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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

New Materials for the Repair of Polyimide Electrical Wire Insulation

Two viable polyimide backbone materials have been identified that will allow the repair of polyimide electrical wire insulation found on the Space Shuttle and other aging aircraft. This identification is the outcome of ongoing efforts to assess the viability of using such polyimides and polyimide precursors (polyamic acids [PAAs]) as repair materials for aging polyimide electrical wire insulation. These repair materials were selected because they match the chemical makeup of the underlying wire insulation as closely as possible. This similarity allows for maximum compatibility, coupled with the outstanding physical properties of polyimides. The two polyimide backbone materials allow the polymer to be extremely flexible and to melt at low temperatures. A polymer chain end capping group that allows the polymer to crosslink into a nonflowable repair upon curing at around 200 C was also identified.

Source record↗
NASA NTRS2003

Nanoscale Hot-Wire Probes for Boundary-Layer Flows

Hot-wire probes having dimensions of the order of nanometers have been proposed for measuring temperatures (and possibly velocities) in boundary-layer flows at spatial resolutions much finer and distances from walls much smaller than have been possible heretofore. The achievable resolutions and minimum distances are expected to be of the order of tens of nanometers much less than a typical mean free path of a molecule and much less than the thickness of a typical flow boundary layer in air at standard temperature and pressure. An additional benefit of the small scale of these probes is that they would perturb the measured flows less than do larger probes. The hot-wire components of the probes would likely be made from semiconducting carbon nanotubes or ropes of such nanotubes. According to one design concept, a probe would comprise a single nanotube or rope of nanotubes laid out on the surface of an insulating substrate between two metallic wires. According to another design concept, a nanotube or rope of nanotubes would be electrically connected and held a short distance away from the substrate surface by stringing it between two metal electrodes. According to a third concept, a semiconducting nanotube or rope of nanotubes would be strung between the tips of two protruding electrodes made of fully conducting nanotubes or ropes of nanotubes. The figure depicts an array of such probes that could be used to gather data at several distances from a wall. It will be necessary to develop techniques for fabricating the probes. It will also be necessary to determine whether the probes will be strong enough to withstand the aerodynamic forces and impacts of micron-sized particles entrained in typical flows of interest.

Tedjojuwono, Ken T.↗
NASA NTRS2012

Fabrication of a Kilopixel Array of Superconducting Microcalorimeters with Microstripline Wiring

A document describes the fabrication of a two-dimensional microcalorimeter array that uses microstrip wiring and integrated heat sinking to enable use of high-performance pixel designs at kilopixel scales (32 X 32). Each pixel is the high-resolution design employed in small-array test devices, which consist of a Mo/Au TES (transition edge sensor) on a silicon nitride membrane and an electroplated Bi/Au absorber. The pixel pitch within the array is 300 microns, where absorbers 290 microns on a side are cantilevered over a silicon support grid with 100-micron-wide beams. The high-density wiring and heat sinking are both carried by the silicon beams to the edge of the array. All pixels are wired out to the array edge. ECR (electron cyclotron resonance) oxide underlayer is deposited underneath the sensor layer. The sensor (TES) layer consists of a superconducting underlayer and a normal metal top layer. If the sensor is deposited at high temperature, the ECR oxide can be vacuum annealed to improve film smoothness and etch characteristics. This process is designed to recover high-resolution, single-pixel x-ray microcalorimeter performance within arrays of arbitrarily large format. The critical current limiting parts of the circuit are designed to have simple interfaces that can be independently verified. The lead-to-TES interface is entirely determined in a single layer that has multiple points of interface to maximize critical current. The lead rails that overlap the TES sensor element contact both the superconducting underlayer and the TES normal metal

Chervenak, James↗
NASA NTRS2011

The WIRED Survey. I. A Bright IR Excess Due to Dust Around the Heavily Polluted White Dwarf Galex J193156.8+011745

