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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 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
NASA NTRS1977

Effect of surface cooling and roughness on transition for the Shuttle Orbiter

An analysis of roughness-induced boundary-layer transition examines the sensitivity of the Orbiter boundary-layer transition criteria to surface cooling, to surface roughness, and to the assumed flow-field model. The experimental data were obtained using a 0.0175-scale Orbiter with surface roughness represented by misaligned heat-shield tiles for surface temperatures from 0.12 stagnation temperature (a value typical of entry conditions) to 0.42 stagnation temperature (a value typical of continuous-flow wind-tunnels). Tile misalignment had only a slight effect on the heat transfer and on the trasition locations for wall temperature = 0.42 stagnation temperature. Cooling the boundary layer caused the tile-induced disturbances to increase significantly, promoting premature transition. Correlation of the effects of the misalignment height and of surface cooling in promoting transition are presented and predictions are made for typical Orbiter entry conditions.

Bertin, J. J.↗
NASA NTRS2019

Effect of 3D Roughness Patch on Instability Amplification in a Supersonic Boundary Layer

Surface roughness is known to have a substantial impact on the aerothermodynamic loading of high-speed vehicles, particularly via its influence on the laminar-turbulent transition process within the boundary layer. Numerical simulations are performed to investigate the effects of a distributed region of densely packed, sinusoidal shape roughness elements on a Mach 3.5 flat plate boundary layer for flow conditions corresponding to the planned conditions of an upcoming experiment in the Mach 3.5 Supersonic Low Disturbance Tunnel at the NASA Langley Research Center. Analysis of convective instabilities in the wake of the roughness patch was reported in a previous paper and the current work extends that analysis to instability amplification across the length of the roughness patch. Quasi-parallel stability analysis of the modified boundary layer flow over the patch indicates two dominant families of unstable disturbances, namely, a group of high frequency modes that amplify in localized regions along the roughness patch and another group of low frequency modes that have smaller peak amplification rates but amplify steadily both above the roughness patch and in the wake region behind it. The results suggest that the amplification factors associated with the high-frequency modes are sufficiently low, at least for the roughness patches considered in this paper, so that these modes are unlikely to have a major influence on the transition process. The amplification of the low-frequency modes within the region of the roughness patch is further quantified via direct numerical simulations. Results confirm the strongly destabilizing influence of the roughness patch on the first mode instabilities, yielding an N-factor increment of ΔN ≈ 3.6 for a roughness patch length of eight wavelengths.

Laminar turbulent transition↗
NASA NTRS2023

BOLT II Forebody Surface Measurement Analysis

Surface impression molds of the nosetip/forebody interface, discrete tripping elements, and other surface imperfections were formed on the BOLT II flight vehicle prior to its launch in March 2022. The silicon-rubber molds cast on the interface between the nickel nosetip and the stainless steel forebody were measured using a 3D optical measurement system and a stylus profilometer and were evaluated for step direction and height. The step around the nosetip/forebody interface was found to vary in both magnitude and direction, but values were generally modest with most samples below 60 μm across the span and only two samples, both cast in the gutter, with step values larger than 100 μm. Impressions of the secondary-side tripping elements were strictly scanned with the optical device and similar methods were used to calculate trip height as step height. The measured centerline trip height was 2623 ±12 μm, while the leading-edge, quadrant 2 and 3, trip heights were 897 ±5 μm and 891 ±18 μm, respectively. Surface imperfections on the nose and forebody were also evaluated. Surface roughness values and spectra were estimated, and profiles were extracted across the imperfections to quantify the magnitude of those features.

Trip height↗
NASA NTRS1980

Radar observation of snowpacks

Radar observations of snowpacks were made at test sites in Kansas, South Dakota, and Colorado using truck mounted scatterometers covering the 1 to 18 GHz frequency range and the atmospheric window frequency of 35 GHz. Experiments were conducted as a function of snow depth, wetness, and surface roughness. The acquired data were used to model the backscattering coefficient in terms of snow and underlying soil parameters. The results indicate that the radar return (1) increase with increasing water equivalent; (2) decrease with increasing wetness; (3) is sensitive to the snow surface roughness only when the snow is wet;(4) is sensitive to the state (frozen or thawed) of the underlying soil if the snow is dry; and (5) is repetitive from one site to another and from one season to the next. Additionally, the measurements indicate the multifrequency observation or day-night observations may potentially provide the means for monitoring snow water equivalent, snow wetness, and the soil state.

