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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 559 records · Page 31
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Ultra-high temperature carbide foams and methods of fabricating the same

Ultra-high temperature carbide (UHTC) foams and methods of fabricating and using the same are provided. The UHTC foams are produced in a three-step process, including UHTC slurry preparation, freeze-drying, and spark plasma sintering (SPS). The fabrication methods allow for the production of any kind of single- or multi-component UHTC foam, while also providing flexibility in the shape and size of the UHTC foams to produce near-net-shape components.

Agarwal, Arvind↗
DOE OSTI2024

Electrical conductivity of a warm neutron star crust in magnetic fields: Neutron-drip regime

We compute the anisotropic electrical conductivity tensor of the inner crust of a compact star at nonzero temperature by extending a previous work on the conductivity of the outer crust. The physical scenarios, where such crust is formed, involve protoneutron stars born in supernova explosions, binary neutron star mergers, and accreting neutron stars. The temperature-density range studied covers the transition from a semidegenerate to a highly degenerate electron gas and assumes that the nuclei form a liquid, i.e., the temperature is above the melting temperature of the lattice of nuclei. The electronic transition probabilities include (i) the screening of electron-ion interaction in the hard-thermal-loop approximation for the QED plasma, (ii) the correlations of the ionic component in a one-component plasma, and (iii) finite nuclear size effects. The conductivity tensor is obtained from the Boltzmann kinetic equation in relaxation time approximation accounting for the anisotropy introduced by a magnetic field. The sensitivity of the results towards the matter composition of the inner crust is explored by using several compositions of the inner crust, which were obtained using different nuclear interactions and methods of solving the many-body problem. The standard deviations of relaxation time and components of the conductivity tensor from the average are below ≤25% except close to crust-core transition, where nonspherical nuclear structures are expected. Finally, our results can be used in dissipative magnetohydrodynamics simulations of warm compact stars.

Physics↗
NASA NTRS1996

Health Monitoring System for Composite Structures

An automated system was developed to monitor the health status of composites. It uses the vibration characteristics of composites to identify a component's damage condition. The vibration responses are characterized by a set of signal features defined in the time, frequency and spatial domains. The identification of these changes in the vibration characteristics corresponding to different health conditions was performed using pattern recognition principles. This allows efficient data reduction and interpretation of vast amounts of information. Test components were manufactured from isogrid panels to evaluate performance of the monitoring system. The components were damaged by impact to simulate different health conditions. Free vibration response was induced by a tap test on the test components. The monitoring system was trained using these free vibration responses to identify three different health conditions. They are undamaged vs. damaged, damage location and damage zone size. High reliability in identifying the correct component health condition was achieved by the monitoring system.

Tang, S. S.↗
NASA NTRSDate not supplied

Acoustic Emission Methods for the Health Evaluation of Integrated Pressure Components

At the request of the Pressure Systems Senior Discipline Expert, to overcome the access and detectable flaw size limitations of other nondestructive evaluation (NDE) methods for integrated components, a technique akin to seismology was advanced to perceive the earliest signs of cracking in titanium components before they escalate into serious issues. In this project we achieved a landmark in Acoustic Emission (AE) testing with the first NASA Probability of Detection (POD) study. This is an important first step to the certification of the AE method for flight components and was based on the testing of notched panels. By working closely with industry allies and employing approved methods from the boiler and pressure vessel sector, we not only met but surpassed all POD benchmarks with our test and acceptance criteria. In experiments involving solution heat-treated and aged 6Al-4V-Ti alloy tested with broadband sensors, we recorded a 96% success rate, with zero false positives reported. Our research shows that in some cases, AE testing can locate smaller cracks than other NDE methods. An industry tool for scaling results to full pressure vessels is highlighted. However, before applying our findings to NASA components, tests to validate the transfer functions are advised.

acoustic↗
DOE OSTI2023

Multi-modal chemical characterization of highly viscous submicrometer organic particles

