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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

Statistical Design of Experiments Enables Rapid Exploration of Perfluorobutane Sulfonate Degradation

The phase-out of long-chain PFAS has led to the proliferation of highly recalcitrant short-chain analogs, and mineralization technologies for these short-chain PFAS are needed to mitigate their deleterious effects on environmental and human health. In this study, we utilize a statistical design of experiments, specifically, response surface methodology, to rapidly evaluate the electrochemical degradation of the short-chain PFAS, perfluorobutane sulfonate (PFBS). We evaluate the impacts of the three primary electrochemical parameters (concentration of PFBS, concentration of supporting electrolyte, and applied current) over multiple orders of magnitude on the three primary reaction outcomes of electrochemical PFBS degradation (incomplete PFBS decomposition, complete PFBS mineralization as fluorine, and anodic energy consumption). Our results correspond with literature and clearly identify the well-known tradeoff between energy consumption and complete mineralization. Intriguingly, partial PFBS decomposition and energy consumption demonstrate nonlinear dependencies in the current/supporting electrolyte concentration space and the current/PFBS concentration space, respectively. These findings highlight the utility of the response surface methodology model to efficiently interrogate a large parameter space, identifying both common results and less-obvious interactions between electrochemical parameters and their influences on reaction outcomes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Separations Consortium: Lignin Rich Stream Fractionation and Purification

In support of the Bioenergy Technologies Office in converting lignin to fuels and chemicals, this project develops scalable separations based on membranes and Electordeionization (EDI) to recover low molecular weight (LMW) compounds from lignin rich streams. The project addresses three technology barriers in developing the bioeconomy; (1) Cost of production (2) Selective separation of organic acid species, and (3) Advanced bioprocess development. Specifically, membrane cascades using Tangential Flow Filtration (TFF) are investigated for the recovery of LMW lignin compounds from lignin rich streams such as Alkaline Pretreatment Liquor (APL), Reductive Catalytic Fractionation (RCF) oil, and Catalytic Oxidation oil. Process concepts, including dynamic filtration, are investigated to meet specific performance targets indicated by the consortium's Industrial Advisory Board for the membrane filtration including maintaining permeance > 1 LMH/bar and an overall cost target of < $1/kg of LMW lignin. EDI is investigated as an integral part of the membrane cascade to recover LMW aromatic acids and as an alternative to nanofiltration. Economic analysis of the processes is presented with a focus on minimizing energy consumption and capital expenditure. Furthermore, a sensitivity analysis is presented to identify key cost drivers and optimize holistic process operating conditions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

03.02.02.45: Energy Efficiency Improvement Approaches in Ice Related Processes

The primary objective of this project was to facilitate the dislocation of the interfacial ice layer by employing advanced materials and ultrasonic vibration to reduce ice adhesion strength. This work employed two technical approaches that were thoroughly investigated and previously reported. The effectiveness of these approaches, both individually and in combination, has been quantified, demonstrating notable energy savings. The projected payback period for these enhancements is approximately 2.2 years or less, contingent upon specific energy costs. Furthermore, these advancements hold significant promise for reducing carbon emissions across various equipment scales. This study particularly focused on the ultrasonic deicing technique for diverse structures, utilizing numerical simulations to evaluate performance and potential benefits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Bias Correction in Urban Building Energy Modeling for Chicago Using Machine Learning

Urban-scale building energy modeling (UBEM) holds promise for optimizing energy usage across extensive geographic regions. However, there is a recognized bias between simulated energy consumption and actual measured data. This study, based on building data from Chicago, delved into bias correction techniques for enhancing the accuracy of UBEM energy consumption estimates. Initially, the AutoBEM simulation yielded a normalized mean bias error (NMBE) of 1.1% and 51% of Coefficient of the Variation of the Root Mean Square Error (CVRMSE) after outlier exclusion. To address this, three bias correction methods were deployed: Average Mean Bias Error based bias correction, Quantile mapping bias correction, and Machine learning-based bias correction using Linear Regression and Random Forest models. Post-correction results exhibited marked improvement. The NMBE values were diminished to 0 for Average MBE-based, 0.36 for Quantile Mapping, and 0 for Machine Learning-based corrections. Concurrently, the CVRMSE values registered reductions from an original 51 to 50.8 for Quantile Mapping, and 38.56 for Machine Learning-based corrections, pointing towards the effectiveness of specific bias correction methods in refining the precision of UBEM energy predictions. Such accurate estimations are paramount for informed energy planning and urban policy-making.

