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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 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Prediction of Long-Term Geochemical Change in Bentonite Based on the Interpretative THMC Model of the FEBEX In Situ Test

Since nuclear energy is crucial in the decarbonization of the energy supply, one hurdle to remove is the handling of high-level radioactive waste (HLW). Disposal of HLW in a deep geological repository has long been deemed a viable permanent option. In the design of a deep geological repository, compacted bentonite is the most commonly proposed buffer material. Predicting the long-term chemical evolution in bentonite, which is important for the safety assessment of a repository, has been challenging because of the complex coupled processes. Models for large-scale tests and predictions based on such models have been some of the best practices for such purposes. An 18-year-long in situ test with two dismantling events provided a unique set of chemical data that allowed for studying chemical changes in bentonite. In this paper, we first developed coupled thermal, hydrological, mechanical, and chemical (THMC) models to interpret the geochemical data collected in the in situ test and then extended the THMC model to 200 years to make long-term prediction of the geochemical evolution of bentonite. The interpretive coupled THMC model shows that the geochemical profiles were strongly affected by THM processes such as evaporation/condensation, porosity change caused by swelling, permeability change, and the shape of concentration profiles for major cations were largely controlled by transport processes, but concentration levels were regulated by chemical reactions, and the profiles of some species such as pH, bicarbonate, and sulfate were dominated by these reactions. The long-term THMC model showed that heating prolongs the time that bentonite becomes fully saturated in the area close to the heater/canister; however, once the bentonite becomes fully saturated, high concentrations of ions in bentonite near the heater, which was observed in the field test, will disappear; illitization continues for 50 years but will not proceed further.

Zheng, Liange↗
NASA NTRS2018

Design, Fabrication, and Critical Current Testing of No-Insulation Superconducting Rotor Coils for NASA's 1.4 MW High-Efficiency Megawatt Motor

NASA Glenn Research Center is developing a 1.4 MW high-efficiency electric machine for future electrified aircraft to reduce energy consumption, emissions, and noise. This wound-field, synchronous machine employs a self-cooled, superconducting rotor to achieve excellent specific power and efficiency. This paper discusses the design and fabrication of the no-insulation high temperature superconducting (HTS) rotor coils and compares them to conventionally insulated HTS coils. Two sub-scale test coils with epoxy on only one axial face were fabricated. Critical current testing of the coils at 77 K and self field was conducted to study the influence of thermal cycling on their critical current and n-value. After two or four aggressive thermal cycles between 77 K and about 278 K (5 degree C), the critical current and n-value were nearly unchanged, indicating very little to no degradation.

electric aircraft propulsion↗
DOE OSTI2023

Evolution of dislocation substructures in metals via high-strain-rate nanoindentation

Deformation at high strain rates often results in high stresses on many engineering materials, potentially leading to catastrophic failure without proper design. High-strain-rate mechanical testing is thus needed to improve the design of future structural materials for a wide range of applications. Although several high-strain-rate mechanical testing techniques have been developed to provide a fundamental understanding of material responses and microstructural evolution under high-strain-rate deformation conditions, these tests are often very time consuming and costly. In this work, we utilize a high-strain-rate nanoindentation testing technique and system in combination with transmission electron microscopy to reveal the deformation mechanisms and dislocation substructures that evolve in pure metals from low (10 –2 s –1 ) to very high indentation strain rates (10 4 s –1 ), using face-centered cubic aluminum and body-centered cubic molybdenum as model materials. The results help to establish the conditions under which micro- and macro-scale tests can be compared with validity and also provide a promising pathway that could lead to accelerated high-strain-rate testing at substantially reduced costs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Electrochemical Hydrogen Compression Cell Design (CRADA Final Report)

Electrochemical compression and purification is a high potential technology that is likely to outcompete mechanical compression for hydrogen end use applications. However, testing and understanding what is occurring within the cell is difficult as it is not readily accessible through experimentation. Thus, the main target is to increase performance and reduce cost of electrochemical hydrogen compression (EHC) and purification (EHP) cells and stacks using multiscale mathematical modeling informed by experiment. The models can provide physical insight into limiting processes and develop mitigation methods, which can be proven out through rapid sub-scale testing of the devices.

