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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

The earth radiation budget satellite system of the early 1980's

Climate study by the proposed earth radiation budget satellite system (ERBSS) is discussed. The system would use TIROS-N and ERBS-A/AEM satellites. The objectives are (1) to determine, for a minimum of one to two years, the monthly average radiation budget on regional, zonal, and global scales; (2) to determine the equator-to-pole energy transport gradient; and (3) to determine the average diurnal variation in the radiation budget on a regional and monthly scale. Date interpretation, data analysis, sampling analysis, ERBSS capabilities and instrumentation are considered.

Copper, J. E.↗
NASA NTRS1976

Thermal design and analysis of a hydrogen-burning wind tunnel model of an airframe-integrated scramjet

An aerodynamic model of a hydrogen burning, airframe integrated scramjet engine has been designed, fabricated, and instrumented. This model is to be tested in an electric arc heated wind tunnel at an altitude of 35.39 km (116,094 ft.) but with an inlet Mach number of 6 simulating precompression on an aircraft undersurface. The scramjet model is constructed from oxygen free, high conductivity copper and is a heat sink design except for water cooling in some critical locations. The model is instrumented for pressure, surface temperature, heat transfer rate, and thrust measurements. Calculated flow properties, heat transfer rates, and surface temperature distributions along the various engine components are included for the conditions stated above. For some components, estimates of thermal strain are presented which indicate significant reductions in plastic strain by selective cooling of the model. These results show that the 100 thermal cycle life of the engine was met with minimum distortion while staying within the 2669 N (600 lbf) engine weight limitation and while cooling the engine only in critical locations.

Guy, R. W.↗
DOE OSTI2023

London penetration depth of electron-irradiated Ba 0 . 47 K 0 . 53 Fe 2 As 2

We have characterized an electron-irradiated Ba 1-x K x Fe 2 As 2 (x = 0.53) single-crystal using two different experimental techniques: magneto-optic measurements and microwave measurements. The crystal has been measured before as well as after the 2.5 MeV electron irradiation process. After irradiation it was annealed in a number of steps, between 90 °C and 180 °C, and measured after each annealing step. Most microwave measurements were performed by means of a copper cavity, taking advantage of the TE 011 and TM 110 modes, allowing for the determination of the London penetration depths changes δλ ab (T) and δλ c (T), ie perpendicular and parallel to the sample c-axis. Appropriate equations, based on perturbation theory, were derived to calculate the penetration depths changes δλ ab and δλ c for a rectangular prism geometry. The sample showed a full recovery of its T c , however the observed behavior of δλ c and δλ ab was not monotonic vs annealing temperature, displaying a minimum of δλ c and δλ ab at 120 °C. In conclusion, this finding was confirmed by magneto-optic measurements, where besides verifying the sample uniformity and the absence of visible defects, the lower critical field H c1 of the Ba 1-x K x Fe 2 As 2 single-crystal was obtained and the London penetration depth λab(0) was calculated.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1990

A transient plasticity study and low cycle fatigue analysis of the Space Station Freedom photovoltaic solar array blanket

The Space Station Freedom photovoltaic solar array blanket assembly is comprised of several layers of materials having dissimilar elastic, thermal, and mechanical properties. The operating temperature of the solar array, which ranges from -75 to +60 C, along with the material incompatibility of the blanket assembly components combine to cause an elastic-plastic stress in the weld points of the assembly. The weld points are secondary structures in nature, merely serving as electrical junctions for gathering the current. The thermal mechanical loading of the blanket assembly operating in low earth orbit continually changes throughout each 90 min orbit, which raises the possibility of fatigue induced failure. A series of structural analyses were performed in an attempt to predict the fatigue life of the solar cell in the Space Station Freedom photovoltaic array blanket. A nonlinear elastic-plastic MSC/NASTRAN analysis followed by a fatigue calculation indicated a fatigue life of 92,000 to 160,000 cycles for the solar cell weld tabs. Additional analyses predict a permanent buckling phenomenon in the copper interconnect after the first loading cycle. This should reduce or eliminate the pulling of the copper interconnect on the joint where it is welded to the silicon solar cell. It is concluded that the actual fatigue life of the solar array blanket assembly should be significantly higher than the calculated 92,000 cycles, and thus the program requirement of 87,500 cycles (orbits) will be met. Another important conclusion that can be drawn from the overall analysis is that, the strain results obtained from the MSC/NASTRAN nonlinear module are accurate to use for low-cycle fatigue analysis, since both thermal cycle testing of solar cells and analysis have shown higher fatigue life than the minimum program requirement of 87,500 cycles.

