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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 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Comparison of Mg-based liquid metal ion sources for scalable focused-ion-implantation doping of GaN

We compare the suitability of various magnesium-based liquid metal alloy ion sources (LMAISs) for scalable focused-ion-beam (FIB) implantation doping of GaN. We consider GaMg, MgSO 4 $\bullet$7H 2 O, MgZn, AlMg, and AuMgSi alloys. Although issues of oxidation (GaMg), decomposition (MgSO 4 $\bullet$7H 2 O), and excessive vapor pressure (MgZn and AlMg) were encountered, the AuMgSi alloy LMAIS operating in a Wien-filtered FIB column emits all Mg isotopes in singly and doubly charged ionization states. We discuss the operating conditions to achieve <20 nm spot size Mg FIB implantation and present Mg depth profile data from time-of-flight secondary ion mass spectrometry. We also provide insight into implantation damage and recovery based on cathodoluminescence spectroscopy before and after rapid thermal processing. Prospects for incorporating the Mg LMAIS into high-power electronic device fabrication are also discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Lithium-Ion Batteries with Safer Current Collectors

The US Department of Energy’s Oak Ridge National Laboratory and Soteria Battery Innovation Group collaborated to develop a metallized polymer film as a current collector for lithium-ion batteries and design slit patterns for electrodes to improve battery safety. The metallized polymer film serves as a fuse that will break under high temperature resulting from a short circuit. Consequently, the short circuit will be broken and the heat generated from the short circuit will be alleviated to avoid thermal runaway. The electrodes with slit patterns are expected to be broken into small segments upon mechanical impact, which can isolate the damaged electrodes from the rest. Thus, the heat generation associated with the mechanical impact will be reduced, along with the likelihood of thermal runaway. This effort aimed to improve lithium-ion battery safety by replacing traditional metal foils with metallized polymer films as current collector and introducing slit patterns to battery electrodes. The metallized polymer films were polyethylene terephthalate with a thin metal (aluminum for cathodes and copper for anodes) coating on both sides. Slit patterns with various geometries and dimensions were designed via simulation. Temperature distribution on cells with electrodes with and without slit patterns was also simulated via nemerical modeling. Electrodes on traditional metal foils and metallized polymer films were coated via a pilot-scale slot-die coater at the US Department of Energy Battery Manufacturing Facility at Oak Ridge National Laboratory. The electrodes were calendered to 35% porosity and punched out with and without slit patterns. Pouch cells were assembed with the electrodes inside a dry room for electrochemical and safety testing. Electrodes coated on metallized polymer films exhibited comparable electrochemical performance to their counterparts coated on traditional metal foils. They also showed improved safety in nail penetration and indentation tests.

25 ENERGY STORAGE↗
NASA NTRS1974

Vacuum jacketed composite propulsion feedlines for cryogenic launch and space vehicles, volume 1

Thin metallic liners that provide leak-free service in cryogenic propulsion systems are overwrapped with a glass-fiber composite that provides strength and protection from handling damage. The resultant tube is lightweight, strong, and has a low thermal flux. The inside commodity flow line and the outside vacuum jacket were fabricated using this method. Several types of vacuum jackets were fabricated and tested at operating temperatures from 294 to 21 K (+70 to minus 423 F) and operating pressure up to 69 N/cm2 (100 psi). The primary objective of the program was to develop vacuum jacket concepts, using previously developed concepts for the inner line. All major program objectives were met resulting in a design concept that is adaptable to a wide range of aerospace vehicle requirements. Major items of development included convolution of thin metallic sections up to 46 cm (18 in.) in diameter, design and fabrication of an extremely lightweight tension membrane concept for the vacuum jacket, and analytical tools that predict the failure mode and levels.

Spond, D. E.↗
NASA NTRS1976

External tank gaseous oxygen line simulated lightning tests

Tests were made to evaluate the effects of lightning strikes on the shuttle external tank gaseous oxygen pressurization line. This line, designed to conduct gaseous oxygen may also act as a lightning conductor. Questions have been raised as to the potential hazard of this line as a lightning conductor with speculation as to the damage that might occur to the pressurization line, and the adjacent thermal protective surfaces, from a lightning strike. The region of investigation was from above the cone of the launch tower lightning protection to 15.24 km (50, 000 ft) altitude. Tests were performed on samples of thin wall stainless steel tubing filled with gaseous oxygen under simulated flight conditions. No specimen malfunctions occurred when the tests were conducted according to JSC specifications. Based on the JSC specifications and the results of these tests, it is concluded that a lightning strike will not cause a malfunction of the shuttle external tank gaseous oxygen line made of the representative material tested.

