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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Scan strategies in EBM-printed IN718 and the physics of bulk 3D microstructure development

Three-dimensional (3D) characterization provides opportunities for understanding processing-structure relationships in additively manufactured (AM) materials. Bulk samples of Inconel 718 were fabricated via electron beam melting (EBM) in order to study microstructural development as a function of energy input and beam scan strategy. TriBeam tomography of bulk Inconel 718 microstructures built under steady-state growth conditions reveals the sensitivity of microstructure formation and evolution to machine process parameters. Here, samples manufactured using a narrow range of energy input per unit build area result in varied grain morphologies and crystallographic textures. Using TRUCHAS, a thermal simulation software, the thermal history of bulk scan strategies was predicted, and combined with a calibrated microstructure-processing map to accurately predict bulk grain morphologies. The solidification parameters and the 3D measured nucleation density are used to predict the transition between columnar and equiaxed grain morphologies, providing a process map to guide AM parameter choices to locally control as-printed microstructure. A two-dimensional metric for characterizing bulk grain morphology was also found to agree well with predictions from the process map calibrated by 3D data. Combined with 3D tomography and thermal modelling, the physics of structure development were understood at a new level of detail with respect to the competing processes of grain nucleation and epitaxial growth.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Regional applicability and potential of salt-gradient solar ponds in the United States. Volume 2: Detailed report

A comprehensive assessment of the regional applicability and potential of salt-gradient solar ponds in the United States is provided. The assessment is focused on the general characteristics of twelve defined geographic regions. Natural resources essential to solar ponds are surveyed. Meteorological and hydrogeological conditions affecting pond performance are examined. Potentially favorable pond sites are identified. Regional thermal and electrical energy output from solar ponds is calculated. Selected pond design cases are studied. Five major potential market sectors are evaluated in terms of technical and energy-consumption characteristics, and solar-pond applicability and potential. Relevant pond system data and financial factors are analyzed. Solar-pond energy costs are compared with conventional energy costs. The assessment concludes that, excepting Alaska, ponds are applicable in all regions for at least two market sectors. Total solar pond energy supply potential in the five market sectors examined is estimated to be 8.94 quads/yr by the year 2000, approximately 7.2% of the projected total national energy demand.

Lin, E. I. H.↗
NASA NTRS1984

Directional solidification of Al2-Cu-Al and Al3-Ni-Al eutectics during TEXUS rocket flight

One lamellar eutectic sample and one fiber-like eutectic sample were solidified directionally during the TEXUS-6 rocket flight. The microstructures and the results of the thermal analysis, obtained from the temperatures recorded on the cartridge skin, are compared. No appreciable modifications of the regularity of the eutectic structures were observed by passing from 1 g to 0.0001 g in these experiments. No steady state growth conditions were achieved in these experiments.

Favier, J. J.↗
NASA NTRS1997

Photoelectron Effects on the Self-Consistent Potential in the Collisionless Polar Wind

The presence of unthermalized photoelectrons in the sunlit polar cap leads to an enhanced ambipolar potential drop and enhanced upward ion acceleration. Observations in the topside ionosphere have led to the conclusion that large-scale electrostatic potential drops exist above the spacecraft along polar magnetic field lines connected to regions of photoelectron production. A kinetic approach is used for the O(+), H(+), and photoelectron (p) distributions, while a fluid approach is used to describe the thermal electrons (e) and self-consistent electric field (E(sub II)) electrons are allowed to carry a flux that compensates for photoelectron escape, a critical assumption. Collisional processes are excluded, leading to easier escape of polar wind particles and therefore to the formation of the largest potential drop consistent with this general approach. We compute the steady state electric field enhancement and net potential drop expected in the polar wind due to the presence of photoelectrons as a function of the fractional photoelectron content and the thermal plasma characteristics. For a set of low-altitude boundary conditions typical of the polar wind ionosphere, including 0.1% photoelectron content, we found a potential drop from 500 km to 5 R(sub E) of 6.5 V and a maximum thermal electron temperature of 8800 K. The reasonable agreement of our results with the observed polar wind suggests that the assumptions of this approach are valid.