Chowdhury, Shovan↗

Smart connected worker edge platform for smart manufacturing: Part 2—Implementation and on‐site deployment case study

Abstract In this paper, we describe specific deployments of the Smart Connected Worker (SCW) Edge Platform for Smart Manufacturing through implementation of four instructive real‐world use cases that illustrate the role of people in a Smart Manufacturing paradigm through which affordable, scalable, accessible, and portable (ASAP) information technology (IT) acquires and contextualizes data into information for transmission to operation technologies (OT). For case one, the platform captures the relationships between energy consumption and human workflows for improved energy productivity while workers interact with machines during semiconductor manufacturing. The platform utilizes human cognition to identify anomalous machine behavior for root cause analysis of system faults via neural network (NN) that recognize alarm postures of workers with cameras. For case two, a smart assembly line is demonstrated for state monitoring and fault detection. Machine learning (ML) models are used to recognize system states and identify fault scenarios with human intervention. For case three, the platform monitors human–machine interactions to classify manufacturing machine states for proper operations and energy productivity. Internal energy states of individual or collections of manufacturing equipment are determined via NN based algorithms that disaggregate signals associated with smart metering typically deployed at manufacturing facilities. These methods predict the real time energy profile of each machine from the total energy profile of a manufacturing site. For case four, a software defined sensor system built with scientific workflow engines is demonstrated for contextualizing data from laser surface refraction for characterization, and diagnostics in the processing of additively manufactured titanium alloy.

Donovan, Richard P.↗

Nondestructive Photo-Cross-Linking of Microphase-Separated Diblock Polymers through Coumarin Dimerization

The effect of long-wavelength ultraviolet photocrosslinking on microphase-separated coumarin-containing block polymers was studied by photo-rheometry and small-angle X-ray scattering. This model system consisted of three photocrosslinkable diblock polymers of poly(methoxyethyl acrylate)-b-poly(hexyl methacrylate-co-coumarin methacrylate) with different volume fractions of the crosslinkable coumarin-containing block, which microphase separated into lamellar and cylindrical morphologies. All polymers stiffened upon exposure to 365 nm light, with much greater relative increases in moduli recorded for lamellae-forming polymers (ca. 3200% increase) compared to the cylinder-forming polymer (ca. 550% increase). Disordering transitions that were evident in uncrosslinked samples were no longer observed after crosslinking in the ordered state, and domain sizes were found to remain stable to heating. The photocrosslinking reaction only proceeded under active irradiation, indicating a high degree of spatiotemporal control over curing in this system. Finally, at constant concentration of couamarin within the crosslinkable block, the cure rate was largely independent of polymer composition, suggesting a constant local concentration of coumarin moieties within the segregated crosslinkable domains. Lastly, these findings establish a set of specific structure-property relationships governing the phase-selective photocrosslinking of diblock polymers that can guide the design of robust nanostructured materials.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Developing an Energy Service Interface Specification

Developing an Energy Service Interface (ESI) specification requires engaging a community of stakeholders including grid operators, Information and Communication Technology implementors, integrators, and finally standards bodies who will define an interface that respects and boundaries of ownership and roles of responsibility in order to activate millions of Distributed Energy Resource for the provision of grid services. By applying Interoperability Maturity Model Criteria and ESI principles to common grid-DER service use cases, the Grid Modernization Lab Consortium team will engage subject matter experts to develop a specification, with an eventual goal of informing development of ESI compliant profiles or standards. The ESI Specification is intended to specify the characteristics, attributes, or qualities that need to be addressed in ESI compliant standards or profiles. This includes addressing interoperability criteria and the service-performance style of the interface.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Ten questions concerning reinforcement learning for building energy management

As buildings account for approximately 40% of global energy consumption and associated greenhouse gas emissions, their role in decarbonizing the power grid is crucial. The increased integration of variable energy sources, such as renewables, introduces uncertainties and unprecedented flexibilities, necessitating buildings to adapt their energy demand to enhance grid resiliency. Consequently, buildings must transition from passive energy consumers to active grid assets, providing demand flexibility and energy elasticity while maintaining occupant comfort and health. This fundamental shift demands advanced optimal control methods to manage escalating energy demand and avert power outages. Reinforcement learning (RL) emerges as a promising method to address these challenges. Here, in this paper, we explore ten questions related to the application of RL in buildings, specifically targeting flexible energy management. We consider the growing availability of data, advancements in machine learning algorithms, open-source tools, and the practical deployment aspects associated with software and hardware requirements. Our objective is to deliver a comprehensive introduction to RL, present an overview of existing research and accomplishments, underscore the challenges and opportunities, and propose potential future research directions to expedite the adoption of RL for building energy management.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