08 HYDROGEN↗
NASA NTRS1972

Beryllium heat shield technology in the area of thermal protection devices

For future space applications, it is important that thermal protection systems be reusable for space shuttle flights. Beryllium offers a unique combination of properties for use as a heat shield material (stiffness, lightweight, ability to absorb heat). In order to adequately test these properties, it was necessary to fabricate heat shields. The concept used was a two-section test panel 99.1 x 99.1 cm (39 x 39 inch) with each section made of two 0.051 cm (0.020 inch) thick beryllium corrugations brazed together as a mirror image, with titanium (Ti-6Al-4V) used as standoffs to support the panel structure. The work prior to fabrication included brazability of both beryllium and titanium, forming of beryllium and titanium, machining processes involving beryllium and chem-milling beryllium. Sub-scale samples were made of all details before actual fabrication of the large panel. The full scale test panel was hot-formed at 950 K, chem-milled to 0.041 + or - 0.005 cm (0.016 + or - 0.002 inches), trimmed, vacuum brazed, drilled and assembled.

Muhl, A. E.↗
NASA NTRS2009

Recovering Aerodynamic Side Loads on Rocket Nozzles using Quasi-Static Strain-Gage Measurements

During over-expanded operation of rocket nozzles, which is defined to be when the exit pressure is greater than internal pressure over some part of the nozzle, the nozzle will experience a transverse forcing function due to the pressure differential across the nozzle wall. Over-expansion occurs during the nozzle start-up and shutdown transient, even in high-altitude engines, because most test facilities cannot completely reproduce the near-vacuum pressures at those altitudes. During this transient, the pressure differential moves axially down the nozzle as it becomes pressurized, but this differential is never perfectly symmetric circumferentially. The character of the forcing function is highly complex and defined by a series of restricted and free shock separations. The subject of this paper is the determination of the magnitude of this loading during sub-scale testing via measurement of the structural dynamic response of the nozzle and its support structure. An initial attempt at back-calculating this load using the inverse of the transfer function was performed, but this attempt was shown to be highly susceptible to numerical error. The final method chosen was to use statically calibrated strain data and to filter out the system fundamental frequency such that the measured response yields close to the correct dynamic loading function. This method was shown to capture 93% of the pressure spectral energy using controlled load shaker testing. This method is one of the only practical ways for the inverse determination of the forcing function for non-stationary excitations, and, to the authors' knowledge, has not been described in the literature to date.

Brown, Andrew↗
DOE OSTI2025

Deep Neural Network Assisted Distributed Strain and Temperature Fiber Sensor System for Natural Gas Pipeline Monitoring

Natural gas pipeline integrity monitoring is crucial to detect potential leaks, find structural issues, and prevent environmental damage. This article presents a system of natural gas pipeline monitoring that uses a specialized double Brillouin peak sensing fiber along with the Brillouin optical time domain analysis (BOTDAs) technique. The calibrated sensing fiber coefficients for strain and temperature are 41.8 kHz/ με and 0.9 MHz/°C for peak 1; and 47.2 kHz/ με , and 1.11 MHz/°C for peak 2, respectively. Initially, lab tests were performed by installing a short section of double Brillouin peak fiber (DBPF) on a 1-in steel pipe under pressure up to 1000 per square inch (psi) at elevated temperatures. Simultaneous distributed measurements of temperature and pressure-induced hoop strain were successfully measured. Considering the long processing speed to extract Brillouin frequency shift (BFS), we employ a novel probabilistic deep neural network (PDNN) framework for rapid BFS prediction. Additionally, using the Finite Element Method, the effects of the pipeline pressure on hoop strain were modeled and compared to the experimental hoop strain under the same set of pipeline conditions. Finally, an actual 4-in outer diameter steel natural gas pipeline was used for pilot-scale tests, where hoop strain was measured at various pressure levels. Leaks were simulated to demonstrate accurate pipeline integrity monitoring. At an internal pipe pressure of 1000 psi, hoop strain of approximately 300 με was observed, and the sensitivity was calculated as 0.28 με /psi. The results of this pilot-scale study demonstrated that the system is capable of performing distributed monitoring sufficient to detect pipeline pressure and the presence of leaks to ensure the safe operation of gas pipelines in the field.

