a molten chloride environment – The effect of thermal and chemical purifications

There is currently an ever-increasing demand for higher process efficiencies in next generation (Gen3) concentrating solar power (CSP). Higher process efficiencies may be procured by increasing the operating temperature, and simultaneously, minimizing the degradation of materials used for construction of CSP plants (e.g., piping, thermal storage tanks, solar receivers and heat exchangers). Thus, understanding materials corrosion in the presence of molten salt mixtures used as thermal energy storage media and heat transfer fluids is indispensable for CSP development. The present paper provides insights into the effects of salt purification on the corrosion of a nickel-based alloy (Haynes 230) isothermally exposed to a stagnant chloride-based salt mixture at 800 °C. The MgCl 2 -based salt mixture was thermally dehydrated and chemically treated with (0.1 and 0.5 wt %) elemental magnesium. Results reveal the electrochemical nature of the corrosion process, and the formation of corrosion products such as oxides (MgO, MgCr 2 O 4 , and MgAl 2 O 4 ) and nitrides (CrN) on the alloy surface and in sub-surface regions. Magnesium additions enhanced the ability to resist corrosion by reducing the concentration of impurities (H 2 O, MgOH + , OH - species) and polarizing the alloy surface. The formation of nitrides in all cases studied indicates the impact of using nitrogen as a protective gas in the system. Results also reveal that a single step treatment of the salt using metallic Mg could be considered as a measure to control the salt's impurity level, e.g., if required for system control.

14 SOLAR ENERGY↗
DOE OSTI2024

Focused Ion Beam Tomography of Alloy 617 Corroded in Molten Chloride Salt

Materials qualification of reactor structural materials is a critical step in rapid implementation of advanced nuclear reactor technologies, particularly to assess the corrosion performance in these designs. Accelerated qualification of reactor structural materials requires incorporating powerful computational toolsets, such as phase field modelling in the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, to predict the evolution of structural materials due to corrosion. Accordingly, computational toolsets will require experimental data generated at appropriate length scales to validate accuracy. Focused ion beam (FIB) provides a high degree of control over manipulation of materials for analytical purposes, including capturing data on the evolution in the microstructure and elemental composition of materials at the mesoscale, an appropriate length scale for phase field modelling of intergranular diffusion phenomena using the MOOSE framework. For instance, the FEI Helios G4 UX dual beam plasma FIB microscope at the Irradiated Materials Characterization Laboratory (IMCL) is capable of backscatter diffraction (EBSD) and energy-dispersive x-ray spectroscopy (EDS) documenting the evolution in the microstructure and elemental composition, respectively. The Helios can perform EDS and EBSD three-dimensionally (3D) using tomography, which is then combined using different software packages to visualize 3D volumes correlating elemental composition to microstructural data. The purpose of this investigation was to develop a streamlined characterization and data processing workflow for 3D tomography studies on the FEI Helios G4 plasma FIB. The investigation is segmented into three parts: 1) Optimizing the data collection workflow, 2) identifying appropriate data processing and visualization software (i.e. DREAM.3D, MIPAR, and VGStudioMax), and 3) establishing an infrastructure for public release. The optimization of the data collection workflow is in collaboration with members of the U220 department to setup formal training on the tomography operation of the G4, through ThermoFisher Scientific, and exploring DREAM.3D, MIPAR, and VGStudioMax data processing/visualization software packages. VGStudioMax currently demonstrates the most promise for future use. Optimization of the data collection and processing workflow is still ongoing. A collaboration with INL High Performance Computing (HPC) established an open-source license for expediting the public release of FIB tomography datasets through HPC. FIB tomography data generated by the G4 will provide comprehensive data for validating 3D phase field mesoscale modelling tools within the MOOSE framework for accelerated qualification of reactor structural materials.

Copeland-Johnson, Trishelle↗
NASA NTRS1973

Control valve: Hot gas fast response

The design of a warm gas control valve is reviewed outlining the problems posed by the requirement for extremely fast response combined with a severe environment and a hot, dirty, and corrosive operating fluid.

Hollis, J. T.↗
NASA NTRS1981

Experience with high performance V/STOL fighter projects at MBB

Flight control systems and aerodynamic aspects of experimental V/STOL aircraft are discussed. The VJ 101 C featured tilting engines for increased thrust, reheat for takeoff, simple translation, triangular decentralization of the engines for thrust modulation, and moderate ground effects. Two experimental aircraft were built, with and without reheat, capable of Mach 2 and Mach 1.04, respectively. The mechanical flight control system and tests are outlined, both for hover rig and flight configurations. Ground suction, acoustic and thermal loading, sodium silicate coatings to avoid ground corrosion, and recirculation are considered. Results of the follow-on project to the VJ 101 C, the AVS, which was developed by NASA, are reviewed, and it is noted that trends toward thrust-to-weight ratios exceeding one, in concert with low wing loading, favor the development of V/STOL aircraft.