With the launch of the Wide-Field Infrared Survey Explorer (WISE), a new era of detecting planetary debris around white dwarfs (WDs) has begun with the WISE InfraRed Excesses around Degenerates (WIRED) Survey. The WIRED survey will be sensitive to substellar objects and dusty debris around WDs out to distances exceeding 100 pc, well beyond the completeness level of local WDs and covering a large fraction of known WDs detected with the SDSS DR4 WD catalog. In this paper, we report an initial result of the WIRED survey, the detection of the heavily polluted hydrogen WD (spectral type DAZ) GALEX Jl93156.S-KlI1745 at 3.35 and 4.6/Lm. We find that the excess is consistent with either a narrow dusty ring with an inner radius of 29 RWD. outer radius of 40 RWD, and a face-on inclination, or a disk with an inclination of 70 , an inner radius of 23 RWD. and an outer radius of 80 RWD. We also report initial optical spectroscopic monitoring of several metal lines present in the photosphere and find no variability in the line strengths or radial velocities of the lines. We rule out all but planetary mass companions to GALEXl931 out to 0.5 AU.

Debes, John H.↗
NASA NTRS2012

Fabrication of Microstripline Wiring for Large Format Transition Edge Sensor Arrays

We have developed a process to integrate microstripline wiring with transition edge sensors (TES). The process includes additional layers for metal-etch stop and dielectric adhesion to enable recovery of parameters achieved in non-microstrip pixel designs. We report on device parameters in close-packed TES arrays achieved with the microstrip process including R(sub n), G, and T(sub c) uniformity. Further, we investigate limits of this method of producing high-density, microstrip wiring including critical current to determine the ultimate scalability of TES arrays with two layers of wiring.

Chervenak, James A.↗
NASA NTRS2012

Precision Mass Property Measurements Using a Five-Wire Torsion Pendulum

A method for measuring the moment of inertia of an object using a five-wire torsion pendulum design is described here. Typical moment of inertia measurement devices are capable of 1 part in 10(exp 3) accuracy and current state of the art techniques have capabilities of about one part in 10(exp 4). The five-wire apparatus design shows the prospect of improving on current state of the art. Current measurements using a laboratory prototype indicate a moment of inertia measurement precision better than a part in 10(exp 4). In addition, the apparatus is shown to be capable of measuring the mass center offset from the geometric center. Typical mass center measurement devices exhibit a measurement precision up to approximately 1 micrometer. Although the five-wire pendulum was not originally designed for mass center measurements, preliminary results indicate an apparatus with a similar design may have the potential of achieving state of the art precision.

Swank, Aaron J.↗
NASA NTRS2016

Development of a High Performance, Low-Profile Translation Table with Wire Feedthrough

NEAScout, a 6U cubesat, will use an 85 sq m solar sail to travel to a near-earth asteroid for observation. Over the course of the 3-year mission, a combination of reaction wheels, cold gas reaction control system, and a slow rotisserie roll about the solar sail's normal axis were expected to handle attitude control and adjust for imperfections in the deployed sail. As the design for NEAScout matured, one of the critical design parameters, the offset in the center of mass and center of pressure (CP/CM offset), proved to be sub-optimal. After significant mission and control analysis, the CP/CM offset was addressed and a new subsystem was introduced to NEAScout. This system, called the Active Mass Translator (AMT), would reside near the geometric center of NEAScout and adjust the CM by moving one portion of the flight system relative to the other. The AMT was given limited design space-about 17 mm of the vehicle's assembly height-and was required to generate +/-10 cm by +/-5 cm translation to sub-millimeter accuracy. Furthermore, the design must accommodate a large wire bundle of small gage, single strand wire and coax cables fed through the center of the mechanism. The bend radius, bend resistance, and the exposure to deep space environment complicates the AMT design and operation and necessitated a unique design to mitigate risks of wire bundle damage, binding, and cold-welding during operation. This paper will outline the design constraints for the AMT, discuss the methods and reasoning for design, and identify the lessons learned through the design downselect process and breadboarding for designing low-profile translation stages with feedthrough capabilities.

