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DOE OSTI2025

SiC Receiver/Reactor by Additive Manufacturing for Concentrated Solar Thermocatalysis with Thermal Energy Storage (Final Technical Report - Public)

The direct use of solar thermal energy provides opportunities for low-cost heating sources for a variety of applications. Ultra-high temperatures around 1000°C are high value and highly useful for energy-demanding industries. Many materials cannot withstand these conditions. In the area of Sustainable Chemicals, further limitations on material stability exist. Combining state-of-the-art materials with new designs provides a promising pathway for harvesting solar thermal energy and performing high temperature chemical processes. However, conventional manufacturing limits the potential for design flexibility. In this project, Additive Manufacturing was combined with advanced materials and new chemical reactor designs. In addition, 24/7 energy is necessary for chemical processing, and designs for ultra-high temperature thermal storage were devised. Specifically, preliminary design of a novel solar thermal receiver was developed in this project and designed to work with thermocatalytic reactors for producing sustainable chemicals and fuels. An ultra-high temperature particle storage system and heat exchangers were proposed to transport ultra-hot air as thermal fluid for the system. On a broader scale, this system could be used to tap solar thermal energy for a centralized facility with capability of transferring that heat to various segments at a full range of temperatures to 1000°C. The project pushed the temperature boundaries past those in current use, and Additive Manufacturing was envisaged for fabricating the receiver to meet requirements of extreme environments. An extensive analysis of silicon carbide additive manufacturing was performed to compare the thermal and mechanical properties of complex geometries compared to conventional material and those manufactured via other methods. The Additive Manufacturing via Binder-Jet printing was optimized and characterized to provide high quality and reproducible components capable of withstanding the proposed extreme environments. The designs for the concentrating solar thermal cavity with ultra-hot air thermal fluid showed high performance in simulations, attributable to the complex optimized geometries of the 3D printed systems. The bright future of Additive Manufacturing with advanced materials developments should provide more options and even higher quality as the technology further develops. Current costs for Additive Manufacturing of advanced ceramics is relatively low, however post-processing of the materials for extreme environments is currently high. There is little industrial-scale infrastructure for these, but it is growing as niche applications become more mainstream. The results of the project can be translated into similar extreme environments for concentrating solar thermal energy as well as its integration with ultra-hot air thermal fluids. A number of industries that require ultra-high temperatures need to electrify or otherwise decarbonize for climate goals, and this project showed that theoretically there is a pathway to do so with direct concentrated solar thermal power.

10 SYNTHETIC FUELS↗

NASA NTRS1987

Water facilities in retrospect and prospect: An illuminating tool for vehicle design

Water facilities play a fundamental role in the design of air, ground, and marine vehicles by providing a qualitative, and sometimes quantitative, description of complex flow phenomena. Water tunnels, channels, and tow tanks used as flow-diagnostic tools have experienced a renaissance in recent years in response to the increased complexity of designs suitable for advanced technology vehicles. These vehicles are frequently characterized by large regions of steady and unsteady 3-D flow separation and ensuing vortical flows. The visualization and interpretation of the complicated fluid motions about isolated vehicle components and complete configurations in a time and cost effective manner in hydrodynamic test facilities is a key element in the development of flow control concepts, and, hence, improved vehicle designs. A historical perspective of the role of water facilities in the vehicle design process is presented. The application of water facilities to specific aerodynamic and hydrodynamic flow problems is discussed, and the strengths and limitations of these important experimental tools are emphasized.

Erickson, Gary E.↗

NASA NTRS1991

A pressure control analysis of cryogenic storage systems

Self-pressurization of cryogenic storage tanks due to heat leak through the thermal protection system is examined along with the performance of various pressure control technologies for application in microgravity environments. Methods of pressure control such as fluid mixing, passive thermodynamic venting, and active thermodynamic venting are analyzed using the homogeneous thermodynamic model. Simplified equations suggested may be used to characterize the performance of various pressure control systems and to design space experiments.

