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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

The Chevron Foil Thrust Bearing: Improved Performance Through Passive Thermal Management and Effective Lubricant Mixing

An improved foil thrust bearing is described that eliminates or reduces the need for forced cooling of the bearing foils while at the same time improves the load capacity of the bearing, enhances damping, provides overload tolerance, and eliminates the high speed load capacity drop-off that plagues the current state of the art. The performance improvement demonstrated by the chevron foil thrust bearing stems from a novel trailing edge shape that splays the hot lubricant in the thin film radially, thus preventing hot lubricant carry-over into the ensuing bearing sector. Additionally, the chevron shaped trailing edge induces vortical mixing of the hot lubricant with the gas that is naturally resident within the inter-pad region of a foil thrust bearing. The elimination of hot gas carry-over in combination with the enhanced mixing has enabled a completely passive thermally managed foil bearing design. Laboratory testing at NASA has confirmed the original analysis and reduced this concept to practice.

foil bearing↗
DOE OSTI2022

Optimising Foil Selection for Neutron Activation Systems

Abstract Neutron spectrum unfolding using activation foils is currently the primary technique planned for measuring the neutron energy spectrum at the first wall of power-generating fusion reactors. Room for improvement in the effectiveness of current foil selection was identified, and a program produced to select foils procedurally in order to maximise the accuracy of the unfolding procedure. Using Kullback–Leibler Divergence to quantify the accuracy, the spectrum unfolded by the procedurally selected set of foils is found to be more accurate than the spectrum unfolded by a set of foils used in the literature.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Sequential separation of battery electrode materials and metal foils in aqueous media

To recycle high-value lithium-ion battery components, it is imperative to efficiently separate electrode materials from current collector foils and to separate cathodes from anodes. This study investigates the delamination behaviors of cathodes and anodes from their respective current collectors in aqueous media. Whereas anode films can easily detach from copper foils in water, the delamination of cathode films does not exhibit the same behavior in water; instead, the cation exchange reaction results in lithium leaching and aluminum corrosion in the presence of water. Here, a buffer solution with surfactant additives has been designed to prevent aluminum corrosion and to improve solution wetting behavior, thereby facilitating cathode delamination. The delamination difference enables the sequential recovery of electrode materials and metal foils at different separation stages, simplifying the traditionally intricate processes within a one-pot recovery system. The recovered materials retain their crystal structure and morphology, and there are no signs of aluminum corrosion or residues on the metal foils. The sequential separation technique achieves nearly 100% separation efficiency for electrode materials from metal foils and over 98% separation efficiency for cathode and anode materials.

25 ENERGY STORAGE↗
DOE OSTI2020

Extended magnetohydrodynamics simulations of thin-foil Z-pinch implosions with comparison to experiments

Cylindrical foil liners, with foil thicknesses on the order of 400 nm, are often used in university-scale Z-pinch experiments (~1 MA in 100 ns) to study physics relevant to inertial confinement fusion efforts on larger-scale facilities (e.g., the MagLIF effort on the 25-MA Z facility at Sandia National Laboratories). The use of ultrathin foil liners typically requires a central support rod to maintain the structural integrity of the liner target assembly prior to implosion. The radius of this support rod sets a limit on the maximum convergence ratio achievable for the implosion. In recent experiments with a support rod and a preimposed axial magnetic field, helical instability structures in the imploding foil plasma were found to persist as the foil plasma stagnated on the rod and subsequently expanded away from the rod. We have now used the 3D extended magnetohydrodynamics simulation code PERSEUS (which includes Hall physics) to study these experiments. The results suggest that it is the support rod which is responsible for the helical structures persisting beyond stagnation. Furthermore, we find that as the radius of the support rod decreases (i.e., as the convergence ratio increases), the integrity and persistence of the helical modes diminish. In the limit with no support rod, we find that the structure of the final stagnation column is governed by the structure of the central precursor plasma column. Furthermore, these simulation results and their comparisons to experiment are presented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Analytic solutions for Asay foil trajectories with implications for ejecta source models and mass measurements