Few, Alex↗
NASA NTRS2016

Cu-Al-Ni Shape Memory Single Crystal Wires with High Transformation Temperature

CN-250X is a new material with higher performance than Nickel-Titanium Shape Memory Alloy (SMA). For space mechanisms, the main disadvantage of Nickel-Titanium Shape Memory Alloy is the limited transformation temperature. The new CN-250X Nimesis alloy is a Cu-Al-Ni single crystal wire available in large quantity because of a new industrial process. The triggering of actuators made with this Cu-Al-Ni single crystal wire can range from ambient temperature to 200 C in cycling and even to 250 C in one-shot mode. Another advantage of CN-250X is a better shape recovery (8 to 10%) than Ni-Ti (6 to 7%). Nimesis is the first company able to produce this type of material with its new special industrial process. A characterization study is presented in this work, including the two main solicitation modes for this material: tensile and torsion. Different tests measure the shape recovery of Cu-Al-Ni single crystals wires during heating from room temperature to a temperature higher than temperature of end of martensitic transformation.

Hautcoeur, Alain↗
NASA NTRS2016

Wire Rope Failure on the Guppy Winch

On January 6, 2016 at El Paso, the Guppy winch motor was changed. After completion of the operational checks, the load bar was being reinstalled on the cargo pallet when the motor control FORWARD relay failed in the energized position. The pallet was pinned at all locations (each pin has a load capacity of 16,000 lbs.) while the winch was running. The wire rope snapped before aircraft power could be removed. After disassembly, the fractured wire rope was shipped to ES4 lab for further characterization of the wire rope portion of the failure. The system was being operated without a clear understanding of the system capability and function. The proximate cause was the failure of the K48 -Forward Winch Control Relay in the energized position, which allowed the motor to continuously run without command from the hand controller, and operation of the winch system with both controllers connected to the system. This prevented the emergency stop feature on the hand controller from functioning as designed. An electrical checkout engineering work instruction was completed and identified the failed relay and confirmed the emergency stop only paused the system when the STOP button on both connected hand controllers were depressed simultaneously. The winch system incorporates a torque limiting clutch. It is suspected that the clutch did not slip and the motor did not stall or overload the current limiter. Aircraft Engineering is looking at how to change the procedures to provide a checkout of the clutch and set to a slip torque limit appropriate to support operations.

Figert, John↗
NASA NTRS2018

Printed Wiring Board Technology Infusion and Supplier Capability Overview

Risk based technology infusion is a deliberate and systematic process which defines the analysis and communication methodology by which new technology is applied and integrated into existing and new designs, identifies technology development needs based on trends analysis and facilitates the identification of shortfalls against performance objectives. This presentation at QLF 2018 provides the audience a snapshot of quality variations in printed wiring board quality, as assessed, using experiences in processing and risk analysis of PWB structural integrity coupons. The presentation will focus on printed wiring board quality metrics used, the relative type and number of non-conformances observed and trend analysis using statistical methods. Trend analysis shows the top five non-conformances observed across PWB suppliers, the root cause(s) behind these non-conformance and suggestions of mitigation plans. The trends will then be matched with the current state of the PWB supplier base and its challenges and opportunities. The presentation further discusses the methods being applied at GSFC for evaluating candidate printed wiring board technologies which promote the adoption of higher throughput and faster processing technology for GSFC missions.