Lin, C.-S.↗

NASA NTRS1991

Vapor condensation at the free surface of an axisymmetric liquid mixed by a laminar jet

This paper presents numerical solutions of jet-induced mixing in a partially full cryogenic tank. An axisymmetric laminar jet is discharged from the central part of the tank bottom toward the liquid-vapor interface. Liquid is withdrawn at the same volume flow rate from the outer part of the tank. The jet is at a temperature lower than the interface, which is maintained at a certain saturation temperature. The interface is assumed to be flat and shear free and the condensation-induced velocity is assumed to be negligibly small compared with radial interface velocity. Finite-difference method is used to slove the nondimensional form of steady-state continuity, momentum, and energy equations. Calculations are conducted for jet Reynolds numbers ranging from 150 to 600 and Prandtl numbers ranging from 0.85 to 2.65. The effects of previously stated parameters on the condensation Nusselt and Stanton numbers that characterize the steady-state interface condensation process are investigated. Detailed analysis is performed to gain a better understanding of the fundamentals of fluid mixing and interface condensation.

Lin, Chin-Shun↗

NASA NTRS1991

A pressure control analysis of cryogenic storage systems

Lin, C.-S.↗

NASA NTRS1992

Instabilities in astrophysical jets. II - Numerical simulations of slab jets

Numerical simulations of an unstable supersonic slab-symmetric jet are described. The instabilities within the jet are characterized by growing internal body waves and their coupled surface waves that are also predicted in linear perturbation theory. The characteristic theory of fluid dynamics is used to help interpret the wave morphologies. It is demonstrated that these waves can be excited by imposing an arbitrary disturbance. From the numerical simulations, it is found that the sound waves propagating against the flow slow down as they propagate outward, and they grow in amplitude. These waves eventually disrupt the jet at a certain length. This disruption length is related to the jet Mach number and the perturbation intensity. Thus, the Mach number of a jet observed with a radio telescope can be estimated by measuring the disruption length and estimating the perturbation intensity. The jet Mach numbers in radio tailed sources determined in this way agree quite well with estimates from ram pressure bending arguments. The wiggles and flares observed in many extragalactic jets, especially in tailed radio sources, appear to be intimately related to instabilities and the jet disruption process.

Zhao, Jun-Hui↗

NASA NTRS2003

Life-Prediction Parameters of Sapphire Determined for the Design of a Space Station Combustion Facility Window

To characterize the stress corrosion parameters and predict the life of a sapphire window being considered for use in the International Space Station's Fluids and Combustion Facility, researchers at the NASA Glenn Research Center conducted stress corrosion tests, fracture toughness tests, and reliability analyses, as shown in the figures. Standardized test methods, developed and updated by the author under the auspices of American Society for Testing and Materials, were employed. One interesting finding is that sapphire exhibits a susceptibility to stress corrosion in water similar to that of glass. In addition to generating the stress corrosion parameters and fracture toughness data, closed-form expressions for the variances of the crack growth parameters were derived. The expressions allow confidence bands to be easily placed on life predictions of ceramic components. Brittle materials such as sapphire and quartz are required for windows in a variety of applications such as the Fluids and Combustion Facility. To minimize the launch weight of such facilities, researchers must design the windows to be as lightweight as possible. The safe use of lightweight, brittle windows in structural applications is limited by two factors: low fracture toughness and slow crack growth, or stress corrosion. Stress corrosion of these and other optical materials can occur in relatively common environments, such as humid air. Access to the data has been requested by designers for use in the life prediction of a Northrop Grumman F16 instrument window and a Jet Propulsion Laboratory instrument window. One Space Act Agreement has been formed. Future work includes the measurement of the life of subscale windows.