Khazanov, G. V.↗
NASA NTRS2006

Design Parameters Influencing Reliability of CCGA Assembly: A Sensitivity Analysis

Area Array microelectronic packages with small pitch and large I/O counts are now widely used in microelectronics packaging. The impact of various package design and materials/process parameters on reliability has been studied through extensive literature review. Reliability of Ceramic Column Grid Array (CCGA) package assemblies has been evaluated using JPL thermal cycle test results (-50(deg)/75(deg)C, -55(deg)/100(deg)C, and -55(deg)/125(deg)C), as well as those reported by other investigators. A sensitivity analysis has been performed using the literature da to study the impact of design parameters and global/local stress conditions on assembly reliability. The applicability of various life-prediction models for CCGA design has been investigated by comparing model's predictions with the experimental thermal cycling data. Finite Element Method (FEM) analysis has been conducted to assess the state of the stress/strain in CCGA assembly under different thermal cycling, and to explain the different failure modes and locations observed in JPL test assemblies.

reliability↗
NASA NTRS2007

Pan and Tilt Platform for a Thermal Vacuum Video Camera

The purpose of the Space Simulation Test Engineering (SSTE) Section at NASA Goddard Space Flight Center is "to provide full service test support, engineering expertise, and state-of-the-art facilities to perform simulated space and thermal cycle testing of Earth orbit and deep space flight hardware"(ref. 1). During the Integration & Testing phase of space flight projects, flight hardware must successfully demonstrate its functionality under conditions similar to the actual environment experienced in space. When testing hardware with mechanical components, such as antenna extensions, door openings, or solar panel deployments, visual observation would allow test personnel to verify mechanical operations in real-time. A video camera can supply data that the usual sensors inside a TV chamber cannot provide. Since mechanical functional testing could affect multiple regions of a test item, a camera with a fixed position may not be able to monitor and record the performance of different components of a mechanism, especially for large test items. By mounting the camera to a Pan and Tilt Platform, the camera can cover a larger area and its field-of-view (FOV) will increase significantly. This paper details the design process for the Pan and Tilt Platform.

Lui, Yan↗
DOE OSTI2021

Experimental thermal equation of state of B 2–KCl

The alkali halides are often used as optically-transparent pressure-transmitting media and thermal insulators in laser-heated diamond anvil cell experiments. High P-T equations of state for these materials would allow them to be used simultaneously as sensitive in situ pressure markers, making sample preparation and data analysis simpler. KCl is especially useful for this application because its high melting point, crystallographic simplicity, and low electron density are ideal for use in high-temperature X-ray diffraction experiments. However, the high-temperature static equation of state data for this material is limited in pressure to 8 GPa. As experiments routinely exceed 100 GPa in pressure and thousands of Kelvin, it is necessary for the equation of state of KCl to be determined experimentally at these conditions if it is to be used as an equation of state calibrant in the future. This work combines new high-pressure, high-temperature data of the B2 phase of KCl (up to 167 GPa and 2400 K) with the previously published room-temperature data of Dewaele et al. (2012) to produce a Mie-Gruneisen-Debye thermal equation of state for this material. The room temperature equation of state parameters are similar to those reported previously: V 0 = 32.0(3) cm 3 /mole, K 0 = 24(1) GPa and $K$$^{'}_{0}$ = 4.56(5). The thermal parameters, 0 and q, are 2.9(4) and 1.0(1), respectively. While a q of 1 is expected, the 0 is higher than expected from previous calculations, lower pressure experimental data, and the available shockwave data. Here, previously-reported equations of state underestimate the pressure of KCl at high temperatures.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Multi-Scale Modeling for Plasma-Enhanced Ammonia Decomposition over Carbides and Nitrides

Ammonia is a carbon-free hydrogen carrier, but its decomposition typically requires high temperatures over costly Ru-based catalysts due to the large barrier for N≡N bond formation. We develop a multiscale framework combining density functional theory, zero-dimensional plasma kinetics, and microkinetic modeling to elucidate how non-thermal plasma (NTP) enables low-temperature NH 3 decomposition over Co-based carbides and nitrides, benchmarked against Ru and Co. Under thermal conditions, all catalysts are limited by N≡N bond formation, with Co 3 C(001) most active owing to its negatively charged surface, strong N* binding, and low activation barriers of N≡N bond formation. Plasma-induced vibrational excitation of NH 3 and its reactive radicals promotes a radical-driven •NH 2 –N* coupling pathway that dominates on Co 3 C(001) and Co 3 N(001), shifting the rate-limiting step to NH 3 (v1) dissociation, increasing turnover frequencies by up to 6 orders of magnitude, and reducing the temperature needed to reach a turnover frequency of 5 s –1 from >680 °C (Ru and Co under thermal condition) to 267 °C (Co 3 C) and 415 °C (Co 3 N). These results identify Co-based carbides and nitrides as promising plasma-active catalysts for energy-efficient hydrogen production from ammonia.