We consider the trajectory of an Asay foil ejecta diagnostic for scenarios where ejecta are produced at a singly shocked planar surface and fly ballistically through a perfect vacuum to the sensor. We do so by building upon a previously established mathematical framework derived for the analytic study of stationary sensors. First, we derive the momentum conservation equation for the problem, in a form amenable to accelerating sensors, in terms of a generic ejecta source model. The result is an integrodifferential equation of motion for the foil trajectory. This equation yields an easily calculable closed-form implicit solution for the foil trajectory in instant-production scenarios. From there, we derive a boundary condition that particle velocity distributions must satisfy if their associated foil trajectories are to exhibit a smooth initial acceleration, as occurs in some experiments. This condition is identical to one derived previously from a consideration of piezoelectric voltage data obtained in similar experiments. We also compare techniques for inferring accumulated ejecta masses from foil trajectories, first by deriving the exact solution, and then by quantifying the error imposed by a frequently used approximate solution (both subject to the assumption of instantaneous ejecta production). Finally, we examine the common practice of presenting inferred cumulative ejecta masses as a function of implied ejecta velocity, establishing the conditions under which this methodology is most meaningful.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Study of SXR/EUV radiation of exploded foils and wires with spectral, spatial and temporal resolution simultaneously on KING electric discharge facility.

The results of studies of the soft X-ray and extreme ultraviolet (SXR/EUV) radiation of thin flat aluminum foils and wires under the explosion in an electric discharge on the compact high-current KING generator are presented. These studies were based on the SXR/EUV spectroscopy with a spectral resolution of 6 Å, a temporal resolution of 5 ns and a spatial resolution of 200 μm. To study the plasma radiation of exploded foils and wires in the SXR/EUV range, we used a transmission diffraction grating spectrograph which in combination with two additional slits provided spectral and spatial resolution. The spectrograph was coupled with a 4-frame recorder based on a microchannel plate for providing temporal resolution. The analysis and comparison of the spectral, spatial, temporal, and energy characteristics of the SXR/EUV radiation of plasma formed under the explosion of foils and wires of a similar mass made of aluminum was carried out. Here, the spectra were calculated as well and the plasma parameters and their changes in time and space were estimated on the basis of these calculations and comparison with relevant experimental results. Experiments have shown that when foils explode, a single intense source of SXR/EUV radiation is formed with radiated energy in the range of 10-20 J and a power of up to 100 MW in the quantum energy range from 30 to 250 eV. At the same time, the radiation power under the explosion of foils turned out to be about twice above the power under the explosion of wires of comparable mass.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

An In-Depth Analysis of the Transformation of Tin Foil Anodes during Electrochemical Cycling in Lithium-Ion Batteries

Tin foils have an impressive lithium-storage capacity more than triple that of graphite anodes, and their adoption could facilitate a drastic improvement in battery energy density. However, implementation of a dense foil electrode architecture represents a significant departure from the standard blade-cast geometry with a distinct electrochemical environment, and this has led to confusion with regards to the first cycle efficiency of the system. In this work, we investigate the unique behavior of a tin active material in a foil architecture to understand its performance as an anode. We find shallow cycling of the foil results in an irreversible formation (< 40%) due to diffusional trapping, but intermediate and complete utilization allows for a remarkably reversible formation reaction (> 90%). This striking nonlinearity stems from an in situ transformation from bulk metal to porous electrode that occurs during formation cycles and defines electrode-level lithium-transport on subsequent cycles. As a result, an alternative cycling procedure for assessing the stability of foils is proposed to account for this chemomechanical effect.

25 ENERGY STORAGE↗
DOE OSTI2026

FOILPOLARS (Grassmannian Foil Shape Sweeps for Polar Generation) [SWR-26-095]

FOILPOLARS (Grassmannian Foil Shape Sweeps for Polar Generation): Multifidelity aerodynamic polar data generation for hydrofoil/tidal-turbine airfoil sections. Foilpolars ties together three pieces: *AeroSandbox supplies the baseline airfoil coordinates (UIUC database). *G2Aero parameterizes those shapes on a Grassmannian manifold (Karcher mean + PGA basis) and samples new perturbed shapes around that basis. *XFoil (panel method) and NeuralFoil (neural-network surrogate, shipped with AeroSandbox) each solve the resulting shapes for lift, drag, moment, and pressure at the swept angles of attack, Reynolds numbers, and n_crit values. Design optimization of foil shapes in a computationally efficient way requires polars data across many candidate shapes, not just a handful of baseline foils. However, high-fidelity CFD at that scale is too costly, and naive shape perturbation strays from realistic geometries. FOILPOLARS addresses this by loading baseline airfoils (via AeroSandbox) and mapping them onto a Grassmannian manifold (via G2Aero), computing a Karcher mean and principal geodesic analysis (PGA) basis. New shapes are sampled by perturbing PGA coefficients, keeping them close to the manifold of realistic foils. Each sampled shape is evaluated across a configurable sweep of angle of attack, Reynolds number, and critical amplification factor using two solvers: XFoil (panel method) and NeuralFoil (neural-network surrogate), producing a paired dataset of lift, drag, moment, pressure, convergence, and confidence, indexed alongside each shape's PGA coefficients and shared Grassmannian basis in a single xarray dataset. From this, FOILPOLARS produces convergence summaries and comparison plots per shape, Reynolds number, and n_crit. A command-line interface exposes each pipeline stage independently, supporting data-driven design, optimization, and machine-learning workflows for foils.

