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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
DOE OSTI2026

NLR CSP Optical Facilities: Illuminating the Path Forward Through Innovation and Impact: Agreement 38490

This initiative is a multi-faceted project at the National Laboratory of the Rockies (NLR) aimed at strengthening its Concentrating Solar Power (CSP) Optical Facilities to advance the development of low-cost, high-performance materials for solar and other applications. The project's strategy is built on three pillars: strategic stakeholder engagement, diligent facility maintenance and utilization, and the development of new research capabilities. The overarching goal is to ensure the facilities remain state-of-the-art resources for industry and academia, thereby accelerating the conversion of concentrated sunlight into energy. A key driver of the project is an international Advisory Board, which provides critical guidance on research priorities and industry needs, leading to new collaborations and secured funding. This external engagement, combined with proactive outreach to industry partners, ensures the lab's work remains aligned with real-world challenges, including materials durability and performance certification. Significant efforts in facility maintenance have addressed challenges with aging infrastructure. Notable achievements include the complete refurbishment of the hail-damaged Ultra-Accelerated Weathering System (UAWS) and the successful replacement of a failing 15-year-old Lambda 1050 spectrophotometer with a new-generation model, substantially upgrading material characterization capabilities. These maintenance activities were complemented by achieving a prestigious ISO 9001:2015 certification for the Advanced Optical Materials Labs, formally recognizing the quality and reliability of NLR's measurement capabilities. Despite these successes, challenges remain, including high demand for the High Flux Solar Furnace (HFSF) and intermittent failures of other key instruments. The project has delivered major advancements in research techniques and capabilities. At the Flatirons campus, a new indoor laboratory, was established to house advanced deflectometry and photogrammetry systems for heliostat characterization. For on-sun testing, a novel, actively cooled turning mirror was developed for the HFSF, enabling more realistic testing of particle receivers and components. A collaboration with Virginia Tech successfully demonstrated the high-temperature durability of a new solar absorber coating through extensive cyclic testing. Concurrently, new modeling took place to better predict material degradation on rough, fractal surfaces. In summary, this project has systematically enhanced NLR's CSP Optical Facilities through strategic upgrades, rigorous maintenance, and stakeholder-guided research. By overcoming equipment failures, budgetary constraints, and logistical hurdles, the project has reinforced NLR's role as a central hub for CSP innovation and materials testing. Future work will focus on securing diverse funding, expanding collaborations, and continuing to provide the critical infrastructure needed to accelerate the development and deployment of next-generation technologies.

14 SOLAR ENERGY↗
DOE OSTI2024

Radiation Damage Mitigation in FeCrAl Alloy at Sub-Recrystallization Temperatures

Traditional defect recovery methods rely on high-temperature annealing, often exceeding 750 °C for FeCrAl. In this study, we introduce electron wind force (EWF)-assisted annealing as an alternative approach to mitigate irradiation-induced defects at significantly lower temperatures. FeCrAl samples irradiated with 5 MeV Zr 2+ ions at a dose of 10 14 cm −2 were annealed using EWF at 250 °C for 60 s. We demonstrate a remarkable transformation in the irradiated microstructure, where significant increases in kernel average misorientation (KAM) and low-angle grain boundaries (LAGBs) typically indicate heightened defect density; the use of EWF annealing reversed these effects. X-ray diffraction (XRD) confirmed these findings, showing substantial reductions in full width at half maximum (FWHM) values and a realignment of peak positions toward their original states, indicative of stress and defect recovery. To compare the effectiveness of EWF, we also conducted traditional thermal annealing at 250 °C for 7 h, which proved less effective in defect recovery as evidenced by less pronounced improvements in XRD FWHM values.