03 NATURAL GAS↗
NASA NTRS1976

Fire containment tests of aircraft interior panels

The paper describes an experimental program carried out to evaluate a possible method for testing the fire-containment qualities of aircraft interior panels. The experimental apparatus consisted of a burner that simulates various fire loads under different ventilation conditions in an enclosure of approximately the same size as an aircraft lavatory module. Two fire-containment tests are discussed in which two adjoining walls of the enclosure were made from state-of-the-art composite panels; rats were exposed to the combustion products in order to evaluate the toxic threat posed by those products. The results show that the burner can be employed to represent various fire-load conditions and that the methodology developed for fire containment can be useful in evaluating the fire resistance of composite panels before conducting large-scale tests. It is concluded that elements of the fire-containment criteria include the temperature rise on the backface of the panels as a function of time, the flame burn-through by either decomposition or severe distortion of the material, and the toxicity of the combustion gases evolved.

Kourtides, D. A.↗
NASA NTRS2020

Lessons Learned from Recent Space Flight Assessments

This paper highlights four space flight assessments, each with an important lesson. The first assessment points to the challenge of material substitution for weight saving. Space Shuttle’s external tank stringers were changed from Al 2024 to Al 2090 without comprehensive analysis. Lack of understanding the low Short-Transverse (S-T) strength associated with Al 2090 led to widespread cracking. The second assessment addresses the failure to understand that time-dependent relationships and loading interactions of multiple disciplines can lead to non-conservative results. An aerodynamic test article of the Orion Multi-Purpose Crew Vehicle (MPCV) Launch Abort System (LAS) was analyzed for worst-case single discipline loads, showing positive structural margins. When disciplines were combined with time dependent loading, the analysis resulted in negative margins. The third assessment highlights the pitfalls of putting blind trust in historical architecture. The MPCV re-entry heat shield adopted the Apollo design approach despite fundamental differences between the two designs (e.g., the underlying substructure design, material differences, scale, and geometry). Manufacturing resulted in cracking along seams of the cured MPCV heat shield and produced lower mechanical properties of the Avcoat witness panels. Subsequently, the design was changed to a block architecture, which introduced unperceived technical, cost, and schedule risk. The fourth assessment shows how the lack of a comprehensive investigation of design modifications and inappropriate Finite Element Analyses (FEA) can lead to trouble. A mass reduction campaign eliminated highly critical internal struts on the ISS Node-1 pressurized module based on inadequate and uncorrelated FEA. High strains were noted and ignored as a modeling aberration. A system level high fidelity FEA discovered large plastic strains in the gussets of all four radial ports. These findings initiated a full-scale test campaign, new test correlated assembly-level FEA, and significant design modifications.

James P Smith↗
DOE OSTI2024

Effect of Anoxic Iron Corrosion on WIPP Brine Geochemistry FY23 Final Report (U)