ammonia decomposition↗
DOE OSTI2025

Characterization of Heat Transfer in a Trapped-Vortex Combustor Designed for High-Temperature Material Testing

Next generation gas turbines will reduce carbon emissions by improving their cycle efficiencies and implementing hydrogen as a low-carbon fuel. The combined-cycle efficiency can be improved by increasing the combustor outlet temperature and decreasing the cooling air required for hot-section parts. Ultra-high temperature ceramic matrix composites (CMC) can survive increasingly extreme environments due to their strong mechanical properties at expected conditions. The introduction of CMCs in high-hydrogen flame environments requires testing at realistic conditions that mimic the thermochemical and fluid mechanic states in gas-turbine combustors. In this work, we describe a new experiment that has been designed to test high-temperature materials in a combustor-relevant environment. Its trapped-vortex combustor chamber design allows for high levels of fuel flexibility and wide flame stability limits. Testing of monolithic silicon carbide (SiC) samples in this environment was done to characterize the heat transfer to material samples over a wide range of operating conditions, including variations in fuel composition and thermal power. Heat flux measurements were verified in non-reacting and reacting environments after which they were benchmarked with previous literature to verify the operation of the facility with heated air. Testing in combustor-relevant conditions shows high levels of heat flux to the material samples in the combustor, particularly downstream of the anchored flame.

Richins, Porter [Pennsylvania State University , ,↗
DOE OSTI2024

Particle-based high-temperature thermochemical energy storage reactors

Solar and other renewable energy driven gas-solid thermochemical energy storage (TCES) technology is a promising solution for the next generation energy storage systems due to its high operating temperature, efficient energy conversion, ultra-long storage duration, and potential high energy density. Experimental and theoretical studies suggest that the respective gravimetric and volumetric TCES energy storage densities vary from 200 to 3000 kJ kg –1 and 1–3 GJ m –3 . Solar radiation or heat generated from electric furnaces powered by renewable electricity can be stored in the form of chemical energy through endothermic reactions, while the stored chemical energy can be converted to thermal energy via an exothermic reaction when needed. The design of highly effective reactors requires a deep understanding of materials, thermodynamics, chemical kinetics, and transport phenomena. At time of writing, TCES reactors are yet to be deployed at commercially relevant scales, leaving a substantial gap between development efforts and commercial feasibility. Therefore, this review aims to examine the state-of-the-art design and performance of particle-based TCES reactors with different reactive materials. Fundamentals related to TCES reactive materials, reaction conditions, thermodynamics and kinetics, and transport phenomena are reviewed in detail to provide a comprehensive understanding of the reactor design and operation. Five major types of TCES reactors have been comprehensively reviewed and compared, including fixed, moving, rotary, fluidized, and entrained bed reactors. Most reported prototype reactors in the literature operate at lab scale with thermal inputs below 40 kW, and scaled TCES reactors (e.g., at megawatt level) are yet to be demonstrated. The nominal reactor operating temperatures range from 300 to 1500 °C, depending on the selected chemistry, reactive material, and heat sources. To evaluate their designs, the reactors are assessed in aspects of performance, cost, and durability. Discrepancies in performance indicators of energy storage density, extent of reaction, and various energy efficiencies are highlighted. The scale-up of reactors and power block integration, which hold the key to the successful commercialization of TCES systems, are critically analyzed. Furthermore, advanced materials (both reactive materials and ceramic reactor housing materials), effective particle flow control, advanced modeling tools, and novel system design may bring significant improvement to the energy efficiency, storage density and cost competitiveness of particle-based TCES reactors.