FeCrAl alloys↗
NASA NTRS1971

Hypersonic research engine project. Phase 2: Structures and cooling development

Testing of the structures assembly model (SAM) continued at the Langley 8-foot high-temperature structures tunnel. A total of 30 test runs were completed, involving 38 loading cycles for the SAM. Fuel injection was used during 27 of the cycles. That portion of the program specifically aimed at thermal-cycling evaluation was completed. For these runs, tunnel total conditions ranged to 2200 psia and 3000 R. The tunnel nozzle is fixed and produces Mach numbers near 7 at the test conditions. The coolant for all runs was ambient-temperature hydrogen. The condition of the SAM following these runs was satisfactory. Isolated leaks occurred at joints in the cooled structure, but they have not affected operation or resulted in local areas of overheating. Three punctures in the leading edge, caused by foreign object damage, were present during most of the run; however, they showed no signs of propagation or distress due to overheating.

Jilly, L. F.↗
NASA NTRS1971

The role of creep in high temperature low cycle fatigue.

The significance of the role that creep can play in governing high-temperature, low-cycle fatigue resistance is investigated by conducting strain cycling tests on two high-temperature stainless steel alloys and making concurrent measurements of stress, temperature, and strain at various frequencies. The results are then analyzed in terms of damage imposed by creep and fatigue components. It is shown that creep can play an important and sometimes dominant role in low cycle fatigue at high temperatures. The results of the study include the findings that: (1) the simple life-fraction theory described is adequate for calculating creep damage when the cyclic creep rupture curve is used as a basis for analysis; (2) a method of universal slopes originally developed for room temperature use is sufficiently accurate at high temperature to be used to calculate pure fatigue damage; and (3) a linear creep-fatigue damage rule can explain the transitions observed from one failure mode to another.

Manson, S. S.↗
NASA NTRS1974

Performance of LI-1542 reusable surface insulation system in a hypersonic stream

The thermal and structural performance of a large panel of LI-1542 reusable surface insulation tiles was determined by a series of cyclic heating tests using radiant lamps and aerothemal tests in the Langley 8-foot high-temperature structures tunnel. Aerothermal tests were conducted at a free-stream Mach number of 6.6, a total temperature of 1830 K, Reynolds numbers of 2.0 and 4,900,000 per meter, and dynamic pressures of 29 and 65 kPa. The results suggest that pressure gradients in gaps and flow impingement on the header walls at the end of longitudinal gaps are sources for increased gap heating. Temperatures higher than surface radiation equilibrium temperature were measured deep in gaps and at the header walls. Also, the damage tolerance of the LI-1542 tiles appears to be very high. Tile edge erosion rate was slow; could not be tolerated in a shuttle application. Tiles soaked with water and subjected to rapid depressurization and aerodynamic heating showed no visible evidence of damage.

Hunt, L. R.↗
NASA NTRS1978

Effect of temperature on composite sandwich structures subjected to low velocity projectile impact

An experimental investigation was conducted to study the effect of low velocity projectile impact on graphite/epoxy and Kevlar 49- graphite/epoxy sandwich structural components. Testing was performed at moderately low- and high-temperatures to assess the strength degradation of composites as compared to room temperature values. Low energy projectile impact is considered to simulate the damage caused by runway debris such as small rocks, dropping of hand tools during servicing, etc., on secondary aircraft structures fabricated out of composites. The preload and impact energy necessary to cause catastrophic failure were determined. The residual strength of impact-damaged specimens was also measured.

Sharma, A. V.↗
NASA NTRS1980

Effect of temperature on composite sandwich structures subjected to low velocity impact

The effect of low velocity projectile impact on sandwich-type structural components was investigated. The materials used in the fabrication of the impact surface were graphite-, Kevlar-, and boron-fibers with appropriate epoxy matrices. The testing of the specimens was performed at moderately low- and high-temperatures as well as at room temperature to assess the impact-initiated strength degradation of the laminates. Eleven laminates with different stacking sequences, orientations, and thicknesses were tested. The low energy projectile impact is considered to simulate the damage caused by runway debris, the dropping of the hand tools during servicing, etc., on the secondary aircraft structures fabricated with the composite materials. The results show the preload and the impact energy combinations necessary to cause catastrophic failure in the laminates tested. A set of faired curves indicating the failure thresholds is shown separately for the tension-and compression-loaded laminates. The specific-strengths and -modulii for the various laminates tested are also given.