Smith, H. E.↗
NASA NTRS1989

Development of a silicon carbide sewing thread

A silicon carbide (SiC) sewing thread has been designed which consists of a two-ply yarn in a 122 turns-per-meter-twist construction. Two processing aids in thread construction were evaluated. Prototype blankets were sewn using an SiC thread prepared either with polytetrafluoroethylene sizing or with an overwrap of rayon/dacron service yarn. The rayon/dacron-wrapped SiC thread was stronger, as shown by higher break-strength retention and less damage to the outer-mold-line fabric. This thread enables thermal protection system articles to be sewn or joined, or have perimeter close-out of assembled parts when using SiC fabric for high-temperature applications.

Sawko, Paul M.↗
NASA NTRS1988

Requirements and an approach for coating the Gravity Probe B gyroscope rotor

A process to coat a quartz gyroscope rotor uniformly with superconducting niobium as part of a NASA sponsored experiment to test general relativity is described. The requirements for uniformity, film adhesion, and superconducting properties of the niobium thin film rotor coating are discussed. A uniformity of 1.5 percent (peak to valley) (38 nm) with good adhesion, no pinholes larger than 0.25 mm, transition temperature of 9.8 K, and the ability to survive repeated thermal cycling to 4.2 K have been achieved. Problems concerning abrasive damage and electrical arc damage during earthbound testing have been observed. Many hours of ground-based gyro operation demonstrate the applicability of this approach to rotor coating.

Gill, D.↗
NASA NTRS1991

Inelastic Strain Analysis of Solder Joint in NASA Fatigue Specimen

The solder fatigue specimen designed by NASA-GSFC/UNISYS is analyzed in order to obtain the inelastic strain history during two different representative temperature cycles specified by UNISYS. In previous reports (dated July 25, 1990, and November 15, 1990), results were presented of the elastic-plastic and creep analysis for delta T = 31 C cycle, respectively. Subsequent results obtained during the current phase, from viscoplastic finite element analysis of the solder fatigue specimen for delta T = 113 C cycle are summarized. Some common information is repeated for self-completeness. Large-deformation continuum formulations in conjunction with a standard linear solid model is utilized for modeling the solder constitutive creep-plasticity behavior. Relevant material properties are obtained from the literature. Strain amplitudes, mean strains, and residual strains (as well as stresses) accumulated due to a representative complete temperature cycle are obtained as a result of this analysis. The partitioning between elastic strains, time-independent inelastic (plastic) strains, and time-dependent inelastic (creep) strains is also explicitly obtained for two representative cycles. Detailed plots are presented for two representative temperature cycles. This information forms an important input for fatigue damage models, when predicting the fatigue life of solder joints under thermal cycling

Dasgupta, Abhijit↗
NASA NTRS1994

Debris/ice/TPS assessment and integrated photographic analysis for Shuttle Mission STS-59

A debris/ice/thermal protection system assessment and integrated photographic analysis was conducted for shuttle mission STS-59. Debris inspections of the flight elements and launch pad were performed before and after launch. Icing conditions on the external tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle followed by an on-pad visual inspection. High speed photography of the launch was analyzed to identify ice/debris sources and evaluate potential vehicle damage and/or in-flight anomalies. This report documents the ice/debris/ thermal protection system conditions and integrated photographic analysis of shuttle mission STS-59, and the resulting effect on the Space Shuttle Program.

Katnik, Gregory N.↗
NASA NTRS1995

Wire-Arc Spraying Of Metal Onto Insulating Foam

Wire-arc spraying used to deposit protective metallic coats on thermally insulating foams. Process relatively fast and cheap, and does not damage foam or involve toxic and polluting chemicals.