New Effective Material Couple--Oxide Ceramic and Carbon Nanotube-- Developed for Aerospace Microsystem and Micromachine Technologies

The prime driving force for using microsystem and micromachine technologies in transport vehicles, such as spacecraft, aircraft, and automobiles, is to reduce the weight, power consumption, and volume of components and systems to lower costs and increase affordability and reliability. However, a number of specific issues need to be addressed with respect to using microsystems and micromachines in aerospace applications--such as the lack of understanding of material characteristics; methods for producing and testing the materials in small batches; the limited proven durability and lifetime of current microcomponents, packaging, and interconnections; a cultural change with respect to system designs; and the use of embedded software, which will require new product assurance guidelines. In regards to material characteristics, there are significant adhesion, friction, and wear issues in using microdevices. Because these issues are directly related to surface phenomena, they cannot be scaled down linearly and they become increasingly important as the devices become smaller. When microsystems have contacting surfaces in relative motion, the adhesion and friction affect performance, energy consumption, wear damage, maintenance, lifetime and catastrophic failure, and reliability. Ceramics, for the most part, do not have inherently good friction and wear properties. For example, coefficients of friction in excess of 0.7 have been reported for ceramics and ceramic composite materials. Under Alternate Fuels Foundation Technologies funding, two-phase oxide ceramics developed for superior high-temperature wear resistance in NASA's High Operating Temperature Propulsion Components (HOTPC) project and new two-layered carbon nanotube (CNT) coatings (CNT topcoat/iron bondcoat/quartz substrate) developed in NASA's Revolutionary Aeropropulsion Concepts (RAC) project have been chosen as a materials couple for aerospace applications, including micromachines, in the nanotechnology lubrication task because of their potential for superior friction and wearf properties in air and in an ultrahigh vacuum, spacelike environment. At the NASA Glenn Research Center, two-phase oxide ceramic eutectics, Al2O3/ZrO2(Y2O3), were directionally solidified using the laser-float-zone process, and carbon nanotubes were synthesized within a high-temperature tube furnace at 800 C. Physical vapor deposition was used to coat all quartz substrates with 5-nm-thick iron as catalyst and bondcoat, which formed iron islands resembling droplets and serving as catalyst particles on the quartz. A series of scanning electron micrographs showing multiwalled carbon nanotubes directionally grown as aligned "nanograss" on quartz is presented. Unidirectional sliding friction eperiments were conducted at Glenn with the two-layered CNT coatings in contact with the two-phase Al2O3/ZrO2(Y2O3) eutectics in air and in ultrachigh vacuum. The main criteria for judging the performance of the materials couple for solid lubrication and antistick applications in a space environment were the coefficient of friction and the wear resistance (reciprocal of wear rate), which had to be less than 0.2 and greater than 10(exp 5) N(raised dot)/cubic millimetes, respectively, in ultrahigh vacuum. In air, the coefficient of friction for the CNT coatings in contact with Al2O3/ZrO2 (Y2O3) eutectics was 0.04, one-fourth of that for quartz. In an ultrahigh vacuum, the coefficient of friction for CNT coatings in contact with Al2O3/ZrO2 (Y2O3) was one-third of that for quartz. The two-phase Al2O3/ZrO2 (Y2O3) eutectic coupled with the two-layered CNT coating met the coefficient of friction and wear resistance criteria both in air and in an ultrahigh vacuum, spacelike environment. This material's couple can dramatically improve the stiction (or adhesion), friction, and wear resistance of the contacting surfaces, which are major issues for microdevices and micromachines.