Sandhu, Rimple [National Laboratory of the Rockies↗
DOE OSTI2020

Characterization of Uranium Foil Irradiations at the WSU TRIGA Reactor Using a New Reactor Model in SCALE [Slides]

A depleted uranium foil and a highly enriched uranium foil that were irradiated at the Washington State University TRIGA reactor were used to measure the relative production of 237 U and 239 U, two key isotopes of interest in nuclear forensics, as well as their decay daughters 237 Np and 239 Pu. Total fissions in the two foils were also estimated using 99 Mo measurement. A reactor model of the TRIGA was built in the SCALE neutron transport code using dimensions obtained from an existing MCNP geometry. The model was successfully used to simulate foil fissions and the reaction rate ratios in 238 U, using the laboratory-measured isotope ratios as a benchmark. The flux distribution in the foils was determined. Finally, using the continuous energy Tsunami-3d module of SCALE, a sensitivity/uncertainty analysis was performed to determine the effects on the reaction ratio caused by other reactions in the reactor and by uncertainties in the known cross-sections.

07 ISOTOPE AND RADIATION SOURCES↗
NASA NTRS1970

The dynamic characteristics of a turbo-rotor simulator supported on gas-lubricated foil bearings. Part 2: Operation with heating and thermal gradients

A high speed rotor, supported by gas-lubricated foil bearings, is free from self-excited whirl and displays no loss of load capacity when vibrated at frequency equal to the rotational speed. It is demonstrated that in addition to tolerance of geometrical imperfections, misalignment and foreign particles, the foil bearing performs well at elevated temperatures and accommodates appreciable temperature gradients. The foil bearing is endowed with superior wipe-wear characteristics and the flexibility of the foil accounts not only for the stability of the foil bearing, but also for its accommodation of, and compensation for, distortion, contamination, and contact.

Licht, L.↗
NASA NTRS1972

Thermal effects on the clearance and stiffness of foil journal bearings for a Brayton cycle turboalternator

An analysis of foil journal bearings for a NASA Brayton Cycle Unit (BRU) is presented. The study represents an extension of previous work in that it includes the effects of thermal expansion of foil-bearing components, as well as an improved model of the influence of foil flexure. The results presented give the bearing film thickness, the bearing stiffness, and the foil tension as functions of the operating temperatures and the elasto-hydrodynamic and geometrical parameters pertinent to the design of BRU foil bearings. A computer program for the evaluation of design data and for parametric studies is included.

Eshel, A.↗
NASA NTRS1972

Iridium and tantalum foils for spaceflight neutron dosimetry.

Description of a two-foil system of iridium and tantalum which can measure thermal and intermediate energy neutrons at flux densities of 1 neutron/sq cm-sec over a ten-day lunar mission (1,000,000 neutrons/sq cm). The foils are chemically inert and nontoxic, weigh less than 1 g each, and require only routine gamma pulse height analysis for activation measurement. Detection of fluences below 1,000,000 neutrons/sq cm are achieved for counts of foil activity made as late as two months following neutron exposure. Tantalum foils flown in Apollo 11 indicated a mean dose equivalent to the astronauts of less than 16 mrem from thermal plus intermediate energy neutrons, while nuclear emulsion track analysis indicated approximately 17 mrem from neutrons of energy greater than 0.6 MeV. Iridium foils flown on Apollo 12 indicated dose equivalents of 1.8 to 2.8 mrem from thermal neutrons, excluding tissue thermalized SNAP-27 neutrons.