25 ENERGY STORAGE↗
NASA NTRS1992

The gabbro-eclogite phase transition and the elevation of mountain belts on Venus

Among the four mountain belts surrounding Lakshmi Planum, Maxwell Montes is the highest and stands up to 11 km above the mean planetary radius and 7 km above Lakshmi Planum. The bulk composition and radioactive heat production of the crust on Venus, where measured, are similar to those of terrestrial tholeiitic basalt. Because the thickness of the low-density crust may be limited by the gabbro-garnet granulite-eclogite phase transitions, the 7-11 km maximum elevation of Maxwell Montes is difficult to understand except in the unlikely situation that the crust contains a large volume of magma. A possible explanation is that the base of the crust is not in phase equilibrium. It has been suggested that under completely dry conditions, the gabbro-eclogite phase transition takes place by solid-state diffusion and may require a geologically significant time to run to completion. Solid-state diffusion is a strongly temperature-dependent process. In this paper we solve the thermal evolution of the mountain belt to attempt to constrain the depth of the gabbro-eclogite transition and thus to assess this hypothesis quantitatively. The one-dimensional heat equation is solved numerically by a finite difference approximation. The deformation of the horizontally shortening crustal and mantle portions of the thermal boundary layer is assumed to occur by pure shear, and therefore the vertical velocity is given by the product of the horizontal strain rate and depth.

Namiki, Noriyuki↗
NASA NTRS2011

Prognostics of Power MOSFET

This paper demonstrates how to apply prognostics to power MOSFETs (metal oxide field effect transistor). The methodology uses thermal cycling to age devices and Gaussian process regression to perform prognostics. The approach is validated with experiments on 100V power MOSFETs. The failure mechanism for the stress conditions is determined to be die-attachment degradation. Change in ON-state resistance is used as a precursor of failure due to its dependence on junction temperature. The experimental data is augmented with a finite element analysis simulation that is based on a two-transistor model. The simulation assists in the interpretation of the degradation phenomena and SOA (safe operation area) change.

Celaya, Jose Ramon↗
DOE OSTI2020

Energy Demand Management in Buildings Using PCM-Integrated Wall

The buildings in the United States annually consume nearly 40% of total U.S. energy consumption and approximately 75% of U.S. electricity consumption. Almost half of the total U.S. energy consumption in buildings is attributed to the space conditioning through Heating, Ventilation, and Air Conditioning (HVAC) systems. Utilizing thermal energy storage in buildings, particularly integrating phase change material (PCM) in the walls, has been reported to be an effective method of managing the space heating and cooling loads. This presentation covers an in-depth discussion on the integration of a PCM to building walls, the key conditions required for effective utilization of the PCM, and effect of the PCM transition temperature and the PCM location on energy-saving potential of the PCM-integrated wall.

building↗
NASA NTRS2016

Cryogenic Fluid Management Technology and Nuclear Thermal Propulsion

Cryogenic fluid management (CFM) is critical to the success of future nuclear thermal propulsion powered vehicles. While this is an issue for any propulsion system utilizing cryogenic propellants, this is made more challenging by the radiation flux produced by the reactor in a nuclear thermal rocket (NTR). Managing the cryogenic fuel to prevent propellant loss to boil off and leakage is needed to limit the required quantity of propellant to a reasonable level. Analysis shows deposition of energy into liquid hydrogen fuel tanks in the vicinity of the nuclear thermal engine. This is on top of ambient environment sources of heat. Investments in cryogenic/thermal management systems (some of which are ongoing at various organizations) are needed in parallel to nuclear thermal engine development in order to one day see the successful operation of an entire stage. High durability, low thermal conductivity insulation is one developmental need. Light weight cryocoolers capable of removing heat from large fluid volumes at temperatures as low as approx. 20 K are needed to remove heat leak from the propellant of an NTR. Valve leakage is an additional CFM issue of great importance. Leakage rates of state of the art, launch vehicle size valves (which is approximately the size valves needed for a Mars transfer vehicle) are quite high and would result in large quantities of lost propellant over a long duration mission. Additionally, the liquid acquisition system inside the propellant tank must deliver properly conditioned propellant to the feed line for successful engine operation and avoid intake of warm or gaseous propellant. Analysis of the thermal environment and the CFM technology development are discussed in the accompanying presentation.

Taylor, Brian D.↗
DOE OSTI2026

Developing Science-based fueling protocols for 250-bar hydrogen tanks onboard hydrogen ferries: Experiments and modeling

Combined modeling and experimental studies are reported of the fueling of a large (28 kg capacity) 250-bar Type IV hydrogen tank of the type being deployed on early hydrogen ferries, such as the MV Sea Change. The primary goal was to determine how such tanks can be successfully fueled with hydrogen (state of charge greater than 97%) within 45 minutes without exceeding the 82 °C temperature limit for such tanks. The modeling studies show that a gas injector is needed to avoid thermal stratification during hydrogen fueling which can result in potential hot spots. Empirically, precooling of the hydrogen to 0 °C was found to be needed in some of the cases examined, as ambient conditions greatly affected the need for a precooling to achieve the 45-minute fill time desired by end users. The experimental results afforded a calibration of the engineering model SOFIL for these large 250-bar tanks, which now enables using SOFIL to predict volume-averaged hydrogen fueling temperatures to an accuracy of ±2.7°C for these tanks. The model can therefore be used to evaluate potential scenarios for development of a standardized fueling methodology for ferries utilizing large Type-IV tanks.