Armand, Sasan C.↗
NASA NTRS2005

Cross Section Sensitivity and Propagated Errors in HZE Exposures

It has long been recognized that galactic cosmic rays are of such high energy that they tend to pass through available shielding materials resulting in exposure of astronauts and equipment within space vehicles and habitats. Any protection provided by shielding materials result not so much from stopping such particles but by changing their physical character in interaction with shielding material nuclei forming, hopefully, less dangerous species. Clearly, the fidelity of the nuclear cross-sections is essential to correct specification of shield design and sensitivity to cross-section error is important in guiding experimental validation of cross-section models and database. We examine the Boltzmann transport equation which is used to calculate dose equivalent during solar minimum, with units (cSv/yr), associated with various depths of shielding materials. The dose equivalent is a weighted sum of contributions from neutrons, protons, light ions, medium ions and heavy ions. We investigate the sensitivity of dose equivalent calculations due to errors in nuclear fragmentation cross-sections. We do this error analysis for all possible projectile-fragment combinations (14,365 such combinations) to estimate the sensitivity of the shielding calculations to errors in the nuclear fragmentation cross-sections. Numerical differentiation with respect to the cross-sections will be evaluated in a broad class of materials including polyethylene, aluminum and copper. We will identify the most important cross-sections for further experimental study and evaluate their impact on propagated errors in shielding estimates.

Heinbockel, John H.↗
NASA NTRS1987

A critical examination of the dendrite growth models Comparison of theory with experimental data

Three dendrite growth models for directionally solidified succinonitrile-acetone, succinonitrile-salol, aluminum-copper, and lead-paladium alloys are evaluated. The characteristics of the Burden and Hunt (1974) model, the Laxmanan (1985) model, and the Trivedi (1980) model are described. The dendrite tip temperature, tip radius, liquid composition, and primary arm spacing for the alloys are analyzed in terms of growth speed, alloy composition, and temperature gradient. It is observed that the Burden and Hunt model accurately predicts the proper behavior of the parameters, but does not provide good quantitative predictions. A good fit between the experimental data and the Trivedi and Laxmanan models is detected. The advantages of the Trivedi marginal stability analysis and the Laxmanan minimum dendrite tip undercooling approaches are discussed.

Tewari, S. N.↗
NASA NTRS2002

Cryogenic Fracture Toughness Improvement for the Super Lightweight Tank's Main Structural Alloy

Marshall Space Flight Center has developed a two-step (TS) artificial aging technique that can significantly enhance cryogenic fracture toughness and resistance to stress corrosion cracking (SCC) in aluminum-copper-lithium alloy 2195. The new TS aging treatment consists of exposures at 132 C (270 F)/20 hr + 138 C (280 F)/42 hr, which can be readily applied to flight hardware production. TS aging achieves the same yield strength levels as conventional aging, while providing much improved ductility in the short transverse direction. After TS aging, five previously rejected lots of alloy 2195 (lots 950M029B, 960M030F, 960M030J, 960M030K, and 960M030L) passed simulated service testing for use in the super lightweight tank program. Each lot exhibited higher fracture toughness at cryogenic temperature than at ambient temperature. Their SCC resistance was also enhanced. All SCC specimens passed the minimum 10-day requirement in 3.5-percent sodium chloride alternate immersion at a stress of 45 ksi. The SCC lives ranged from 57 to 83 days, with an average of 70 days.