Bonds, James W., Jr.↗
NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt.% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF/HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damages at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, were observed especially for the combined LCF/HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗
NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF-HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damage at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, was observed especially for the combined LCF-HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗
NASA NTRS2003

Case Studies of Fatigue Life Improvement Using Low Plasticity Burnishing in Gas Turbine Engine Applications

Surface enhancement technologies such as shot peening, laser shock peening (LSP), and low plasticity burnishing (LPB) can provide substantial fatigue life improvement. However, to be effective, the compressive residual stresses that increase fatigue strength must be retained in service. For successful integration into turbine design, the process must be affordable and compatible with the manufacturing environment. LPB provides thermally stable compression of comparable magnitude and even greater depth than other methods, and can be performed in conventional machine shop environments on CNC machine tools. LPB provides a means to extend the fatigue lives of both new and legacy aircraft engines and ground-based turbines. Improving fatigue performance by introducing deep stable layers of compressive residual stress avoids the generally cost prohibitive alternative of modifying either material or design. The X-ray diffraction based background studies of thermal and mechanical stability of surface enhancement techniques are briefly reviewed, demonstrating the importance of minimizing cold work. The LPB process, tooling, and control systems are described. An overview of current research programs conducted for engine OEMs and the military to apply LPB to a variety of engine and aging aircraft components are presented. Fatigue performance and residual stress data developed to date for several case studies are presented including: * The effect of LPB on the fatigue performance of the nickel based super alloy IN718, showing fatigue benefit of thermal stability at engine temperatures. * An order of magnitude improvement in damage tolerance of LPB processed Ti-6-4 fan blade leading edges. * Elimination of the fretting fatigue debit for Ti-6-4 with prior LPB. * Corrosion fatigue mitigation with LPB in Carpenter 450 steel. *Damage tolerance improvement in 17-4PH steel. Where appropriate, the performance of LPB is compared to conventional shot peening after exposure to engine operating temperatures.

Prevey, Paul S.↗
NASA NTRS2006

Fission Surface Power for the Exploration and Colonization of Mars

The colonization of Mars will require abundant energy. One potential energy source is nuclear fission. Terrestrial fission systems are highly developed and have the demonstrated ability to safely produce tremendous amounts of energy. In space, fission systems not only have the potential to safely generate tremendous amounts of energy, but could also potentially be used on missions where alternatives are not practical. Programmatic risks such as cost and schedule are potential concerns with fission surface power (FSP) systems. To be mission enabling, FSP systems must be affordable and programmatic risk must be kept acceptably low to avoid jeopardizing exploration efforts that may rely on FSP. Initial FSP systems on Mars could be "workhorse" units sized to enable the establishment of a Mars base and the early growth of a colony. These systems could be nearly identical to FSP systems used on the moon. The systems could be designed to be safe, reliable, and have low development and recurring costs. Systems could also be designed to fit on relatively small landers. One potential option for an early Mars FSP system would be a 100 kWt class, NaK cooled system analogous to space reactors developed and flown under the U.S. "SNAP" program or those developed and flown by the former Soviet Union ("BUK" reactor). The systems could use highly developed fuel and materials. Water and Martian soil could be used to provide shielding. A modern, high-efficiency power conversion subsystem could be used to reduce required reactor thermal power. This, in turn, would reduce fuel burnup and radiation damage .effects by reducing "nuclear" fuels and materials development costs. A realistic, non-nuclear heated and fully integrated technology demonstration unit (TDU) could be used to reduce cost and programmatic uncertainties prior to initiating a flight program.

Houts, Mike↗
NASA NTRS2015

Lunar Plant Experiment: Testing Plant Germination in Lunar Gravity and Ionizing Radiation

We present an open design for a first plant growth module on the Moon (LPX). The primary science goal of lunar habitat is to investigate germination and initial plant growth when subject to the combined effects of lunar gravity and lunar surface radiation. The LPX module has been designed to be a flexible base unit that can be adapted to fly to the lunar surface on a variety of landers and rovers. LPX has size and shape of a 1 Unit CubeSat (10 centimeters on a side) and a total mass of 0.3 kilograms. The base will contain a seed module holding around 50 Arabidopsis seeds and provide approximately 0.5 liters of normal air at standard pressure. By the action of a small pump, water will be released after landing to initiate germination. Images will document the germination, initial growth, phototropism, and circumnutation of the small plants while sunlight remains available. A CO2 sensor tracks the release of CO2 during germination and the subsequent uptake of CO2 by photosynthesis. Simulations indicate that the CO2 peak level will be an increase by 2250 parts per million after 2 earth-days and then decline to about 1000 parts per million after 7 earth-days. The camera and CO2 sensor interfaces are USB. The water pump initiation requires a 5-volt signal. After initiation of germination by the addition of water, the habitat must be maintained above 22 degrees Centigrade to allow for plant growth and below 27 degrees Centigrade to prevent damage to the plants. This relatively tight temperature tolerance will require thermal control systems using reflecting surfaces and insulation that must be specifically designed for each lander or rover. The plant growth unit will function to tilt angles of 20 degrees along any axis. Total image data volume required to gauge the plant growth rate and leaf area is 1 megabyte (minimum data required) to 40 megabytes (preferred data). The lid of the habitat will allow adequate sunlight for plant growth. To provide for optimum growth, light levels in the plant growth stage need to be between 75 and 150 micromoles per meter squared per second interval.