08 HYDROGEN↗
NASA NTRS1980

Effects of moisture, residual thermal curing stresses and mechanical load on the damage development in quasi-isotropic laminates

Classical laminate theory and a finite element model were used to predict stress states prior to the first formation of damage in laminates fabricated from T/300/5208. Crack patterns characteristic of the laminate in a wet or dry condition were also predicted using a shear lag model. Development of edge damage was recorded and observed during the test by transferring an image of the damage from the edge surface on to a thin acetate sheet such that the damage imprinted could be immediately viewed on a microfiche card reader. Moisture was shown to significantly alter the interior and edge dry stress states due to swelling and a reduction of elastic properties and to reduce the transverse strength in 90 deg plies. A model was developed in order to predict changes in first ply failure laminate loads due to differences in stacking sequence together with a wet or dry environmental condition.

Kriz, R. D.↗
DOE OSTI2025

Dynamic Line Rating Models and Their Potential for a Cost‐Effective Transition to Carbon‐Neutral Power Systems

Most transmission system operators (TSOs) currently use seasonally steady-state models considering limiting weather conditions that serve as reference to compute the transmission capacity of overhead power lines. The use of dynamic line rating (DLR) models can avoid the construction of new lines, market splitting, false congestions, and the degradation of lines in a cost-effective way. DLR can also be used in the long run in grid extension and new power capacity planning. In the short run, it should be used to help operate power systems with congested lines. The operation of the power systems is planned to have the market trading into account; thus, it computes transactions hours ahead of real-time operation, using power flow forecasts affected by large errors. In the near future, within a “smart grid” environment, in real-time operation conditions, TSOs should be able to rapidly compute the capacity rating of overhead lines using DLR models and the most reliable weather information, forecasts, and line measurements, avoiding the current steady-state approach that, in many circumstances, assumes ampacities above the thermal limits of the lines. Here, this work presents a review of the line rating methodologies in several European countries and the United States. Furthermore, it presents the results of pilot projects and studies considering the application of DLR in overhead power lines, obtaining significant reductions in the congestion of internal networks and cross-border transmission lines.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

High-burnup fuel stress analysis prior to and during a LOCA transient

High-burnup fuel fragmentation and pulverization have been experimentally observed during simulated loss-of-coolant accident (LOCA) transient testing of high-burnup (>62 GWd/tU) nuclear fuel. The cause of this phenomenon is generally accepted to be the formation of stresses arising from the off-normal conditions. However, the primary mechanism(s) contributing to the stress formation is/are still being debated. Leading hypotheses suggest that the concurrence of fission gas bubbles and high burnup structure on the pellet periphery (i.e., the rim) leave the fuel susceptible to pulverization. Other hypotheses suggest that pulverization is artificially inflated during externally heated tests that do not reproduce prototypic fuel stresses and radial temperature profiles as the fuel transitions from full-power nuclear heating to decay heating. This work performs finite element analyses of fuel pellet temperatures and macroscopic stresses prior to and during a LOCA transient to identify (1) operating conditions that may exacerbate the fuel pellet stress state, (2) differences in predicted stresses with nuclear vs. furnace heating, and (3) how fuel cracking impacts the subsequent stress state in the pellet fragments. Analyses predict that macroscopic transient fuel stresses resulting from constrained thermal expansion will remain below the fracture stress of fresh UO 2 once the fragment size reaches ~4 mm or less. Calculated fuel stresses from simulated LOCA tests performed with representative nuclear vs. electrical heating rates are shown to be equal within 5% and essentially unchanged for all times after the first 27 seconds of the transients. Because the fuel stresses do not change once the temperature profile becomes uniform, macroscopic transient stresses would be no different than those following a normal shutdown. Because pulverization of high burnup fuel does not occur prior to a LOCA test, pulverization of high burnup UO 2 cannot be initiated by differential thermal stresses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