Chen, P. S.↗
NASA NTRS1974

High-temperature, low-cycle fatigue of advanced copper-base alloys for rocket nozzles. Part 1: Narloy Z

Short-term tensile and low-cycle fatigue data are reported for Narloy Z, a centrifugally cast, copper-base alloy. Tensile tests were performed at room temperature in air and in argon at 482, 538 and 593 C using an axial strain rate of .002/sec to the -1 power. In addition tensile tests were performed at 538 C in an evaluation of tensile properties at strain rates of .004 and .01/sec to the -1 power. Ultimate and yield strength values of about 315 and 200 MN/sq m respectively were recorded at room temperature and these decreased to about 120 and 105 respectively as the temperature was increased to 593 C. Reduction in area values were recorded in the range from 40 to 50% with some indication of a minimum ductility point at 538 C.

Conway, J. B.↗
DOE OSTI2025

A Combined Computational and Mathematical Analysis of Interconnect Fatigue Potential in Photovoltaic Modules

A finite element model of a 60-cell monocrystalline silicon glass-polymer photovoltaic module was simulated with ±1.0 kPa and ±2.4 kPa loads applied to the glass to calculate the deformation under load. Cell-to-cell displacements were used to approximate interconnect strain and stress. A mathematical fatigue cycle life relation was fitted to data for the interconnect material (copper), to generate a life prediction at each interconnect location based on the local stress means, reversal extents, and amplitudes. Interconnect stress was found to be significantly asymmetric about zero despite symmetric positive and negative module loads due to laminate thickness offsets about the neutral plane and the effects of module framing. Cycle life results indicated that interconnect fatigue failure was unlikely to occur over a 30-year lifetime of conservative wind and snow load cycles since the typical cell design feature of leaving some unconstrained length between the cell edge and first solder pad increases the effective gauge length and decreases the stress levels below the material endurance limit. Follow-up analyses found that 3.6 mm and 6.4 mm were the minimum unconstrained lengths required to survive the assumed lifetime of wind and snow cycles, respectively, confirming that typical industrial module constructions with 8–15 mm unconstrained lengths should survive conservatively. Notably, large magnitude, low-cycle snow loading was consistently the limiting factor requiring a longer unconstrained interconnect length. Finally, insights and workflows from this study inform module interconnection design limits for survival against mechanical fatigue in deployment environments.

14 SOLAR ENERGY↗
NASA NTRS2017

Ionic Liquids Enabling Revolutionary Closed-Loop Life Support

Minimizing resupply from Earth is essential for future long duration manned missions. The current oxygen recovery system aboard the International Space Station is capable of recovering approximately 50% of the oxygen from metabolic carbon dioxide. For long duration manned missions, a minimum of 75% oxygen recovery is targeted with a goal of greater than 90%. Theoretically, the Bosch process can recover 100% of oxygen, making it a promising technology for oxygen recovery for long duration missions. However, the Bosch process produces elemental carbon which ultimately fouls the catalyst. Once the catalyst performance is compromised, it must be replaced resulting in undesired resupply mass. Based on the performance of a Bosch system designed by NASA in the 1990's, a three year Martian mission would require approximately 1315 kg (2850 lbs) of catalyst resupply. It may be possible to eliminate catalyst resupply with a fully regenerable system using an Ionic Liquid (IL)-based Bosch system. In 2016, we reported the feasibility of using ILs to produce an iron catalyst on a copper substrate and to regenerate the iron catalyst by extracting the iron from the copper substrate and product carbon. Additionally, we described a basic system concept for an IL-based Bosch. Here we report the results of efforts to scale catalyst preparation, catalyst regeneration, and to scale the carbon formation processing rate of a single reactor.

Brown, Brittany R.↗
NASA NTRS2017

Ionic Liquids Enabling Revolutionary Closed-Loop Life Support

Minimizing resupply from Earth is essential for future long duration manned missions. The current oxygen recovery system aboard the International Space Station is capable of recovering approximately 50% of the oxygen from metabolic carbon dioxide. For long duration manned missions, a minimum of 75% oxygen recovery is targeted with a goal of greater than 90%. Theoretically, the Bosch process can recover 100% of oxygen, making it a promising technology for oxygen recovery for long duration missions. However, the Bosch process produces elemental carbon which ultimately fouls the catalyst. Once the catalyst performance is compromised, it must be replaced resulting in undesired resupply mass. Based on the performance of a Bosch system designed by NASA in the 1990's, a three year Martian mission would require approximately 1315 kg (2850 lbs) of catalyst resupply. It may be possible to eliminate catalyst resupply with a fully regenerable system using an Ionic Liquid (IL)-based Bosch system. In 2016, we reported the feasibility of using ILs to produce an iron catalyst on a copper substrate and to regenerate the iron catalyst by extracting the iron from the copper substrate and product carbon. Additionally, we described a basic system concept for an IL-based Bosch. Here we report the results of efforts to scale catalyst preparation, to scale catalyst regeneration, and to scale the carbon formation processing rate of a single reactor.