Distinguishing highly viscous organic particles within complex mixtures of atmospheric aerosol and accurate descriptions of their composition, size distributions, and mixing states are challenges at the forefront of aerosol measurement science and technology. Here, we present results obtained from complementary single-particle measurement techniques employed for the in-depth characterization of highly viscous particles. In this study, we demonstrate advantages and synergy of this multi-modal particle characterization approach based on the analysis of individual viscous particles formed in the air-discharged waste produced by a common sewer pipe rehabilitation technology. Using oil immersion flow microscopy, we investigate particle size distributions and morphology of colloidal components present in field-collected aqueous waste condensates. We compare these results with corresponding measurements of viscous particles formed in drying droplets of the aerosolized discharged waste. The colloidal components and viscous particles were found to be approximately 10 µm and 0.5 µm, respectively. The aerosolized viscous particles exhibited a spherical morphology, while the colloidal particles appeared noticeably fractal, resembling fragments of a cured composite material. Chemical imaging of the viscous particles collected on substrates was performed using scanning electron microscopy and soft X-ray spectro-microscopy techniques. Through these methods, comprehensive description of these particles emerged, confirming their high solid-like viscosity, wide-ranging sizes, diverse carbon speciation with high degrees of oxygenation, and high organic volume fractions. The aerosolized viscous particles were further characterized using high-throughput single particle mass spectrometry. This technique provides real-time measurements of composition, size, and morphological metrics for large numbers of individual particles, enabling the identification of their distinct mass spectrometric signatures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1989

Integrated design optimization research and development in an industrial environment

An overview is given of a design optimization project that is in progress at the GE Research and Development Center for the past few years. The objective of this project is to develop a methodology and a software system for design automation and optimization of structural/mechanical components and systems. The effort focuses on research and development issues and also on optimization applications that can be related to real-life industrial design problems. The overall technical approach is based on integration of numerical optimization techniques, finite element methods, CAE and software engineering, and artificial intelligence/expert systems (AI/ES) concepts. The role of each of these engineering technologies in the development of a unified design methodology is illustrated. A software system DESIGN-OPT has been developed for both size and shape optimization of structural components subjected to static as well as dynamic loadings. By integrating this software with an automatic mesh generator, a geometric modeler and an attribute specification computer code, a software module SHAPE-OPT has been developed for shape optimization. Details of these software packages together with their applications to some 2- and 3-dimensional design problems are described.

Kumar, V.↗
DOE OSTI2023

Corrosion testing needs and considerations for additively manufactured materials in nuclear reactors

Metal additive manufacturing holds significant promise as an enabling technology for the 21st century nuclear energy industry. Metal additive manufacturing (MAM) can allow the fabrication of novel materials and innovative component designs that are not achievable through conventional manufacturing. Due to its very different fabrication methods, as-fabricated MAM components are characteristically different from conventionally manufactured components. MAM materials exhibit very different microstructures from conventional cast or wrought materials. For example, austenitic stainless steels fabricated by laser powder bed fusion exhibit columnar grain structures, dislocation cell structures, and melt pool fingerprints. In addition, MAM fabrication may result in defects such as porosity, incomplete processing of the feedstock (e.g., lack of fusion in melt-based methods), and oxide inclusions. Heat treatments may further evolve the microstructure, microsegregation, and stresses within the component. Furthermore, MAM components have a rough surface with feature sizes on the order of the feedstock material, as opposed to smooth surfaces resulting from conventional machining and forming operations. As a result, the corrosion behavior of MAM components will likely be significantly different from that of conventionally formed components. Corrosive environments for structural materials within advanced reactor environments include molten fluoride and chloride salts, liquid sodium and lead-bismuth, and high-temperature helium. The Advanced Materials and Manufacturing Technologies program within the Department of Nuclear Energy in the United States Department of Energy is assessing the unique concerns of MAM component corrosion and testing methodologies in advanced nuclear reactor environments. We discuss these concerns and testing strategies in this paper.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Geometrical effects on the measured neutron residual stress in additively manufactured cold spray AA6061

Aluminum cold spray additive builds were made with varying wall widths and geometries to explore the effects of build geometry on residual stress development in the additively sprayed material. Deposition rates of over 750 g/hr were achieved without any cracking or delamination of the additively manufactured components. Neutron residual stress measurements revealed a maximum tensile residual stress of 41 MPa at the interface of the substrate and a maximum compressive residual stress of −35 MPa in the cold sprayed material. While there was not found to be significant residual stress changes between the cold sprayed walls, the cold sprayed cylinder had varying residual stress throughout the diameter with the outer diameter having a higher tensile residual stress than the interior. The low residual stress and minimal geometrical dependency demonstrate further part size is possible without concerns for component failure in AA6061. The application of common coating residual stress models to full scale additive builds is evaluated and discussed. The lack of residual stress evolution was studied by in-situ coating property measurement that revealed that the deposition stress of the AA6061 sprays reduced with increased layer thickness. In conclusion, this study provides insight into the evolution of residual stress in cold spray additive components and how both the mechanics and material responses differ from coatings.