first plant growth↗
NASA NTRS2020

Molecular Simulations of Ultrafast Radiation Induced Melting at Metal-Semiconductor Interfaces

Understanding radiation induced ultrafast melting at material interfaces is essential in designing robust electronic devices for aviation/space applications and in laser machining. While it is difficult to achieve the spatial and temporal resolution required to quantify the phenomenon experimentally, simulations can provide the detailed mechanisms of the structural changes that happen during phase transition. In this work, we use molecular simulations to study the effect of radiation damage on silicon carbide (SiC) - tungsten (W) interfaces which is of interest in high power electronics. A multi-scale approach is involved wherein the reactions at the interfaces are quantified using ab-initio molecular dynamics (MD) simulations and classical MD simulations are employed to understand the structural and diffusional changes across the material interface. Finally, coarse-grained Lennard-Jones type models are used to study the larger scale mechanisms and structures obtained due to the induced damages. We show that the response of the material to radiation damage depends on factors such as energy of the incident radiation, thermal properties, and molecular structure of the material.

Ravichandran, Ashwin↗
NASA NTRSDate not supplied

Technology Development of a Solid State 266 nm Laser for NASA’s Dragonfly Mission

NASA’s Dragonfly mission is a rotorcraft lander which will explore several geologic locations on Saturn’s moon, Titan and investigate evidence of surface-level prebiotic chemistry as well as search for chemical signatures of water-based and/or hydrocarbon-based life. To perform molecular composition investigations in-situ, the payload includes the Dragonfly Mass Spectrometer (DraMS), being developed at NASA’s Goddard Space Flight Center (GSFC). DraMS will utilize laser desorption mass spectrometry (LDMS) to interrogate surface samples and measure the organic composition. Enabling this science capability is the Throttled Hydrocarbon Analysis by Nanosecond Optical Source (THANOS) laser being developed at NASA-GSFC. The THANOS laser is comprised of a solid state, passively Q-Switched Nd:YAG oscillator which is frequency converted to 266 nm and utilizes a RTP high voltage electro-optic for pulse energy control. The laser outputs <2.0 ns pulses with a maximum energy of approximately 200 uJ which can be emitted in 1 - 50 shot bursts at 100 Hz while performing LDMS science operations. While operating, the laser has the capability to throttle its UV pulse energy output from full attenuation to maximum energy to provide varying levels of fluence on samples in the DraMS instrument. This paper reports the technology development and space qualification effort of the THANOS laser including vibration, thermal vacuum cycling, radiation as well as Titan atmospheric composition optical damage testing performed at NASA-GSFC from 2019 through 2022.

Matthew W Mullin↗
NASA NTRS1998

Simulated Solar Flare X-Ray and Thermal Cycling Durability Evaluation of Hubble Space Telescope Thermal Control Candidate Replacement Materials

During the Hubble Space Telescope (HST) second servicing mission (SM2), astronauts noticed that the multilayer insulation (MLI) covering the telescope was damaged. Large pieces of the outer layer of MLI (aluminized Teflon fluorinated ethylene propylene (Al-FEP)) were torn in several locations around the telescope. A piece of curled up Al-FEP was retrieved by the astronauts and was found to be severely embrittled, as witnessed by ground testing. Goddard Space Flight Center (GSFC) organized a HST MLI Failure Review Board (FRB) to determine the damage mechanism of FEP in the HST environment, and to recommend replacement insulation material to be installed on HST during the third servicing mission (SM3) in 1999. Candidate thermal control replacement materials were chosen by the FRB and tested for environmental durability under various exposures and durations. This paper describes durability testing of candidate materials which were exposed to charged particle radiation, simulated solar flare x-ray radiation and thermal cycling under load. Samples were evaluated for changes in solar absorptance and tear resistance. Descriptions of environmental exposures and durability evaluations of these materials are presented.

deGroh, Kim K.↗