A 280-day study was completed to evaluate the effect of zero-valent iron (Fe 0 ) on the Waste Isolation Pilot Plant (WIPP) brine geochemistry under anticipated reducing conditions. Hydrogen (H 2 ) gas is expected to be present in the repository after closure due to the anoxic corrosion of a vast quantity of iron contained in the waste forms disposed at WIPP; therefore, a background argon atmosphere containing H 2 was chosen for this study. WIPP groundwater brine pH and E h will impact the mobility and fate of plutonium within the repository. Modeling and laboratory results for Castile WIPP brine indicate that equilibrium fa values relative to the standard hydrogen electrode (SHE) are 40 mV more reducing (i.e., more negative) than those for Salado WIPP brine (-480 mV vs. -440 mV, respectively) because of the higher pH of the Castile brine (pH 9 .3 for Castile vs. pH 8.8 for Salado). The E h and pH data were corrected for the effects of high ionic strength. The experimental results for both brines are consistent with thermodynamic predictions using OLI Systems' Mixed Solvent Electrolyte chemical equilibrium model. The measured and corrected pH and E h data from this study are provided in Table ES-I and Table ES-2, respectively. The experimental study, with four test conditions in triplicate, was performed in a dual glovebox with a nominally 3 vol.% H 2 in argon atmosphere (target H 2 range: 3 ± I vol.%). Simulants containing MgO only ( experimental control) and MgO+Fe 0 (WIPP base case) were prepared for both the Salado and Castile brines. MgO was included in all simulants to account for the use of bulk magnesium oxide in the WIPP repository. Fe 0 was included in some simulants to incorporate the effects of the anoxic corrosion of iron and in-situ hydrogen generation in the study. The brine compositions were developed by Sandia National Laboratory (SNL; Xiong, 2008) and have been used in previous WIPP evaluations. The test method (agitation, etc.) is partially based on ASTM D3987-12. Twelve rounds of periodic measurements of pH and E h were performed over the course of the study. Chemical analysis results for liquids and solids (ICP-MS, ICP-ES, IC Anion, TIC, SEM-EDX) are consistent with the pH, E h , and thermodynamic modeling results. This study included the following conditions that deviate from anticipated post-closure conditions following brine intrusion, but were selected to facilitate bench-scale testing to validate modeling of pH and E h for the post-closure WIP P repository: an anoxic glove box atmosphere containing ≤ 4 vol. % H 2 vs. substantially higher H 2 gas concentrations assumed in the WIPP Performance Assessment (PA); a significantly higher liquid-to-solid test ratio compared to the much lower phase ratio anticipated in the WIP P repository; agitation of the simulant bottles to maximize mass transfer; and finally the use of Fe 0 reagents having a much greater surface area than expected in the WIP P repository. Non-representative conditions were chosen for various reasons such as: to provide bounding conservative results, to provide a margin of safety for testing, or to facilitate simulant sub-sampling and analysis. In a parallel effort, aqueous electrolyte thermodynamic models were developed for the synthetic Salado and Castile brines to inform the experimental design, facilitate laboratory data interpretation, and allow extension of evaluations beyond the parameters tested. Thermodynamic modeling simulations including the MgO and Fe 0 additives that are directly relevant to the experimental measurements (e.g., pH calibration curve, ORP corrections) are included in this report. The measured fa of the simulants was close to the OLI model predictions for both brines and was largely controlled by the background H 2 partial pressure in the vapor phase as well as H 2 generated in situ in the aqueous phase by the Fe 0 corrosion. The H 2 gas-phase concentration tested and thermodynamically evaluated was much lower than is assumed in the WIPP PA; however, H 2 (g) concentrations significantly below this level are still predicted to result in very reducing conditions. In conclusion: • The experimental results are consistent with thermodynamic model predictions for fa, pH, and the effects of high ionic strength. • Evidence to date suggests that the H2 concentration in the glovebox atmosphere ultimately determined the final E h values of the simulants and resulted in highly reducing conditions. As a result, little difference was observed between the control simulants containing only MgO and the WIPP base-case simulants that contained MgO and Fe 0 . • This test methodology is recommended for future studies evaluating WIPP repository conditions. The methodology includes: (1) background H 2 in argon with agitation ( or could alternatively include in-situ-generated H 2 in sealed bottles); (2) carefully measured and corrected ORP data ( with much effort focused on allowing the probes to fully stabilize); and (3) ionic-strength-corrected pH data. Other best practices, such as simulant sparging/handling, ORP probe replacement, etc., should also be considered. • The coupling of experimental studies and thermodynamic modeling is also highly recommended because these methods inform and direct one another leading to greater confidence in and understanding of the results.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Evaluation of Degradation Mechanisms for Solid Secondary Waste Grout Waste Forms