Salem, Jonathan A.↗

NASA NTRS2006

Orbiter Return-To-Flight Entry Aeroheating

The Columbia accident on February 1, 2003 began an unprecedented level of effort within the hypersonic aerothermodynamic community to support the Space Shuttle Program. During the approximately six month time frame of the primary Columbia Accident Investigation Board activity, many technical disciplines were involved in a concerted effort to reconstruct the last moments of the Columbia and her crew, and understand the critical events that led to that loss. Significant contributions to the CAIB activity were made by the hypersonic aerothermodynamic community(REF CAIB) in understanding the re-entry environments that led to the propagation of an ascent foam induced wing leading edge damage to a subsequent breech of the wing spar of Columbia, and the subsequent breakup of the vehicle. A core of the NASA hypersonic aerothermodynamics team that was involved in the CAIB investigation has been combined with the United Space Alliance and Boeing Orbiter engineering team in order to position the Space Shuttle Program with a process to perform in-flight Thermal Protection System damage assessments. This damage assessment process is now part of the baselined plan for Shuttle support, and is a direct out-growth of the Columbia accident and NASAs response. Multiple re-entry aeroheating tools are involved in this damage assessment process, many of which have been developed during the Return To Flight activity. In addition, because these aeroheating tools are part of an overall damage assessment process that also involves the thermal and stress analyses community, in addition to a much broader mission support team, an integrated process for performing the damage assessment activities has been developed by the Space Shuttle Program and the Orbiter engineering community. Several subsets of activity in the Orbiter aeroheating communities support to the Return To Flight effort have been described in previous publications (CFD?, Cavity Heating? Any BLT? Grid Generation?). This work will provide a description of the integrated process utilized to perform Orbiter tile damage assessment, and in particular will seek to provide a description of the integrated aeroheating tools utilized to perform these assessments. Individual aeroheating tools will be described which provide the nominal re-entry heating environment characterization for the Orbiter, the heating environments for tile damage, heating effects due to exposed Thermal Protection System substrates, the application of Computational Fluid Dynamics for the description of tile cavity heating, and boundary layer transition prediction. This paper is meant to provide an overall view of the integrated aeroheating assessment process for tile damage assessment as one of a sequence of papers on the development of the boundary layer transition prediction capability in support of Space Shuttle Return To Flight efforts.

Campbell, Charles H.↗

NASA NTRS2017

Bulk Hydrogen Content OF High-Silica Rocks in Gale Crater With the Active Dynamic Albedo of Neutrons Experiment

The Mars Science Laboratory (MSL) Curiosity rover recently traversed over plateaus of mafic aeolian sandstones (the 'Stimson' formation) that overlie mudstones (the 'Murray' formation). Within the Stimson formation we observed many lighter-toned, halo-forming features, that are potentially indicative of fluid alteration (see Fig. 1). These halo features extend for tens of meters laterally and are approx.1 meter wide. The halo features were characterized by Curiosity's geochemical instruments: Alpha Proton X-Ray Spectrometer (APXS), Chemin, Chemcam and Sample Analysis at Mars (SAM). With respect to the host (unaltered) Stimson rocks, fracture halos were significantly enriched in silicon and low in iron [1]. Changes in hydrogen abundance (due to its large neutron scattering cross section) greatly influence the magnitude of the thermal neutron response from the Dynamic Albedo of Neutrons (DAN) instrument [2]. There are also some elemental species, e.g. chlorine, iron, and nickel, that have significant microscopic neutron absorption cross sections. These elements can be abundant and variable results provide a useful estimate of the lower bound for bulk hydrogen content (assuming a homogeneous distribution).

Gabriel, T. S. J.↗

NASA NTRS2016

FluidCam 1 & 2 - UAV-based Fluid Lensing Instruments for High-Resolution 3D Subaqueous Imaging and Automated Remote Biosphere Assessment of Reef Ecosystems