PCB fabrication↗
NASA NTRS2024

Evaluation of an Al-Cu-Zn-Mg Alloy for Wire-Fed Additive Manufacturing

A collaborative research study was conducted to evaluate an experimental Al-Cu-Zn-Mg alloy, designated Al C380H, developed by Arconic Corporation for wire-fed additive manufacturing (AM) techniques such as NASA’s electron beam freeform fabrication (EBF 3 ) process and the wire arc additive manufacturing (WAAM) process. The goal of the study was to determine, based upon metallurgical properties, whether additively manufactured Al C380H represented a viable alternative for applications currently using wrought 7xxx series aluminum. Al 2319 and Al 7075 were also deposited as AM-compatible and non-AM-compatible baselines, respectively. Evaluation was based on tensile, fracture, and corrosion properties. The strength and ductility of Al C380H-T6 materials produced by EBF3 and WAAM were sufficiently lower than typical values for Al 7050-T7 to indicate that additively manufactured Al C380H is not a viable replacement for current parts fabricated with Al 7050, due largely to the significant losses in Zn and Mg and development of porosity during deposition. EBF 3 parameters that reduced porosity, such as increasing electron beam current, higher raster frequency, sharper beam focus, and slower travel speed, augmented de-alloying of fugitive solute. Further enhancement of Zn and Mg content in Al C380H feedstock wire combined with adjustments to deposition conditions to minimize porosity may enable production of Al C380H parts by EBF 3 or WAAM that are viable replacements for current Al 7050 wrought products.

electron beam freeform fabrication (EBF3)↗
DOE OSTI2015

Manufacturing Process Development to Produce Depleted Uranium Wire for EBAM Feedstock

Wire produced from depleted uranium (DU) is needed as feedstock for the Electron-Beam Additive Manufacturing (EBAM) process. The goal is to produce long lengths of DU wire with round or rectangular cross section, nominally 1.5 mm (0.060 inches). It was found that rolling methods, rather than swaging or drawing, are preferable for production of intermediate quantities of DU wire. Trials with grooveless rolling have shown that it is suitable for initial reductions of large stock. Initial trials with grooved rolling have been successful, for certain materials. Modified square grooves (square round-bottom vee grooves) with 12.5 % reduction of area per pass have been selected for the reduction process.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Time-Resolved PIV/PTV Measurements on Interior Subchannels of a Wire-Wrapped 61-pin Hexagonal Fuel Bundle

Liquid metal fast reactor fuel bundles using sodium as a coolant typically utilize a tightly packed triangular lattice of fuel pins enclosed in a hexagonal duct. Often, the fuel pins are helically wrapped with a wire spacer. The primary function of the wire spacers is to maintain a gap between adjacent fuel pins. They also enhance sub-channel mixing to increase convective heat transfer and mitigate vortex-induced vibration. Texas A and M University has conducted isothermal flow experiments in a wire-wrapped 61-pin hexagonal fuel bundle to support the research on advanced nuclear fuel development sponsored by the Department of Energy (DOE). These tests produced high spatial and temporal resolution measurements of the velocity field and pressure at different locations in the fuel bundle. The experimental facility employs matched-index-of-refraction (MIR) techniques and laser diagnostic velocity measurement techniques such as particle image velocimetry (PIV), particle tracking velocimetry (PTV), and laser Doppler velocimetry (LDV). The result of this experimental activity will be an experimental database of pressure and velocity field measurements that will be suitable for validating computational fluid dynamics (CFD) methods, such as Reynolds-averaged Navier-Stokes (RANS) and highly resolved large eddy simulation (LES). PIV results on the set of edge subchannels near the hexagonal duct have been presented in another paper. This paper presents PIV results on two sets of interior subchannels, defined as Interior- 1 and Center-2, at a Reynolds number (Re) of 19,000 in the turbulent regime.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Emittance Measurements with Wire Scanners in the Fermilab Side-coupled Linac

The Fermilab Side-Coupled Linac accelerates H-beam from 116 MeV to 400 MeV through seven 805 MHz modules. Twelve wire scanners are present in the Side Coupled Linac and four are present in the transfer line between the Linac and the Booster synchrotron ring. These wire scanners act as important diagnostic instruments to directly collect information on the beam's transverse distribution. The manipulation of the conditions of wire scanner data collection enables further characterization of the beamline, such as calculating emittance and the Twiss parameters of the beam at select regions, which we present here.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

ECAR-6415 Rev 0 CFD Analysis of the Primary Coolant Apparatus Test Core with Wire Spacers for Heterogeneous Power Distributions