Aulehla, F.↗
NASA NTRS1994

Triton 2 (1B)

The goal of this project was to perform a detailed design analysis on a conceptually designed preliminary flight trainer. The Triton 2 (1B) must meet the current regulations in FAR Part 23. The detailed design process included the tasks of sizing load carrying members, pulleys, bolts, rivets, and fuselage skin for the safety cage, empennage, and control systems. In addition to the regulations in FAR Part 23, the detail design had to meet established minimums for environmental operating conditions and material corrosion resistance.

Clark, Michelle L.↗
NASA NTRS1974

Effects of low-pressure air on oxygen contamination and lithium corrosion of a tantalum alloy, T-111, at 980 and 1260 C

The effects were studied of low-pressure air on contamination and corrosion in the tantalum alloy T-111/lithium system at 980 and 1260 C. Capsules of T-111 containing lithium were exposed to six vacuum levels between 1 x 10 to the 8th power and 0.0003 torr by controlled air leakage into a vacuum system. Capsules exposed at 980 C and 0.0002 torr failed from intragranular oxidation. The remainder of the capsules completed the 96-hour tests. The depth of oxygen contamination was greater at 980 C than at 1260 C. Tests made at 0.0001 and 0.00001 torr levels caused large increases in the oxygen content of the T-111. Tests at 0.000001 torr or less produced no significant contamination. No lithium corrosion of the T-111 was observed under any of the conditions.

Gahn, R. F.↗
DOE OSTI2020

Localized Corrosion Behavior of Non-Equiatomic NiFeCrMnCo Multi-Principal Element Alloys

A series of single phase Ni 38 Fe 20 Cr x Mn 21–0.5x Co 21–0.5x multi-principal element alloys (MPEAs) were fabricated and their localized corrosion behavior was tested in 0.6 M NaCl solution. These MPEAs were found to be susceptible to localized corrosion, exhibiting pitting at room temperature, as indicated by positive hysteresis loops and low repassivation potentials observed in cyclic potentiodynamic polarization experiments. The pitting resistance increased with increasing Cr content. Interestingly, even the MPEAs with low chromium content, Ni 38 Fe 20 Cr 6 Mn 18 Co 18 and Ni 38 Fe 20 Cr 10 Mn 16 Co 16 , exhibited passivity and localized corrosion. Here, the passivity observed in these low chromium MPEAs is likely derived from their relatively high nickel content. Crystallographic pit morphology was observed in most of these MPEAs, suggesting the absence of a salt film on the dissolving pit surface. Such crystallographic pit morphology indicates that the pit growth in most of these MPEAs was under charge-transfer/ohmic control.

36 MATERIALS SCIENCE↗
DOE OSTI2021

New Insights into the Bulk and Surface Defect Structures of Ceria Nanocrystals from Neutron Scattering Study

Neutron diffraction and pair distribution function studies coupled with Raman spectroscopy have successfully unraveled the detailed oxygen defect structures of ceria nanocubes and nanorods. Two types of defect sites are revealed for the ceria nanocrystals: surface and bulk defects. It is proposed that the surface oxygen defects in both types of CeO 2 nanocrystals are predominantly the partially reduced Ce 3 O 5+x , with the bulk defect structures dominated by interstitial Frenkel-type oxygen vacancies. Ceria nanorods possess much higher concentration of surface oxygen defects relative to the nanocubes, albeit with only slightly higher concentration of bulk Frenkel-type oxygen vacancies. Upon annealing the nanorod sample at 600 °C under vacuum (~10 –4 to 10 –5 mbar), a partially reduced ceria phase with long-range oxygen vacancy ordering (Ce 3 O 5+x ) has been observed experimentally for the first time. This intriguing observation that surface defect phases can take on ordered defect sublattices under certain conditions is of great value in understanding the temperature-dependent catalytic performance of ceria nanocrystals. Furthermore, a drastic decrease of the surface vacancies in the ceria nanocrystals is observed upon exposure to SO 2 , especially for the nanorods, a likely origin for the sulfur poisoning effect on ceria-based materials. This study suggests that tailoring surface morphology is a promising strategy to control defect properties of ceria nanomaterials. It also provides fundamental insights to stabilize surface oxygen defects in CeO 2 nanocrystals to achieve high redox performance under corrosive environments such as under SO 2 /SO x exposure.

36 MATERIALS SCIENCE↗
NASA NTRS1969

Improved pH buffering agent for sodium hypochlorite

Sodium citrate/citric acid was found to be an effective buffer for pH control when used with sodium hypochlorite. The mixture does not corrode aluminum. The buffer appears to form a type of conversion coating that may provide corrosion-resistant properties to aluminum in other applications.

Nash, J. R.↗