Additive manufacturing↗
NASA NTRS1990

An expert system based software sizing tool, phase 2

A software tool was developed for predicting the size of a future computer program at an early stage in its development. The system is intended to enable a user who is not expert in Software Engineering to estimate software size in lines of source code with an accuracy similar to that of an expert, based on the program's functional specifications. The project was planned as a knowledge based system with a field prototype as the goal of Phase 2 and a commercial system planned for Phase 3. The researchers used techniques from Artificial Intelligence and knowledge from human experts and existing software from NASA's COSMIC database. They devised a classification scheme for the software specifications, and a small set of generic software components that represent complexity and apply to large classes of programs. The specifications are converted to generic components by a set of rules and the generic components are input to a nonlinear sizing function which makes the final prediction. The system developed for this project predicted code sizes from the database with a bias factor of 1.06 and a fluctuation factor of 1.77, an accuracy similar to that of human experts but without their significant optimistic bias.

Friedlander, David↗
NASA NTRS2012

Optical Density Analysis of X-Rays Utilizing Calibration Tooling to Estimate Thickness of Parts

This process is designed to estimate the thickness change of a material through data analysis of a digitized version of an x-ray (or a digital x-ray) containing the material (with the thickness in question) and various tooling. Using this process, it is possible to estimate a material's thickness change in a region of the material or part that is thinner than the rest of the reference thickness. However, that same principle process can be used to determine the thickness change of material using a thinner region to determine thickening, or it can be used to develop contour plots of an entire part. Proper tooling must be used. An x-ray film with an S-shaped characteristic curve or a digital x-ray device with a product resulting in like characteristics is necessary. If a film exists with linear characteristics, this type of film would be ideal; however, at the time of this reporting, no such film has been known. Machined components (with known fractional thicknesses) of a like material (similar density) to that of the material to be measured are necessary. The machined components should have machined through-holes. For ease of use and better accuracy, the throughholes should be a size larger than 0.125 in. (.3 mm). Standard components for this use are known as penetrameters or image quality indicators. Also needed is standard x-ray equipment, if film is used in place of digital equipment, or x-ray digitization equipment with proven conversion properties. Typical x-ray digitization equipment is commonly used in the medical industry, and creates digital images of x-rays in DICOM format. It is recommended to scan the image in a 16-bit format. However, 12-bit and 8-bit resolutions are acceptable. Finally, x-ray analysis software that allows accurate digital image density calculations, such as Image-J freeware, is needed. The actual procedure requires the test article to be placed on the raw x-ray, ensuring the region of interest is aligned for perpendicular x-ray exposure capture. One or multiple machined components of like material/ density with known thicknesses are placed atop the part (preferably in a region of nominal and non-varying thickness) such that exposure of the combined part and machined component lay-up is captured on the x-ray. Depending on the accuracy required, the machined component fs thickness must be carefully chosen. Similarly, depending on the accuracy required, the lay-up must be exposed such that the regions of the x-ray to be analyzed have a density range between 1 and 4.5. After the exposure, the image is digitized, and the digital image can then be analyzed using the image analysis software.

Grau, David↗
DOE OSTI2025

Computational alchemy clarifies origins of alloy strengthening

Solid solution strengthening (SSS) is widely used to enhance mechanical properties of metals. Originally developed for dilute alloys, classical SSS theories are presently challenged by the rise of complex concentrated alloys (CCA) with nearly equiatomic compositions. Here, we propose and develop a method of “computational alchemy” in which interatomic interactions are modified to systematically vary two key physical parameters defining SSS - atomic size misfit and elastic stiffness misfit - over a maximally wide range of two misfits. The resulting alchemical alloys are subjected to massive (~10 8 atoms) molecular dynamics (MD) simulations reproducing full complexity of plastic strength response. At variance with prevailing views, stiffness misfit is observed to contribute to SSS on par if not more than size misfit. Furthermore, depending on exactly how two misfits are combined, they result in synergistic (amplification) or antagonistic (compensation) effect on alloy strengthening. Unlike real CCAs in which each component element comes with its own specific size and stiffness, our alchemical model alloys span the space of two misfits continuously revealing trends in alloy strengthening unrecognized so far. Our study demonstrates unique value of intentionally unrealistic models for gaining deep physical insights into material behaviors that are difficult to reveal otherwise.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Si-Ge Nano-Structured with Tungsten Silicide Inclusions