Brown, Brittany R.↗
DOE OSTI2023

Reduced metal nanocatalysts for selective electrochemical hydrogenation of biomass-derived 5-(hydroxymethyl)furfural to 2,5-bis(hydroxymethyl)furan in ambient conditions

Selective electrochemical hydrogenation (ECH) of biomass-derived unsaturated organic molecules has enormous potential for sustainable chemical production. However, an efficient catalyst is essential to perform an ECH reaction consisting of superior product selectivity and a higher conversion rate. Here, we examined the ECH performance of reduced metal nanostructures, i.e., reduced Ag (rAg) and reduced copper (rCu) prepared via electrochemical or thermal oxidation and electrochemical reduction process, respectively. Surface morphological analysis suggests the formation of nanocoral and entangled nanowire structure formation for rAg and rCu catalysts. rCu exhibits a slight enhancement in ECH reaction performance in comparison to the pristine Cu. However, the rAg exhibits more than two times higher ECH performance without compromising the selectivity for 5-(HydroxyMethyl) Furfural (HMF) to 2,5-bis(HydroxyMethyl)-Furan (BHMF) formation in comparison to the Ag film. Moreover, a similar ECH current density was recorded at a reduced working potential of 220 mV for rAg. This high performance of rAg is attributed to the formation of new catalytically active sites during the Ag oxidation and reduction processes. This study demonstrates that rAg can potentially be used for the ECH process with minimum energy consumption and a higher production rate.

2,5- bis(hydroxymethyl)furan (BHMF)↗
DOE OSTI2021

Void-free Copper Electrodeposition in High Aspect Ratio, Full Wafer Thickness Through-Silicon Vias with Endpoint Detection

High density interconnects are required for increased input/output for microelectronics applications, incentivizing the development of Cu electrochemical deposition (ECD) processes for high aspect ratio through-silicon vias (TSVs). This work outlines Cu ECD processes for 62.5 μ m diameter TSVs, etched into a 625 μ m thick silicon substrate, a 10:1 aspect ratio. Cu ECD in high aspect ratio features relies on a delicate balance of electrolyte composition, solution replenishment, and applied voltage. Implementing a CuSO 4 -H 2 SO 4 electrolyte, which contains suppressor and a low chloride concentration, allows for a tunable relationship between applied voltage and localized deposition in the vias. A stepped potential waveform was applied to move the Cu growth front from the bottom of the via to the top. Sample characterization was performed through mechanical cross-sections and X-ray computed tomography (CT) scans. The CT scans revealed small seam voids in the Cu electrodeposit, and process parameters were tuned accordingly to produce void-free Cu features. During the voltage-controlled experiments, measured current data showed a characteristic current minimum, which was identified as an endpoint detection method for Cu deposition in these vias. We believe this is the first report of this novel endpoint detection method for TSV filling.

42 ENGINEERING↗
DOE OSTI2020

Revisiting Competing Paths in Electrochemical CO 2 Reduction on Copper via Embedded Correlated Wavefunction Theory