Miyoshi, Kazuhisa↗

Simulating Energy and Security Interactions in Semiconductor Manufacturing: Insights from the Intel Minifab Model

Semiconductor manufacturing is a highly complex. Fabrication plants must deal with re-entrant flows to support multiple types of wafers being produced simultaneously, each with their own deadlines and specifications. The manufacturing process itself depends upon the ability to control and programmatically adjust a variety of environmental conditions including temperature, humidity, and air quality. In addition, wafer fabrication consumes large amounts of electricity. Emerging technologies may help reduce the energy footprint of such facilities but can introduce cybersecurity risks. Therefore, this paper presents a modeling and simulation framework to quantify tradeoffs between operational measures of performance, energy consumption, and cybersecurity controls. We augment the Intel Minifab model, with the Purdue Enterprise Reference Architecture (PERA) for cybersecurity as well as tool-level energy consumption data from a real-world semiconductor manufacturing testbed. In this manner, we intend to provide stakeholders with a systematic, data-driven approach to evaluate emerging risks within the manufacturing process.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Modeled Results of Four Residential Energy Efficiency Measure Packages for Deriving Advanced Building Construction Research Targets

The Advanced Building Construction (ABC) Initiative from the U.S. Department of Energy Building Technologies Office is working to accelerate industrialized construction innovations for decarbonizing buildings. To inform performance and cost targets for research under the ABC Initiative, this analysis used the ResStock™ tool to evaluate the energy savings, utility bill impacts, and carbon emissions impacts of four simulated upgrade packages with specific target performance levels on a large sample of residential dwelling units (approximately 550,000) representative of the U.S. housing stock.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Chemical looping air separation with Sr 0.8 Ca0.2Fe 0.9 Co 0.1 O 3-δ perovskite sorbent: Packed bed modeling, verification, and optimization

Chemical looping air separation (CLAS) represents a promising approach for efficient O 2 production from the air. This present study aims at optimizing the absorber/desorber operations and the separation process with extensive experimental validation. Specifically, a one-dimensional packed bed model was developed to investigate the CLAS operation with a Sr 0.8 Ca 0.2 Fe 0.9 Co 0.1 O 3-δ perovskite sorbent. The redox thermodynamics of perovskite sorbent was measured by TGA and then incorporated into a linear driving force model to describe the O 2 absorption and desorption rates. Both 4-step and 5-step air separation cycle configurations, with various cyclic structures, were performed in a subpilot-scale packed bed. The model predicted O2 purity and productivity were consistent with experimental results, supporting its accuracy and applicability. Parametric analysis and multi-objective optimization were further carried out to assess the performance of CLAS. Both O 2 purity and recovery increased monotonically with the cycle time, airflow rate, steam flow rate, and absorption pressure. Meanwhile, optimal O 2 productivity and power consumption can only be achieved by specific combinations of these parameters. The optimized results showed that CLAS can be highly competitive when compared to conventional pressure swing adsorption (PSA) or cryogenic distillation. The 5-step cycle configuration achieved a minimum power consumption of 118 kW·h for producing 1 ton O 2 with ≥ 95% purity. The maximum O 2 productivity reached 0.0932 g O2 /(g sorbent ·h) with 390 kW·h/ton O 2 of energy consumption (95% pure). The optimization results also indicate that CLAS can potentially be more efficient than cryogenic distillation even when the required O 2 purity is above 99%.

42 ENGINEERING↗

The Doubly Labeled Water Method for Measuring Human Energy Expenditure: Adaptations for Spaceflight

It is essential to determine human energy requirements in space, and the doubly labeled water method has been identified as the most appropriate means of indirect calorimetry to meet this need. The method employs naturally occurring, stable isotopes of hydrogen (H-2, deuterium) and oxygen (O-18) which, after dosing, mix with body water. The deuterium is lost from the body as water while the O-18 is eliminated as both water and CO2. The difference between the two isotope elimination rates is therefore a measure of CO2 production and hence energy expenditure. Spaceflight will present a unique challenge to the application of the doubly labeled water method. Specifically, interpretation of doubly labeled water results assumes that the natural abundance or 'background' levels of the isotopes remain constant during the measurement interval. To address this issue, an equilibration model will be developed in an ongoing ground-based study. As energy requirements of women matched to counterparts in the Astronauts Corps are being determined by doubly labeled water, the baseline isotope concentration will be changed by consumption of 'simulated Shuttle water' which is artificially enriched. One group of subjects will be equilibrated on simulated Shuttle water prior to energy determinations by doubly labeled water while the others will consume simulated Shuttle water after dosing. This process will allow us to derive a prediction equation to mathematically model the effect of changing background isotope concentrations.