Primary Coolant Apparatus Test (PCAT) is a thermal-hydraulic test loop for Microreactor Applications Research Validation and Evaluation (MARVEL) reactor. The heater elements were manufactured within a straightness tolerance for the designated gap thickness of 1.0 mm, but several elements have been distorted out of tolerance during the welding process. The distortion of heater rods can lead to flow maldistribution and excessive hotspot where the gap between two heater rods is too tight. In order to secure the heater-to-heater gap in an acceptable range, wire spacers are adopted for the PCAT. The wire spacers affect the thermal-hydraulic performance of the PCAT because they enhance the flow mixing among the flow subchannels in the core region. The objectives of this ECAR is to evaluate the effects of the wire spacers on the thermal-hydraulic performance of the PCAT core region by assuming several heterogeneous power distributions.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
NASA NTRSDate not supplied

Metallic Powder Core Tubular Wire Development for Additive Manufacturing

NASA Langley Research Center (LaRC) in Hampton, VA, and the Center for Welding, Joining, and Coating Research (CWJCR) in the Department of Metallurgical and Materials Engineering at the Colorado School of Mines (CSM) in Golden, CO, have collaborated for nearly fifteen years to develop metallic powder core tubular wire (PCTW) feedstock for additive manufacturing (AM) using electron beam deposition. The motivation for this development was to offset dealloying observed during deposition of titanium and aluminum alloy solid wire feedstock in the LaRC electron beam freeform fabrication (EBF3) system and to explore novel alloy compositions by tailoring the powder fill. EBF3 is a fusion-based AM process that is performed under vacuum and is consequently prone to vaporization loss of low vapor pressure alloying elements. Research spanning four graduate student research projects succeeded in developing the basic methodology to fabricate PCTW, the mass balance equations used to define the powder fill, microstructure control through particulate inoculation, and the feasibility of producing metal matrix composite materials.

powder core tubular wire (PCTW)↗
DOE OSTI2022

Build plate conduction cooling for thermal management of wire arc additive manufactured components

Wire arc additive manufacturing (WAAM) allows for quick, large component manufacturing with fast deposition rates while leveraging readily available wire feedstock that is significantly cheaper than metal powder. However, the increased deposition rate of this process requires enhanced thermal management as failures can occur due to overheating. A common strategy to mitigate overheating is to dwell, or pause, between individual layers; however, this can significantly increase build times and eliminate the advantage of additive manufacturing being able to manufacture components quickly. To help mitigate this issue, this study explores the use of active cooling to maintain process control and to decrease overall build time. In this work, conductive cooling applied to either the bottom or side of the print substrate was explored. Results from this study showed that bottom build plate active cooling can be used to decrease dwell times by up to 50% and decrease cool-down to room temperature after the building process by up to 75%. Results from this study demonstrate that the use of active cooling strategies for WAAM can be used for better thermal control over the process and should be further investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Formation of High-Field Pinning Centers in Superconducting MgB{sub 2} Wires by Using High Hot Isostatic Pressure Process

This paper demonstrates the effects of hot isostatic pressure (HIP) on the structure and transport critical parameters of in situ MgB{sub 2} wires without a barrier. Our results show that only HIP and nano-boron allow the formation of more high-field pinning centers, which lead to the increase in critical current density (J{sub c}) at high applied magnetic fields. Nano-boron and annealing at a low pressure increase the J{sub c} in the low magnetic field. This indicates that nano-particles create more high-field pinning centers. In addition, the results show that nano-boron improves the connection between the grains. Scanning electron microscope results show that HIP increases the reaction rate between Mg and B, density, and homogeneity of the MgB{sub 2} material. Additionally, HIP allows to create a structure with small grains and voids and eliminates the significance of the number of voids. High isostatic pressure allows to obtain high J{sub c} of 10 A/mm{sup 2} (at 4.2 K) in 10 T and increases irreversible magnetic field (B{sub irr}) and upper critical field (B{sub c2}). Measurements show that these wires have high critical temperature of 37 K.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