We present NASA ESTO FluidCam 1 & 2, Visible and NIR Fluid-Lensing-enabled imaging payloads for Unmanned Aerial Vehicles (UAVs). Developed as part of a focused 2014 earth science technology grant, FluidCam 1&2 are Fluid-Lensing-based computational optical imagers designed for automated 3D mapping and remote sensing of underwater coastal targets from airborne platforms. Fluid Lensing has been used to map underwater reefs in 3D in American Samoa and Hamelin Pool, Australia from UAV platforms at sub-cm scale, which has proven a valuable tool in modern marine research for marine biosphere assessment and conservation. We share FluidCam 1&2 instrument validation and testing results as well as preliminary processed data from field campaigns. Petabyte-scale aerial survey efforts using Fluid Lensing to image at-risk reefs demonstrate broad applicability to large-scale automated species identification, morphology studies and reef ecosystem characterization for shallow marine environments and terrestrial biospheres, of crucial importance to improving bathymetry data for physical oceanographic models and understanding climate change’s impact on coastal zones, global oxygen production, carbon sequestration.

Chirayath, Ved↗

DOE OSTI2023

Characterizing different motility-induced regimes in active matter with machine learning and noise

Here we examine motility-induced phase separation (MIPS) in two-dimensional run-and-tumble disk systems using both machine learning and noise fluctuation analysis. Our measures suggest that within the MIPS state there are several distinct regimes as a function of density and run time, so that systems with MIPS transitions exhibit an active fluid, an active crystal, and a critical regime. The different regimes can be detected by combining an order parameter extracted from principal component analysis with a cluster stability measurement. The principal component-derived order parameter is maximized in the critical regime, remains low in the active fluid, and has an intermediate value in the active crystal regime. We demonstrate that machine learning can better capture dynamical properties of the MIPS regimes compared to more standard structural measures such as the maximum cluster size. The different regimes can also be characterized via changes in the noise power of the fluctuations in the average speed. In the critical regime, the noise power passes through a maximum and has a broad spectrum with a 1/f 1.6 signature, similar to the noise observed near depinning transitions or for solids undergoing plastic deformation.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2005

Microbiological Characterization and Concerns of the International Space Station Internal Active Thermal Control System

Since January 1999, the chemical the International Space Station Thermal Control System (IATCS) and microbial state of (ISS) Internal Active fluid has been monitored by analysis of samples returned to Earth. Key chemical parameters have changed over time, including a drop in pH from the specified 9.5 +/- 0.5 ta = 58.4, an increase in the level of total inorganic carbon (TIC), total organic carbon (TOC) and dissolved nickel (Ni) in the fluid, and a decrease in the phosphate (PO,) level. In addition, silver (AS) ion levels in the fluid decreased rapidly as Ag deposited on internal metallic surfaces of the system. The lack of available Ag ions coupled with changes in the fluid chemistry has resulted in a favorable environment for microbial growth. Counts of heterotrophic bacteria have increased from less than 10 colony-forming units (CFUs)/l00 mL to l0(exp 6) to l0(exp 7) CFUs/100 mL. The increase of the microbial population is of concern because uncontrolled microbiological growth in the IATCS can contribute to deterioration in the performance of critical components within the system and potentially impact human health if opportunistic pathogens become established and escape into the cabin atmosphere. Micro-organisms can potentially degrade the coolant chemistry; attach to surfaces and form biofilms; lead to biofouling of filters, tubing, and pumps; decrease flow rates; reduce heat transfer; initiate and accelerate corrosion; and enhance mineral scale formation. The micro- biological data from the ISS IATCS fluid, and approaches to addressing the concerns, are summarized in this paper.

Roman, Monsi C.↗

NASA NTRS1996

Analysis of Flowfields over Four-Engine DC-X Rockets

The objective of this study is to validate a computational methodology for the aerodynamic performance of an advanced conical launch vehicle configuration. The computational methodology is based on a three-dimensional, viscous flow, pressure-based computational fluid dynamics formulation. Both wind-tunnel and ascent flight-test data are used for validation. Emphasis is placed on multiple-engine power-on effects. Computational characterization of the base drag in the critical subsonic regime is the focus of the validation effort; until recently, almost no multiple-engine data existed for a conical launch vehicle configuration. Parametric studies using high-order difference schemes are performed for the cold-flow tests, whereas grid studies are conducted for the flight tests. The computed vehicle axial force coefficients, forebody, aftbody, and base surface pressures compare favorably with those of tests. The results demonstrate that with adequate grid density and proper distribution, a high-order difference scheme, finite rate afterburning kinetics to model the plume chemistry, and a suitable turbulence model to describe separated flows, plume/air mixing, and boundary layers, computational fluid dynamics is a tool that can be used to predict the low-speed aerodynamic performance for rocket design and operations.