Traditional silicon germanium high temperature thermoelectrics have potential for improvements in figure of merit via nano-structuring with a silicide phase. A second phase of nano-sized silicides can theoretically reduce the lattice component of thermal conductivity without significantly reducing the electrical conductivity. However, experimentally achieving such improvements in line with the theory is complicated by factors such as control of silicide size during sintering, dopant segregation, matrix homogeneity, and sintering kinetics. Samples are prepared using powder metallurgy techniques; including mechanochemical alloying via ball milling and spark plasma sintering for densification. In addition to microstructural development, thermal stability of thermoelectric transport properties are reported, as well as couple and device level characterization.

thermoelectricity↗
NASA NTRS2015

WSi2 in Si(1-x)Ge(x) Composites: Processing and Thermoelectric Properties

Traditional SiGe thermoelectrics have potential for enhanced figure of merit (ZT) via nano-structuring with a silicide phase, such as WSi2. A second phase of nano-sized silicides can theoretically reduce the lattice component of thermal conductivity without significantly reducing the electrical conductivity. However, experimentally achieving such improvements in line with the theory is complicated by factors such as control of silicide size during sintering, dopant segregation, matrix homogeneity, and sintering kinetics. Samples were prepared using powder metallurgy techniques; including mechano-chemical alloying, via ball milling, and spark plasma sintering for densification. Processing, micro-structural development, and thermoelectric properties will be discussed. Additionally, couple and device level characterization will be introduced.

Thermoelectric Power Generation↗
NASA NTRS1999

Combustion of Two-Component Miscible Droplets in Reduced Gravity

This paper presents recent theoretical and experimental results from an ongoing research program that deals with reduced-gravity combustion of bi-component droplets initially in the mm size range or larger. The primary objectives of the research are to study the effects of droplet internal flows, thermal and solutal Marangoni stresses, and species volatility differences on liquid species transport and overall combustion phenomena (e.g., gas-phase unsteadiness, burning rates, sooting, radiation, and extinction). The research program utilizes a reduced-gravity environment so that buoyancy effects are rendered negligible. Use of large droplets also facilitates visualization of droplet internal flows, which is important to this research. This program is a continuation of extensive ground based experimental and theoretical research on bi-component droplet combustion which has been ongoing for several years. The focal point of this research program is a flight experiment (Bi-Component Droplet Combustion Experiment, BCDCE). This flight experiment is still under development. However, supporting ground studies have been performed, and preliminary data have been obtained from flight experiments (Fiber Supported Droplet Combustion Experiment, FSDC-1 and FSDC-2). These flight experiments were performed during the STS-73/USML-2 and STS-94/MSL- I missions. In the experiments, droplets composed of low- and high-volatility species are burned. The low-volatility components are initially present in small amounts. As combustion of a droplet proceeds, the liquid surface mass fraction of the low-volatility component will increase with time, resulting in a sudden and temporary decrease in droplet burning rates as the droplet rapidly heats to temperatures close to the boiling point of the low-volatility component. This decrease in burning rates causes a sudden and temporary contraction of the flame. The decrease in burning rates and the flame contraction can be observed experimentally. Measurements of burning rates as well as the onset time for flame contraction allow effective liquid-phase species diffusivities to be calculated, e.g., using asymptotic theory. A goal of the research is to relate effective liquid species diffusivities to droplet internal flow characteristics. Droplet internal flows will be visualized in future flight and ground-based experiments.

Shaw, B. D.↗
NASA NTRS2004

Bi-Component Droplet Combustion in Reduced Gravity

This research deals with reduced-gravity combustion of bi-component droplets initially in the mm size range or larger. The primary objectives of the research are to study the effects of droplet internal flows, thermal and solutal Marangoni stresses, and species volatility differences on liquid species transport and overall combustion phenomena (e.g., gas-phase unsteadiness, burning rates, sooting, radiation, and extinction). The research program utilizes a reduced gravity environment so that buoyancy effects are rendered negligible. Use of large droplets also facilitates visualization of droplet internal flows, which is important for this research. In the experiments, droplets composed of low- and high-volatility species are burned. The low-volatility components are initially present in small amounts. As combustion of a droplet proceeds, the liquid surface mass fraction of the low-volatility component will increase with time, resulting in a sudden and temporary decrease in droplet burning rates as the droplet rapidly heats to temperatures close to the boiling point of the low-volatility component. This decrease in burning rates causes a sudden and temporary contraction of the flame. The decrease in burning rates and the flame contraction can be observed experimentally. Measurements of burning rates as well as the onset time for flame contraction allow effective liquid-phase species diffusivities to be calculated, e.g., using asymptotic theory. It is planned that droplet internal flows will be visualized in flight and ground-based experiments. In this way, effective liquid species diffusivities can be related to droplet internal flow characteristics. This program is a continuation of extensive ground-based experimental and theoretical research on bi-component droplet combustion that has been ongoing for several years. The focal point of this program is a flight experiment (Bi-Component Droplet Combustion Experiment, BCDCE). This flight experiment is under development. However, supporting ground-based studies have been performed. Some of the most recent ground-based research is summarized.