The overall objective of this work is to provide defensibility for the long-term performance of grouted Hanford SSW streams when disposed in a near surface disposal facility, IDF, on the Hanford Site. Providing defensibly for the long-term performance of the grouted waste forms is consistent with the research and development activities identified in the Performance Assessment Maintenance Plan, (Westcott et al. 2019), that are necessary to address the assumptions made in the PA. Specifically, this work addresses two areas identified for further research and development activities in the plan: (1) “Evaluate ongoing research on transport characteristics of cementitious materials using accelerated tests to approximate the effects of aging/alteration/weathering”; and (2) “Evaluate ongoing research on microbial effects on transport processes in cementitious materials.” The assembled subject matter expert team evaluated a list of degradation mechanisms and supporting processes and provided rankings of areas where further research and development (R&D) are needed. From this assessment, high priority R&D areas include: (1) the effects of carbonation, Ca leaching, and SSW dimensional change in grout waste forms; (2) updated model representations of grouted waste forms; and (3) scaled testing demonstrations. Moderate priority items including a paper study on possible microbial influence, reoxidation rates, radionuclide/contaminant dissolution from SSW in the grout and freeze thaw behavior. Other processes evaluated were either deemed unlikely to occur, to have little impact on the SSW waste forms, or to occur at time frames beyond those considered (>10,000 years). The assessments and proposed R&D approaches are expected to support an update to the WRPS SSW roadmap.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1980

Scale model performance test investigation of exhaust system mixers for an Energy Efficient Engine /E3/ propulsion system

A scale model performance test was conducted as part of the NASA Energy Efficient Engine (E3) Program, to investigate the geometric variables that influence the aerodynamic design of exhaust system mixers for high-bypass, mixed-flow engines. Mixer configuration variables included lobe number, penetration and perimeter, as well as several cutback mixer geometries. Mixing effectiveness and mixer pressure loss were determined using measured thrust and nozzle exit total pressure and temperature surveys. Results provide a data base to aid the analysis and design development of the E3 mixed-flow exhaust system.

Kuchar, A. P.↗
NASA NTRS1988

Design, development, and test of Shuttle/Centaur G-prime cryogenic tankage thermal protection systems

The thermal protection systems (TPS) for the Shuttle/Centaur were designed to provide fail-safe thermal protection during prelaunch, launch ascent, and on-orbit operations as well as during potential abort, where the Shuttle and Centaur would return to earth. The TPS selected used a helium-purged polyimide foam beneath three radiation shields for the liquid-hydrogen (LH2) tank and radiation shields only for the liquid-oxygen (LO2) tank. A double-walled vacuum bulkhead separated the two tanks. The LH2 tank had one 1.9 cm-thick layer of foam on the forward bulkhead and two layers on the larger-area sidewall. Full scale tests of the flight vehicle in a simulated Shuttle cargo bay gave total prelaunch heating rates of 29.5 and 12.9 kW for the LH2 and LO2 tanks, respectively. Calorimeter tests on a representative sample of the LH2 tank sidewall TPS indicated that the measured unit heating one would rapidly decrease from the prelaunch rate of about 300 W/sq m to a desired rate less than 4 W/sq m once on-orbit.

Macneil, Peter N.↗
NASA NTRS1955

Effect of surface roughness on characteristics of spherical shock waves

An investigation has been conducted on a small-scale test layout in which direct observation of the shock wave movement with time could be made in order to determine the effects of surface roughness on the characteristics of spherical shock waves. Data were obtained with 15-gram pentolite charges at four heights of burst, both for a smooth surface and for a surface completely covered with pyramid-shaped roughness elements. The observations resulted in determinations of shock peak overpressure and Mach stem height as a function of distance for each test. Comparison of the smooth-surface data with those obtained for the extremely rough condition showed a small net effort of roughness on the shock peak overpressures at the surface for all burst heights, the effect being to lower the overpressures. The effect of surface roughness on the Mach stem formation and growth was to delay the formation at the greatest charge height and to lower the height of the Mach stem for all heights.Comparison of the free-air shock peak overpressures with larger scale data showed good similarity of the overpressure-distance relationships. The data did not fit a geometrical similarity parameter for the path of the triple point at different heights of burst suggested by other investigators. A simple similarity parameter (relating the horizontal distance to the theoretical point of Mach formation) was found which showed only a small influence of burst height on the path of the triple point. While the data presented provide knowledge of the effect of many surface-roughness elements on the overall shock characteristics, the data do not provide insight into the details of the air-flow characteristics along the surface, nor the relative contribution of individual roughness elements to the results obtained.