English, R. A.↗
NASA NTRS1973

Design, fabrication, and performance of foil journal bearing for the brayton rotating unit

Foil bearings were designed and manufactured to replace pivoted-shoe journal bearings in an existing Brayton Cycle turbo-alternator-compressor. The design of this unconventional rotor support was accomplished within the constraints and space limitations imposed by the present machine, and the substitution of foil bearings was effected without changes or modification other machine components. A housing and a test rig were constructed to incorporate the new foil-bearing support into a unified assemble with an air-driven rotor and the gimbal-mounted thrust bearing, seals, and shrouds of an actual Brayton Rotating Unit. The foil bearing required no external pressure source, and stable self-acting rotation was achieved at all speeds up to 43,200 rpm. Excellent wipe-wear characteristics of the foil bearing permitted well over 1000 start-stop cycles with no deterioriation of performance in the entire speed range.

Licht, L.↗
NASA NTRS1974

Quasi-static analysis of foil journal bearings for a Brayton cycle turboalternator

A quasi-static analysis is presented for foil journal bearings designed for a NASA Brayton Cycle Turboalternator. Included in the analysis are effects of 'slack' (due to flexural rigidity of the foil), of frictionally restrained extension of the foil-length in contact with cylindrical guides, of fluid inertia and compressibility, and of thermal expansion of rotor, foil and supporting structure. Comparisons are made with results of early experiments performed by Licht (1968, 1969) and recent data of Licht and Branger (1973). Variatons of film thickness, foil tension and bearing stiffness are presented graphically as functions of pertinent parameters for the case of operation in zero-gravity environment.

Eshel, A.↗
NASA NTRS1975

Some properties of Ni-Cu foils and their behavior when heated in hydrogen

Nickel foils of nominal thickness 0.1 and 1 micron have been resistively evaporated onto copper-foil substrates of thickness 25 and 2.5 microns. In depositions in which the pressure was as high as 0.00001 torr, the deposited nickel was not shiny and appeared granular in a 100x microscope. Foils evaporated in higher vacuums were shiny, but became granular if heated to 500 C in oxygen at pressures greater than 0.000005 torr, or in carbon dioxide at pressures greater than 0.0000005 torr. This phenomenon has been interpreted as recrystallization. Foils heated to 500 C at pressures of hydrogen above 0.0003 torr exhibit cracking characteristic of hydrogen embrittlement. The bimetallic foils curled concave toward the nickel during evaporation, consistent with a connected-island form of film growth.

Morrison, R. A.↗
NASA NTRS1984

Bending fatigue of electron-beam-welded foils. Application to a hydrodynamic air bearing in the Chrysler/DOE upgraded automotive gas tubine engine

A hydrodynamic air bearing with a compliment surface is used in the gas generator of an upgraded automotive gas turbine engine. In the prototype design, the compliant surface is a thin foil spot welded at one end to the bearing cartridge. During operation, the foil failed along the line of spot welds which acted as a series of stress concentrators. Because of its higher degree of geometric uniformity, electron beam welding of the foil was selected as an alternative to spot welding. Room temperature bending fatigue tests were conducted to determine the fatigue resistance of the electron beam welded foils. Equations were determined relating cycles to crack initiation and cycles to failure to nominal total strain range. A scaling procedure is presented for estimating the reduction in cyclic life when the foil is at its normal operating temperature of 260 C (500 F).

Saltsman, J. F.↗
NASA NTRS1989

Surface treatment using metal foil liner

A metal foil liner can be used to seal large area surfaces. Characteristics of the two-layer foil liner are discussed. Micrographs for foil-to-foil, foil-to-composite, visible seams, and hidden seams are examined.

Garvey, Ray↗
NASA NTRS1992

H Ly-alpha transmittance of thin foils of C, Si/C, and Al/C for keV particle detectors

A class of instruments designed for remote sensing of space plasmas by measuring energetic neutral atoms (ENA) uses a thin foil as both a signal generator and a light shield. An ENA imager must look directly at the ENA source region, which is also usually an intense source of H Ly-alpha (1216 A) photons. It is desirable to minimize the energy threshold for ENA detectors, at the same time maximizing the blocking of H Ly-alpha. Optimizing filter design to meet these two contrary requirements has led us to measure the transmittance of thin C, Si/C, and Al/C foils at H Ly-alpha. Our results indicate that (1) transmittance of less than 0.0007 can be achieved with 7 micro-g/sq cm Si on 1.7 micro-g/sq cm C; (2) an Si/C composite foil with a thin carbon layer is more effective in blocking UV radiation while having the lowest energy threshold of all the foils measured; and (3) transmittance of Si/C foils of known Si and C thicknesses cannot be accurately predicted, but must be measured.

Drake, V. A.↗