Sharma, A. V.↗
NASA NTRS1980

Silicon halide-alkali metal flames as a source of solar grade silicon

The feasibility of using continuous high-temperature reactions of alkali metals and silicon halides to produce silicon in large quantities and of suitable purity for use in the production of photovoltaic solar cells was demonstrated. Low pressure experiments were performed demonstrating the production of free silicon and providing experience with the construction of reactant vapor generators. Further experiments at higher reagent flow rates were performed in a low temperature flow tube configuration with co-axial injection of reagents and relatively pure silicon was produced. A high temperature graphite flow tube was built and continuous separation of Si from NaCl was demonstrated. A larger scaled well stirred reactor was built. Experiments were performed to investigate the compatability of graphite based reactor materials of construction with sodium. At 1100 to 1200 K none of these materials were found to be suitable. At 1700 K the graphites performed well with little damage except to coatings of pyrolytic graphite and silicon carbide which were damaged.

Olson, D. B.↗
NASA NTRS1982

High-temperature fatigue in metals

The presentation focuses primarily on the progress we at NASA Lewis Research Center have made. The understanding of the phenomenological processes of high temperature fatigue of metals for the purpose of calculating lives of turbine engine hot section components is discussed. Improved understanding resulted in the development of accurate and physically correct life prediction methods such as Strain-Range Partitioning for calculating creep fatigue interactions and the Double Linear Damage Rule for predicting potentially severe interactions between high and low cycle fatigue. Examples of other life prediction methods are also discussed.

Gary R. Halford↗
NASA NTRS1983

High-temperature fatigue in metals - A brief review of life prediction methods developed at the Lewis Research Center of NASA

The presentation focuses primarily on the progress we at NASA Lewis Research Center have made. The understanding of the phenomenological processes of high temperature fatigue of metals for the purpose of calculating lives of turbine engine hot section components is discussed. Improved understanding resulted in the development of accurate and physically correct life prediction methods such as Strain-Range partitioning for calculating creep fatigue interactions and the Double Linear Damage Rule for predicting potentially severe interactions between high and low cycle fatigue. Examples of other life prediction methods are also discussed. Previously announced in STAR as A83-12159

Halford, G. R.↗
NASA NTRS1986

Fast Glazing of Alumina/Silica Tiles

Technique for applying ceramic coating to fibrous silica/alumina insulation tiles prevents cracks and substantially reduces firing time. To reduce thermal stresses in tile being coated, high-temperature, shorttime firing schedule implemented. Such schedule allows coating to mature while substrate remains at relatively low temperature, reducing stress differential between coating and substrate. Technique used to repair tiles with damaged coatings and possibly used in heat-treating objects made of materials having different thermal-expansion coefficients.

Creedon, J. F.↗
NASA NTRS1985

Derivation and test of elevated temperature thermal-stress-free fastener concept

Future aerospace vehicles must withstand high temperatures and be able to function over a wide temperature range. New composite materials are being developed for use in designing high-temperature lightweight structures. Due to the difference between coefficients of thermal expansion for the new composite materials and conventional high-temperature metallic fasteners, innovative joining techniques are needed to produce tight joints at all temperatures without excessive thermal stresses. A thermal-stress-free fastening technique is presented that can be used to provide structurally tight joints at all temperatures even when the fastener and joined materials have different coefficients of thermal expansion. The derivation of thermal-stress-free fasteners and joint shapes is presented for a wide variety of fastener materials and materials being joined together. Approximations to the thermal-stress-free shapes that result in joints with low-thermal-stresses and that simplify the fastener/joint shape are discussed. The low-thermal-stress fastener concept is verified by thermal and shear tests in joints using oxide-dispersion-strengthened alloy fasteners in carbon-carbon material. The test results show no evidence of thermal stress damage for temperatures up to 2000 F and the resulting joints carried shear loads at room temperature typical of those for conventional joints.