We re-evaluate two key steps in the mechanism of CO 2 reduction on copper at a higher level of theory capable of correcting inherent errors in density functional theory (DFT) approximations, namely, embedded correlated wavefunction (ECW) theory. Here, we consider the CO reduction step on Cu(111), which is critical to understanding reaction selectivity. Here, we optimize embedding potentials at the periodic plane-wave DFT level using density functional embedding theory (DFET). All possible adsorption sites (adsites) for each adsorbate then are screened with ECW theory at the catalytically active site to refine the local electronic structure. Unsurprisingly, DFT and ECW theory predict different adsite preferences, largely because of DFT’s inability to properly situate the CO 2π* level. Differing preferred adsites suggest that different reaction pathways could emerge from DFT versus ECW theory. Starting from these preferred ECW theory adsites, we then obtain reaction pathways at the plane-wave DFT level using the climbing-image nudged elastic band method to determine minimum energy paths. Thereafter, we perform ECW calculations at the catalytically active site to correct the energetics at each interpolated structure (image) along the reaction pathways. Via this approach, we confirm that the first step in CO reduction via hydrogen transfer on Cu(111) is to form hydroxymethylidyne (*COH) instead of formyl (*CHO). Although the prediction to preferentially form *COH is consistent with that of DFT, the two theories predict quite different structural and mechanistic behaviors, suggesting that verification is needed for other parts of the mechanism of CO 2 reduction, which is the subject of ongoing work.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Design and Characterization of an Extremely-Sensitive, Large-Volume Gamma-Ray Spectrometer for Environmental Samples

A large volume gamma spectrometer was designed and constructed to analyze foodstuffs and environmental samples having low radionuclide concentrations. This system uses eight 11-cm × 42.5-cm × 5.5-cm NaI(Tl) detectors, chosen due to their relatively high sensitivity and availability and arranged in an octagonal configuration. The sensitive volume of the system is ~28 cm in diameter and ~42 cm deep. Shielding consists of an 86-cm × 86-cm square, 64-cm-tall lead brick enclosure with 18-cm-thick lead walls lined by 0.3-cm-thick copper plates. An aluminum top was machined to suspend the detectors within this shield. The shielding reduces background counts by 72% at 100 keV and 42% at 1,000 keV. The positional variability in sensitivity of the well was determined by both simulation and experiment. A 2.1-L volume of nearly uniform sensitivity, varying less than 10%, exists in the well's center. Energy resolutions of 14.6% and 7.8% were measured for 241 Am and 137 Cs, respectively. Energy resolution shows a 0.2% variation for both 241 Am and 137 Cs as a function of position within all regions of the well’s central sensitive volume. Dead time was also determined to be less than 35% for all sources measured in the system, the largest of which had an activity of 1,760 kBq. Simulated results for various source geometries show higher counts for smaller samples, especially at lower energies due to less attenuation of low energy photons. In conclusion, minimum detectable activities were determined for all source energies used, less than 5.1 Bq kg -1 for reasonable background and sample counting times.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Improving creep resistance of Al-0.27Zr-0.08Sn (wt%) via cold swaging while maintaining high electrical conductivity

This study investigates the effect of mechanical cold work (0, 50, and 90% cross-sectional area reduction via swaging) on the creep properties of cast aluminum alloys with high electrical conductivity including high-purity Al (HP-Al), Al-0.15Zr (Al-Zr), and Al-0.27Zr-0.08Sn (Al-Zr-Sn, wt%). The Al-Zr alloy is strengthened by Zr in solid solution while the Al-Zr-Sn alloy is additionally strengthened by Al3Zr nanoprecipitates (8 nm diameter). After 90% cold swaging, the alloys exhibit grains elongated along the swaging direction with their widths ranging between 8 and 152 μm perpendicular to the swaging direction. Creep testing at 200 °C shows that the minimum creep rate of all 90% swaged alloys shows high sensitivity to stress, which can be modeled via a threshold stress σth. Increasing swaging magnitude from 0 to 50 to 90% in Al-Zr-Sn improves the creep resistance without reducing electrical conductivity. The formation of subgrains, increased dislocation density, and columnar grain structure in swaged alloys all enhance creep resistance. HP-Al swaged to 90% exhibits much lower creep resistance (σth = 18 MPa) due to subgrain coarsening and the absence of precipitates compared to Al-Zr (σth = 40 MPa) and Al-Zr-Sn (σth = 40 MPa), which maintain stable subgrain structures and benefit from solid solution strengthening and Al3Zr nanoprecipitates, respectively. Although Al3Zr precipitates are known to stabilize the deformed microstructure by pinning grain-boundaries, this work demonstrates that Zr in solid solution alone can effectively stabilize the deformed microstructure resulting in enhanced creep resistance. This effect of Zr solute on stabilizing grain boundaries for creep performance was not previously well-defined in the literature. Despite similar creep performances of Al-Zr and Al-Zr-Sn, the latter shows 70% higher room-temperature microhardness and slightly improved electrical conductivity (56%IACS (International Annealed Copper Standard) vs. 57%IACS, respectively). This work provides new insights into creep mechanisms of cold-worked Al–Zr alloys that will guide the design of heat-resistant Al conductors for high-demand applications.