Shaw, Benjamin D.↗
NASA NTRS2001

Bi-Component Droplet Combustion in Reduced Gravity

This research deals with reduced-gravity combustion of bi-component droplets initially in the mm size range or larger. The primary objectives of the research are to study the effects of droplet internal flows, thermal and solutal Marangoni stresses, and species volatility differences on liquid species transport and overall combustion phenomena (e.g., gas-phase unsteadiness, burning rates, sooting, radiation, and extinction). The research program utilizes a reduced-gravity environment so that buoyancy effects are rendered negligible. Use of large droplets also facilitates visualization of droplet internal flows, which is important for this research. In the experiments, droplets composed of low- and high-volatility species are burned. The low-volatility components are initially present in small amounts. As combustion of a droplet proceeds, the liquid surface mass fraction of the low-volatility component will increase with time, resulting in a sudden and temporary decrease in droplet burning rates as the droplet rapidly heats to temperatures close to the boiling point of the low-volatility component. This decrease in burning rates causes a sudden and temporary contraction of the flame. The decrease in burning rates and the flame contraction can be observed experimentally. Measurements of burning rates as well as the onset time for flame contraction allow effective liquid-phase species diffusivities to be calculated, e.g., using asymptotic theory. It is planned that droplet internal flows will be visualized in future flight and ground-based experiments. In this way, effective liquid species diffusivities can be related to droplet internal flow characteristics. This program is a continuation of extensive ground based experimental and theoretical research on bi-component droplet combustion that has been ongoing for several years. The focal point of this program is a flight experiment (Bi-Component Droplet Combustion Experiment, BCDCE). This flight experiment is under development. However, supporting studies have been performed. Because of space limitations, only some of the research performed over the last two years (since the 5th Microgravity Combustion Workshop) is summarized here.

Shaw, B. D.↗
NASA NTRS2003

Bi-Component Droplet Combustion in Reduced Gravity

This research deals with reduced-gravity combustion of bi-component droplets initially in the mm size range or larger. The primary objectives of the research are to study the effects of droplet internal flows, thermal and solutal Marangoni stresses, and species volatility differences on liquid species transport and overall combustion phenomena (e.g., gas-phase unsteadiness, burning rates, sooting, radiation, and extinction). The research program utilizes a reduced-gravity environment so that buoyancy effects are rendered negligible. Use of large droplets also facilitates visualization of droplet internal flows, which is important for this research. In the experiments, droplets composed of low- and high-volatility species are burned. The low-volatility components are initially present in small amounts. As combustion of a droplet proceeds, the liquid surface mass fraction of the low-volatility component will increase with time, resulting in a sudden and temporary decrease in droplet burning rates as the droplet rapidly heats to temperatures close to the boiling point of the low-volatility component. This decrease in burning rates causes a sudden and temporary contraction of the flame. The decrease in burning rates and the flame contraction can be observed experimentally. Measurements of burning rates as well as the onset time for flame contraction allow effective liquid-phase species diffusivities to be calculated, e.g., using asymptotic theory. It is planned that droplet internal flows will be visualized in flight and ground-based experiments. In this way, effective liquid species diffusivities can be related to droplet internal flow characteristics. This program is a continuation of extensive ground based experimental and theoretical research on bi-component droplet combustion that has been ongoing for several years. The focal point of this program is a flight experiment (Bi-Component Droplet Combustion Experiment, BCDCE). This flight experiment is under development. However, supporting ground-based studies have been performed. This ground-based research is summarized below.

Shaw, B. D.↗
NASA NTRS1981

Optical processing for landmark identification

A study of optical pattern recognition techniques, available components and airborne optical systems for use in landmark identification was conducted. A data base of imagery exhibiting multisensor, seasonal, snow and fog cover, exposure, and other differences was assembled. These were successfully processed in a scaling optical correlator using weighted matched spatial filter synthesis. Distinctive data classes were defined and a description of the data (with considerable input information and content information) emerged from this study. It has considerable merit with regard to the preprocessing needed and the image difference categories advanced. A optical pattern recognition airborne applications was developed, assembled and demontrated. It employed a laser diode light source and holographic optical elements in a new lensless matched spatial filter architecture with greatly reduced size and weight, as well as component positioning toleranced.

Casasent, D.↗