Sawyer, J. W.↗
NASA NTRS1986

Studies of implanted iron in silicon by channeling and Rutherford backscattering

Different amounts of 100-keV iron ions have been implanted into high-resistivity p-type FZ-silicon samples. The implantation damage, recovery of damage during various annealing periods and temperatures, movement of iron atoms under annealing and oxidation, and the kinds of defects created after implantation, annealing, or oxidation are all investigated by channeling and backscattering measurements. It is found that the critical fluence of 100-keV iron implanted into silicon at room temperature is about 2.5 x 10 to the 14th Fe/sq cm, and that iron atoms are gettered by silicon oxidation. In this supersaturated region, iron atoms diffuse slightly towards bulk silicon during high-temperature annealing (greater than or equal to 1100 C) but not at all during low-temperature annealing (less than or equal to 1000 C) in dry nitrogen ambient.

Wang, P. W.↗
NASA NTRS1988

Fatigue life prediction modeling for turbine hot section materials

This paper presents a summary of the life prediction methods developed under the NASA Lewis Research Center's Hot Section Technology (HOST) program. A major objective of the fatigue and fracture efforts under the HOST program was to significantly improve the analytic life prediction tools used by the aeronautical gas turbine engine industry. This has been achieved in the areas of high-temperature thermal and mechanical fatigue of bare and coated high-temperature superalloys. Such technical improvements will eventually reduce life cycle costs. The cyclic crack initiation and propagation resistance of nominally isotropic polycrystalline alloys and highly anisotropic single crystal alloys has been addressed. A sizeable data base has been generated for three alloys [cast PWA 1455 (B-1900 + Hf), wrought Inconel 718, and cast single crystal PWA 1480] in bare and coated conditions. Two coatings systems, diffusion aluminide (PWA 273) and plasma sprayed MCrAIY overlay (PWA 286) were employed. Life prediction modeling efforts were devoted to creep-fatigue interaction, oxidation, coatings interactions, multiaxiality of stress-strain states, mean stress effects, cumulative damage, and thermomechanical fatigue. The fatigue crack initiation life models developed to date include the Cyclic Damage Accumulation (CDA) Model of Pratt & Whitney and the Total Strain Version of Strainrange Partitioning (TS-SRP) of NASA Lewis for nominally isotropic materials, and the Tensile Hysteretic Energy Model of Pratt & Whitney for anisotropic superalloys. The fatigue model being developed by the General Electric Company is based upon the concepts of Path-lndependent Integrals (PII) for describing cyclic crack growth under complex nonlinear response at the crack tip due to thermomechanical loading conditions. A micromechanistic oxidation crack extension model has been derived by researchers at Syracuse University. The models are described and discussed in the paper. Only limited verification has been achieved to-date as several of the technical programs are still in progress and the verification tasks are scheduled, quite naturally, near the conclusion of the program. To-date, efforts have concentrated on development of independent models for cyclic constitutive behavior, cyclic crack initiation, and cyclic crack propagation. The transition between crack initiation and crack propagation has not been thoroughly researched as yet, and the integration of these models into a unified life prediction method has not been addressed.