Coello ramirez, Ismael [Northwestern University,]↗
DOE OSTI2021

Synthesis and structural characterization of orthorhombic Cu 3– δ Sb ( δ ≈ 0.1) and hexagonal Cu 3 Sb 1–x In x (x ≈ 0.2) phases

Cu 3 Sb is a known copper-rich phase in the Cu–Sb binary phase diagram. It is reported to be dimorphic, with a low-temperature form adopting the orthorhombic Cu 3 Ti structure type (space group Pmmn , No. 59). The high-temperature form crystallizes in the cubic space group F m 3 - m $Fm‾{3}m$ (No. 225), and is isostructural with BiF 3 . Neither polymorph has been carefully characterized to date, with both structures being assigned to the respective structure type, but never refined. With this study, we provide structural evidence, based on single-crystal and powder X-ray diffraction data that the low-temperature orthorhombic phase exists with a significant amount of defects on one of the Cu-sites. As a result, its composition is not Cu 3 Sb, but rather Cu 3– δ Sb ( δ = 0.13(1)). The cubic form could not be accessed as a part of this study, but another Cu-rich phase, Cu 3 Sb ≈0.8 In ≈0.2 , was also identified. It adopts the hexagonal Ni 3 Sn structure type (space group P 6 3 / mmc , No. 194) and represents an In-substituted variant of a hitherto unknown structural modification of Cu 3 Sb. Whether the latter can exist as a binary phase, or what is the minimum amount of In inclusions needed to stabilize it remains to be determined. Measurements of the thermopower of Cu 3– δ Sb ( δ = 0.13(1)) were conducted in the range of 300–600 K and demonstrated a maximum value of ca. 50 μV/K at 600 K, indicative of a p -type transport mechanism. Electrical resistivity measurements for the same sample confirmed that it exhibits metallic-like behavior, with a room temperature value of 0.43 mΩ cm. Electronic structure calculations show the absence of a band gap. Thermal analysis was utilized to ascertain the congruent melting of both phases.

Crystallography↗
NASA NTRS1991

The effects of space radiation on thin films of YBa2Cu3O(7-x)

This investigation had two objectives: (1) to determine the effects of space radiation on superconductor parameters that are most important in space applications; and (2) to determine whether this effect can be simulated with Co-60 gamma rays, the standard test method for space materials. Thin films of yttrium barium copper oxide (YBCO) were formed by coevaporation of Y, BaF2, and Cu and post-annealing in wet oxygen at 850 C for 3.5 h. The substrate used was (100) silicon with an evaporated zirconia buffer layer. The samples were characterized by four point probe electrical measurements as a function of temperature. The parameters measured were the zero resistance transition temperature T(sub c) and the room temperature resistance. The samples were then exposed to Co-60 gamma-rays in air and in pure nitrogen, and to 780 keV electrons, in air. The parameters were then remeasured. The results are summarized. The results indicate little or no degradation in the parameters measured for samples exposed up to 10 Mrads of gamma-rays in nitrogen. However, complete degradation is preliminarily attributed to the high level of ozone generated in the chamber by the gamma-ray interaction with air. It can be concluded that: (1) the electron component of space radiation does not degrade the critical temperature of the YBCO films described, at least for energies around 800 keV and doses similar to those received by surface materials on spacecraft in typical remote sensing missions; and (2) for qualifying this and other superconducting materials against the space-radiation threat the standard test method used in the aerospace industry, namely, exposure to Co-60 gamma-rays in air, may require some further investigation. As a minimum, the sample must be either in vacuum or in positive nitrogen pressure.

Herschitz, R.↗