Schulz, Leslie O.↗

Modular Stirling Radioisotope Generator

High-efficiency radioisotope power generators will play an important role in future NASA space exploration missions. Stirling Radioisotope Generators (SRGs) have been identified as a candidate generator technology capable of providing mission designers with an efficient, high-specific-power electrical generator. SRGs high conversion efficiency has the potential to extend the limited Pu-238 supply when compared with current Radioisotope Thermoelectric Generators (RTGs). Due to budgetary constraints, the Advanced Stirling Radioisotope Generator (ASRG) was canceled in the fall of 2013. Over the past year a joint study by NASA and the Department of Energy (DOE) called the Nuclear Power Assessment Study (NPAS) recommended that Stirling technologies continue to be explored. During the mission studies of the NPAS, spare SRGs were sometimes required to meet mission power system reliability requirements. This led to an additional mass penalty and increased isotope consumption levied on certain SRG-based missions. In an attempt to remove the spare power system, a new generator architecture is considered, which could increase the reliability of a Stirling generator and provide a more fault-tolerant power system. This new generator called the Modular Stirling Radioisotope Generator (MSRG) employs multiple parallel Stirling convertor/controller strings, all of which share the heat from the General Purpose Heat Source (GPHS) modules. For this design, generators utilizing one to eight GPHS modules were analyzed, which provided about 50 to 450 W of direct current (DC) to the spacecraft, respectively. Four Stirling convertors are arranged around each GPHS module resulting in from 4 to 32 Stirling/controller strings. The convertors are balanced either individually or in pairs, and are radiatively coupled to the GPHS modules. Heat is rejected through the housing/radiator, which is similar in construction to the ASRG. Mass and power analysis for these systems indicate that specific power may be slightly lower than the ASRG and similar to the Multi-Mission Radioisotope Thermoelectric Generator (MMRTG). However, the reliability should be significantly increased compared to ASRG.

Modules↗

Italian prototype building models for urban scale building performance simulation

Urban building energy modeling (UBEM) seeks to evaluate strategies to optimize building energy use at urban scale to support a city's building energy goals. Prototype building models are usually developed to represent typical urban building characteristics of a specific use type, construction year, and climate zone, as detailed characteristics of individual buildings at urban scale are difficult to obtain. This study investigated the Italian building stock, developing 46 building prototypes, based on construction year, for residential and office buildings. The study included 16 single-family buildings, 16 multi-family buildings, and 14 office buildings. Building envelope properties and heating, ventilation, and air conditioning system characteristics were defined according to existing building energy codes and standards for climatic zone E, which covers about half the Italian municipalities. Novel contributions of this study include (1) detailed specifications of prototype building energy models for Italian residential and office buildings that can be adopted by UBEM tools, and (2) a dataset in GeoJSON format of Italian urban buildings compiled from diverse data sources and national standards. Finally, the developed prototype building specifications, the building dataset, and the workflow can be applied to create other building prototypes and to support Italian national building energy efficiency and environmental goals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

EVA Planning: Using Neutral Buoyancy Laboratory (NBL) Training to Predict in-Flight Energy Expenditure