Metal fatigue↗
NASA NTRS1988

In situ fatigue loading stage inside scanning electron microscope

A fatigue loading stage inside a scanning electron microscopy (SEM) was developed. The stage allows dynamic and static high-magnification and high-resolution viewing of the fatigue crack initiation and crack propagation processes. The loading stage is controlled by a closed-loop servohydraulic system. Maximum load is 1000 lb (4450 N) with test frequencies ranging up to 30 Hz. The stage accommodates specimens up to 2 inches (50 mm) in length and tolerates substantial specimen translation to view the propagating crack. At room temperature, acceptable working resolution is obtainable for magnifications ranging up to 10,000X. The system is equipped with a high-temperature setup designed for temperatures up to 2000 F (1100 C). The signal can be videotaped for further analysis of the pertinent fatigue damage mechanisms. The design allows for quick and easy interchange and conversion of the SEM from a loading stage configuration to its normal operational configuration and vice versa. Tests are performed entirely in the in-situ mode. In contrast to other designs, the NASA design has greatly extended the life of the loading stage by not exposing the bellows to cyclic loading. The loading stage was used to investigate the fatigue crack growth mechanisms in the (100)-oriented PWA 1480 single-crystal, nickel-based supperalloy. The high-magnification observations revealed the details of the crack growth processes.

Telesman, Jack↗
NASA NTRS1988

Fatigue life prediction modeling for turbine hot section materials

A major objective of the fatigue and fracture efforts under the Hot Section Technology (HOST) program was to significantly improve the analytic life prediction tools used by the aeronautical gas turbine engine industry. This was achieved in the areas of high-temperature thermal and mechanical fatigue of bare and coated high-temperature superalloys. The cyclic crack initiation and propagation resistance of nominally isotropic polycrystalline and highly anisotropic single crystal alloys were addressed. Life prediction modeling efforts were devoted to creep-fatigue interaction, oxidation, coatings interactions, multiaxiality of stress-strain states, mean stress effects, cumulative damage, and thermomechanical fatigue. The fatigue crack initiation life models developed to date include the Cyclic Damage Accumulation (CDA) and the Total Strain Version of Strainrange Partitioning (TS-SRP) for nominally isotropic materials, and the Tensile Hysteretic Energy Model for anisotropic superalloys. A fatigue model is being developed based upon the concepts of Path-Independent Integrals (PII) for describing cyclic crack growth under complex nonlinear response at the crack tip due to thermomechanical loading conditions. A micromechanistic oxidation crack extension model was derived. The models are described and discussed.

Halford, G. R.↗
NASA NTRS1961

Titanium Nitride: An Oxidizable Coating for the High-Temperature Protection of Graphite

A titanium nitride coating for graphite, prepared by deposition process, protected test specimens for 60 seconds the vapors in a supersonic ceramic-heated air jet with a stagnation temperature of approximately 2,250 K. For the same test conditions, coated specimens showed no damage to the graphite body for the 60-second test, whereas uncoated specimens were very severely damaged after 20 seconds and were destroyed toward the end of the test. A discussion of the coating of these graphite specimens and of some of the conditions necessary for the utilization of oxidizable substances as oxidation-protective coatings for bodies facing high convective heat transfer in the atmosphere is presented.

Wakelyn, N. T.↗
DOE OSTI2024

Experimental and Analytical Verification of ASME Section IiII Division 5 Creep-Fatigue Design Rules

The continuous advancement of structural materials and the growing demands for more reliable and economical structural components in high-temperature reactor applications have necessitated the development of comprehensive design methodologies and design rules. Mechanical degradation of structural components at elevated temperatures subjected to cyclic deformation is controlled by the creep-fatigue damage. Over the past few decades, diligent research efforts have been dedicated to refining the development of elevated temperature design rules in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 5 and to develop conservative design rules that can effectively guard against the risk of creep-fatigue failure. In ASME Section III, Division 5, for a design to pass the creep-fatigue acceptance criteria, creep damage and fatigue damage are evaluated separately, and these damages must not violate the bi-linear creep-fatigue interaction diagram, i.e., the so-called D-diagram. The creep-fatigue damage evaluation procedure assumes that the effects of the actual cyclic loading sequence can be bounded by assuming that the individual loading cycles are uniformly distributed throughout the component design life. In this study, creep-fatigue experiments with variable amplitudes and loading sequencies were designed and performed on Alloy 617 at high temperatures. The results were analyzed to evaluate the loading history effect on creep-fatigue damage accumulation and to verify the assumptions for the creep-fatigue evaluation design rules.

36 - MATERIALS SCIENCE↗