Wang, Ten-See↗

DOE OSTI2021

Actinide in Air (Rn-Progeny Rejected) Alpha Spectroscopy With Tensioned Metastable Fluid Detectors

Here, this article discusses outcome of research for deriving a methodology and apparatus for ascertaining for the presence of ultratrace-level actinides in air from their alpha emission signatures, while remaining blind to the relatively large (1000× higher activity) alpha emissions from Rn-progeny. Apparatus and techniques were developed to collect and characterize alpha-emitting nuclides of Rn-progeny and actinides in air on a polycarbonate 3 μm pore size continuous air monitor (CAM) filter. A wet-chemistry approach was developed and validated for successfully separating the Rn-progeny alpha emitting isotopes of Po-214 and Po-218, while extracting the actinides (U, Pu, Am) in a fluid mixture that is suitable for conduct of alpha spectroscopy with a centrifugally tensioned metastable fluid detector (CTMFD). The resulting α-TMFD technology was compared against the state-of-art “Alpha-Sentry™” Continuous Air Monitor (CAM) system commonly utilized world-wide. Results indicate that the α-TMFD technology can potentially offer complementary and superior performance in multiple performance categories, and ∼18× improvement in the time to detect (e.g., at 0.02 derived air concentration (DAC) within ∼3 h, versus ∼70 h for Alpha-Sentry) for actinides of interest while also remaining ∼100% blind to ∼10 3 × higher Rn-progeny background—with the added potential for offering few keV scale energy resolution without resorting to peak shape fitting, versus ∼300–400 keV for existing CAM systems.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRSDate not supplied

Preliminary Findings of the Experimental Development Unit Cold Flow Test for a Generation Zero Nuclear Propulsion Engine

Nuclear thermal propulsion (NTP) technology will greatly benefit human travel to Mars by significantly shortening transit times, improving crew safety, and providing more mission flexibility than traditional chemical rockets. As part of DRACO follow-on work to develop, build, and fly a generation zero NTP engine, a full scale flight-like experimental design unit (EDU) reactor was constructed to collect sufficient on-ground performance data to characterize flow induced vibrations (FIV) of critical reactor structures/components, inform development of the engine and reactor control algorithm, and collect pressure drop and flow distribution data across the reactor. The fluid conditions for the test program were designed to achieve system responses equivalent to that of an operational engine through all phases of engine operation including reactor startup, mainstage operation, reactor shutdown, and reactor cooldown. Over 100 tests were executed, flowing either GN2 or GHe through the EDU at varying flow rates and pressures. This experiment provided early validation of flow behavior and vibration risks before nuclear testing, boosted critical subsystem TRLs, informed design iterations, and reduced future test costs. The steady-state flow parameters for the experiment were modeled in Ansys Thermal Desktop, allowing rapid tuning and experiment-informed updates to a flight-like test matrix. The EDU dynamic environment was characterized with accelerometers, strain gauges, and high-frequency pressure transducers all sampled at 20 kHz. While many narrow-band oscillations were identified, no significant FIV occurred; the reactor structural responses tend to be enveloped by typical launch vehicle ascent vibration environments (defined up to 2 kHz), although significant energy is also present at higher frequencies.