Metabolic rate (“met rate”) is the amount of energy expended over a period of time and is influenced by many factors including body composition, level of physical activity, resting metabolic rate, sex, age, and food intake. Met rate is measured during Extravehicular Activity (EVA) training at the Neutral Buoyancy Laboratory (NBL) and during in-flight EVAs through indirect calorimetry, calculating energy expenditure from respiratory measurements of O 2 consumption and/or CO 2 production. During Extravehicular Activity (EVA) planning, metabolic cost is important to consider and is used to inform EVA duration based on spacesuit consumables associated with life support systems. Currently, NBL and previous ISS EVA met rate data for specified crewmembers are utilized to predict in-flight EVA metabolic costs based on a proposed EVA timeline. Timeline data collected during training is used to relate met rates to specific EVA activities, which are in turn assigned to more generalized EVA task categories, categorizing by both task type and restraint type. EVA task categories include EVA Setup/Cleanup, Worksite Setup/Cleanup, Cable Routing, Bolts, Fluid Connectors, Electrical Connectors, R&R Work, Miscellaneous Work, Incapacitated Crew Rescue (being rescued or performing), Assisted Crew Rescue (being assisted or performing), and Translation. Restraint types consist of Free-Float, Body Restraint Tether (BRT), Articulating Portable Foot Restraint (APFR), and Space Station Remote Manipulator System (SSRMS). From a crewmember’s historical data, individualized 10th, 50th and 90th percentile met rate estimates are generated for each task category and used to estimate the proposed EVA timeline metabolic cost. In-flight metabolic data (“As-Executed”) from recent ISS US EVAs 85-88 (totaling eight EVA crewmember met rates) was compared with their predicted metabolic cost (“As-Planned”) to evaluate the accuracy of the current met rate estimation method. Across the four EVAs, As-Executed Cumulative EVA Total Metabolic Cost (M = 5893.78 BTU, SD = 816.60) was not significantly different compared to As-Planned Cumulative EVA Total Metabolic Cost (M = 6106.60 BTU, SD = 826.62; t(7) = 0.751 , p = .477). Though not a significant difference, generally, As-Planned total estimates were slightly higher than As-Executed total metabolic cost. Relative Error for Cumulative EVA Total Metabolic Cost ranged from -33% to 14.7%, depending on the crewmember and EVA. When comparing As-Planned to A-Executed EVA task categories for Bolts, Electrical Connectors, EVA Cleanup, EVA Setup, Miscellaneous Work, Translation, Worksite Cleanup, and Worksite Setup during these EVAs, no significant differences were observed, however, there was a significant difference in As-Planned (M = 783.71 BTU, SD = 408.88) compared to As-Executed (M = 608.87 BTU, SD = 425.29) metabolic cost for the task category of Repair-and-Replace (R&R) Work (t(17) = 3.21 , p = .005). Looking closer within the R&R Work task category, As-Executed R&R Work with Free-Float restraint type (M = 706.17 BTU, SD = 352.18) was significantly less than As-Planned R&R Work with Free-Float restraint type (M= 887.96 BTU, SD = 381.42; t(12) = 2.59, p < .024). As-Executed R&R Work with SSRMS Restraint type (M = 355.89 BTU, SD = 534.65) was not significantly different from As-Planned values (M = 512.69 BTU, SD = 383.34; t(4) = 1.88, p = 0.132). These findings suggest that the energy expended performing R&R Work (Free-Float) is lower in flight than predicted. Accurate predictions of the metabolic cost of EVA are essential for planning and executing successful ISS EVAs. Overall, the current met rate prediction method is similar to actual in-flight values, slightly erring on the side of overestimation. Future work includes analysis of more historical in-flight EVA data to increase the power of the analysis, evaluating the NBL-ISS met rate conversion factor between NBL and ISS tasks, as well as exploring methods of substitution when crewmembers are missing prior task category data.

Lauren Cox↗

Use of refinery computer model to predict fuel production

Several factors (crudes, refinery operation and specifications) that affect yields and properties of broad specification jet fuel were parameterized using the refinery simulation model which can simulate different types of refineries were used to make the calculations. Results obtained from the program are used to correlate yield as a function of final boiling point, hydrogen content and freezing point for jet fuels produced in two refinery configurations, each one processing a different crude mix. Refinery performances are also compared in terms of energy consumption.

Flores, F. J.↗

Durability Characterization of Low Ice Adhesion and Impact Resistance Coatings

Glaze, rime and mixed icing conditions can cause significant variation in aerodynamic performance, fuel efficiency, and flight safety. For commercial aircraft, active icing mitigation strategies are utilized to enable safe flight within icing conditions according to the FAR Part 25/29 Appendix C icing envelope. For general aviation and unmanned aerial vehicles that cannot support active anti-icing technologies, avoidance is the only recourse. Passive approaches have been investigated to reduce weight and energy consumption for active systems and to expand the operational envelope for smaller aircraft. Coatings are one passive method to reduce or mitigate ice accretion on frontal surfaces of commercial aircraft with the greatest region of interest being wing leading edges. Aircraft wing leading edges represent an extreme environment. Durability must be considered for any material to be applied as a coating in this area. Currently, there are no specifications regarding coating durability of a low ice adhesion material applied on the wing leading edge. Therefore, a reasonable starting point is to use the durability specifications put forth for an aircraft external coating. Besides the tests called out in these specifications, others were included such as Taber abrasion to simulate wear and erosion. Beyond durability, performance metrics with regards to adhesion strength of accreted in-flight (i.e., impact) icing are central to determine coating usefulness. Determination of this property though is particularly challenging and only a few facilities have the capability to quantify this. An instrument at NASA Langley Research Center [Adverse Environment Rotary Test Stand Jr., (AERTS Jr.)], based on the AERTS system at The Pennsylvania State University, allows for screening numerous coatings subjected to the icing environment. To establish a benchmark for comparison with research coatings, a state-of-the-art (SOA) commercial aircraft coating was subjected to an array of salient durability and performance experiments. The same tests were conducted using a baseline epoxy (BE) resin formulation that demonstrated some initial promising results for comparison. Results from this initial screening will be discussed herein.

Miranda L Beaudry↗