Huber, Paul W↗
NASA NTRS1987

Design, development and test of shuttle/Centaur G-prime cryogenic tankage thermal protection systems

The thermal protection systems for the shuttle/Centaur would have had to provide fail-safe thermal protection during prelaunch, launch ascent, and on-orbit operations as well as during potential abort. The thermal protection systems selected used a helium-purged polyimide foam beneath three rediation shields for the liquid-hydrogen tank and radiation shields only for the liquid-oxygen tank (three shields on the tank sidewall and four on the aft bulkhead). A double-walled vacuum bulkhead separated the two tanks. The liquid-hydrogen tank had one 0.75-in-thick layer of foam on the forward bulkhead and two layers on the larger area sidewall. Full scale tests of the flight vehicle in a simulated shuttle cargo bay that was purged with gaseous nitrogen gave total prelaunch heating rates of 88,500 Btu/hr and 44,000 Btu/hr for the liquid-hydrogen and -oxygen tanks, respectively. Calorimeter tests on a representative sample of the liquid-hydrogen tank sidewall thermal protection system indicated that the measured unit heating rate would rapidly decrease from the prelaunch rate of approx 100 Btu/hr/sq ft to a desired rate of less than 1.3 Btu/hr/sq ft once on orbit.

Knoll, Richard H.↗
NASA NTRS1987

Development and test of the Shuttle/Centaur cryogenic tankage thermal protection system

The Thermal Protection System (TPS) for the Shuttle/Centaur had to provide fail-safe thermal protection during prelaunch, launch ascent, and on-orbit operations as well as during potential abort where the Shuttle and Centaur would return to earth. The TPS selected used a helium-purged polyimide foam beneath three radiation shields for the liquid hydrogen (LH2) tank and radiation shields only for the liquid oxygen (LO2) tank (three shields on the tank sidewall and four on the aft bulkhead). An evacuated common intermediate bulkhead separated the two tanks. The LH2 tank had one 1.9-cm thick layer of foam on the forward bulkhead and two layers on the larger area side-wall. Full scale tests of the flight vehicle in a simulated Shuttle cargo bay, that was purged with gaseous nitrogen, gave total prelaunch heating rates of 25.9 kW and 12.9 kW for LH2 and LO2 tanks, respectively. Calorimeter tests on a representative LH2 tank sidewall TPS sample indicated that the measured unit heating rate would rapidly decrease from the prelaunch rate of 300 W/sq m to a desired rate of less than 4 W/sq m once on-orbit.

Knoll, R. H.↗
NASA NTRS1971

Design and preliminary testing of a Brayton space radiator concept

A low-temperature radiator has been designed to reject 17.62 kW of thermal power from an isotope Brayton power system. This power system has an electrical output of 7.1 kW. The total radiator consists of two radiators connected in series. Both radiators have a redundant coolant loop, shared fins, and are close to flight configuration. A silicone oil is used as the working fluid. Low flow rates and moderate pressure drop in the radiator required a small hydraulic diameter with large heat transfer area and large flow area. To obtain these characteristics and meet schedule limitations, an expanded tube configuration (with an approximately trapezoidal cross section) was selected. Because of the low flow rates and unconventional tube shape, small scale tests were performed to evaluate the validity of existing heat transfer and pressure drop correlations to this case. The results of these tests were in good agreement with predictions.

Miller, T. J.↗
NASA NTRS1958

Wind-tunnel investigation of the heat transfer to the X-15 airplane

Paper describes the wind tunnel test program which has provided a picture of the general distribution of heat transfer coefficients over the X-15 airplane. The tunnel tests have emphasized the importance of the interactions of the flow fields of components and have shown that in some cases, where the local flow direction and total pressure can be reasonably closely inferred, use of experimental pressures to compute flow conditions yields very good predictions of heat transfer rate. There are still some regions of the airplane for which the heat transfer could not be adequately studied because of the size or construction of the model. Such local regions will not necessarily limit the operation of the airplane but will require evaluation in the full-scale tests. (author)

Feller, William V↗