Flow Induced Vibration↗

DOE OSTI2022

Boron isotopes in blue diamond record seawater-derived fluids in the lower mantle

Boron is a quintessential crustal element but its conspicuous presence in diamond – a mantle mineral – raises questions about potential subduction pathways for boron and other volatiles. It has been a long-standing goal to characterize the isotopic composition of boron in blue, boron-bearing (Type IIb) diamonds to reveal its origin. Mineral inclusions indicate that Type IIb diamonds crystallize at transition zone to lower mantle depths, meaning that if the boron is subducted it would trace a pathway of volatile elements into the deep mantle. Here, using off-line laser ablation sampling, we present the first boron isotope compositions, along with trace element contents and carbon isotope compositions, of a suite of blue diamonds mainly sourced from the Cullinan diamond mine in South Africa. The ten analyzed blue diamonds have a wide range in δ 11 B, between -9.2 ± 2‰ and -0.5 ± 2‰, compared to the more restricted range for mid-ocean ridge basalts (-7.1 ± 0.9‰). Carbon isotope values for the blue diamonds range between -20.6 and -1.8‰, with a mode at -17‰, significantly more negative than the main mantle mode at -5‰. Combined, the boron and carbon isotope compositions require fluid input from subducted oceanic lithosphere down into deep mantle source regions of blue diamonds. This finding highlights a deep subduction pathway for volatiles to stoke the source regions of deeply-derived magmas.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

A data-driven framework for permeability prediction of natural porous rocks via microstructural characterization and pore-scale simulation

Understanding the microstructure–property relationships of porous media is of great practical significance, based on which macroscopic physical properties can be directly derived from measurable microstructural informatics. However, establishing reliable microstructure–property mappings in an explicit manner is difficult, due to the intricacy, stochasticity, and heterogeneity of porous microstructures. In this paper, a data-driven computational framework is presented to investigate the inherent microstructure–permeability linkage for natural porous rocks, where multiple techniques are integrated together, including microscopy imaging, stochastic reconstruction, microstructural characterization, pore-scale simulation, feature selection, and data-driven modeling. A large number of 3D digital rocks with a wide porosity range are acquired from microscopy imaging and stochastic reconstruction techniques. A broad variety of morphological descriptors are used to quantitatively characterize pore microstructures from different perspectives, and they compose the raw feature pool for feature selection. Here high-fidelity lattice Boltzmann simulations are conducted to resolve fluid flow passing through porous media, from which reliable permeability references are obtained. The optimal feature set that best represents permeability is identified through a performance-oriented feature selection process, upon which a cost-effective surrogate model is rapidly fitted to approximate the microstructure-permeability mapping via data-driven modeling. This surrogate model exhibits great advantages over empirical/analytical formulas in terms of prediction accuracy and generalization capacity, which can predict reliable permeability values spanning four orders of magnitude. Besides, feature selection also greatly enhances the interpretability of the data-driven prediction model, from which new insights into the mechanism of how microstructural characteristics determine intrinsic permeability are obtained.

58 GEOSCIENCES↗

DOE OSTI2020

Addressing wellbore integrity and thief zone permeability using microbially-induced calcium carbonate precipitation (MICP): A field demonstration

Microbially-induced calcium carbonate precipitation (MICP) is an emerging biotechnology for wellbore integrity applications including sealing defects in wellbore cement and modifying the permeability of rock formations. The goal of this field demonstration was to characterize a failed waterflood injection well and provide proof of principle that MICP can reduce permeability in the presence of oil using conventional oilfield fluid delivery methods. Here we compared well logs performed at the time the well was drilled with ultrasonic logs, sonic cement evaluation, and temperature logs conducted after the well failed. Analysis of these logs suggested that, rather than entering the target waterflood formation, injectate was traveling through defects in the well cement to a higher permeability sandstone layer above the target formation. Sporosarcina pasteurii cultures and urea-calcium media were delivered 2290 ft (698 m) below ground surface using a 3.75 gal (14.2 L) slickline dump bailer to promote mineralization in the undesired flow paths. By Day 6 and after 25 inoculum and 49 calcium media injections, the injectivity [gpm/psi] had decreased by approximately 70%. This demonstration shows that 1) common well logs can be used to identify scenarios where MICP can be employed to reduce system permeability, remediate leakage pathways, and improve waterflood efficiency, and 2) MICP can occur in the presence of hydrocarbons.

42 ENGINEERING↗