Stiles, W. H.↗
NASA NTRS2011

Sea Surface Salinity and Wind Retrieval Algorithm Using Combined Passive-Active L-Band Microwave Data

Aquarius is a combined passive/active L-band microwave instrument developed to map the salinity field at the surface of the ocean from space. The data will support studies of the coupling between ocean circulation, the global water cycle, and climate. The primary science objective of this mission is to monitor the seasonal and interannual variation of the large scale features of the surface salinity field in the open ocean with a spatial resolution of 150 kilometers and a retrieval accuracy of 0.2 practical salinity units globally on a monthly basis. The measurement principle is based on the response of the L-band (1.413 gigahertz) sea surface brightness temperatures (T (sub B)) to sea surface salinity. To achieve the required 0.2 practical salinity units accuracy, the impact of sea surface roughness (e.g. wind-generated ripples and waves) along with several factors on the observed brightness temperature has to be corrected to better than a few tenths of a degree Kelvin. To the end, Aquarius includes a scatterometer to help correct for this surface roughness effect.

ocean salinity↗
DOE OSTI2025

Understanding Geometry and Microstructure Interactions In LPBF By Linking Lab Scale Studies To Real Part Case Examples

The mechanical properties derived from simple tensile tests are uniquely important in the design and qualification of load bearing metallic components. The tensile properties in standards for wrought metallic materials are generally accessible for design and simulation engineers, but this is not the case for additively manufactured metals. This work investigates the influence of tensile specimen geometry on the mechanical properties of laser powder bed fusion (LPBF) additively manufactured Ti-6Al-4V, particularly in relation to properties measured from specimens excised from an exemplar part. A comprehensive analysis was conducted across various specimen geometries, considering factors such as thermal history, cross-sectional area, shape, and surface roughness. Key findings reveal that sample size, particularly cross-sectional area, significantly affects reported tensile properties, with ASTM E8 flat and round specimens exhibiting differences in elastic modulus (13%), yield strength (17%), ultimate tensile strength (UTS) (14%), and elongation to failure (11%). Additionally, surface roughness was found to have a limited impact on ASTM round geometries, but it becomes critical in thin-walled and small high-throughput samples. The ASTM flat samples closely matched the properties of samples excised from the exemplar part, underscoring the necessity of testing witness samples that accurately represent end-use conditions. Furthermore, mechanical properties of samples built within the stitch zone of the exemplar part demonstrated reduced ductility, highlighting the importance of laser alignment and qualification in multi-laser additive manufacturing processes. Overall, this study emphasizes the need for careful consideration of specimen geometry and testing conditions to ensure accurate reporting of mechanical properties in LPBF Ti-6Al-4V.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Glaciological studies in the central Andes using AIRSAR/TOPSAR

The interaction of climate and topography in mountainous regions is dramatically expressed in the spatial distribution of glaciers and snowcover. Monitoring existing alpine glaciers and snow extent provides insight into the present mountain climate system and how it is changing, while mapping the positions of former glaciers as recorded in landforms such as cirques and moraines provide a record of the large past climate change associated with the last glacial maximum. The Andes are an ideal mountain range in which to study the response of snow and ice to past and present climate change. Their expansive latitudinal extent offers the opportunity to study glaciers in diverse climate settings from the tropical glaciers of Peru and Bolivia to the ice caps and tide-water glaciers of sub-polar Patagonia. SAR has advantages over traditional passive remote sensing instruments for monitoring present snow and ice and differentiating moraine relative ages. The cloud penetrating ability of SAR is indispensable for perennially cloud covered mountains. Snow and ice facies can be distinguished from SAR's response to surface roughness, liquid water content and grain size distribution. The combination of SAR with a coregestered high-resolution DEM (TOPSAR) provides a promising tool for measuring glacier change in three dimensions, thus allowing ice volume change to be measured directly. The change in moraine surface roughness over time enables SAR to differentiate older from younger moraines. Polarimetric SAR data have been used to distinguish snow and ice facies and relatively date moraines. However, both algorithms are still experimental and require ground truth verification. We plan to extend the SAR classification of snow and ice facies and moraine age beyond the ground truth sites to throughout the Cordillera Real to provide a regional view of past and present snow and ice. The high resolution DEM will enhance the SAR moraine dating technique by discriminating relative ages based on moraine slope degradation.

Forster, Richard R.↗
DOE OSTI2024

Modeling the Impact of Grain Size on Corrosion Behavior of Ni-Based Alloys in Molten Chloride Salt via Cellular Automata

Molten chloride salts hold significant promise as both thermal transfer and storage media for next-generation concentrated solar power (CSP) systems. However, molten chlorides pose a considerable corrosion risk to structural materials, particularly Ni-based alloys. One approach to enhancing corrosion resistance is through the optimization of grain structure; however, it remains uncertain whether increasing or decreasing grain size enhances corrosion resistance. A cellular automata (CA) program was developed to evaluate the interplay between grain size and corrosion in Ni-based alloy. Our CA program tracks alloy composition, surface roughness, and thickness loss via a graphical user interface, displaying corrosion and diffusion status, and multiple user input cards for tuning the simulation. CA simulations of Inconel 625 indicate enhanced corrosion resistance with increased grain size, with passivating oxides offering limited protection. Additionally, the temporal evolution of alloy surface roughness demonstrates notable fluctuations, with abrupt increases attributed to corrosion along vertical grain boundaries and sudden decreases to grain detachment from the protective film.

Materials Science↗
NASA NTRS1974

Refinement in black chrome for use as a solar selective coating

Black chrome is significant as a solar selective coating because the current extensive use of black chrome in the electroplating industry as a durable decorative finish makes black chrome widely available on a commercial scale and potentially low in cost as a solar selective coating. Black-chrome deposits were modified by underplating with dull nickel or by being plated on rough surfaces. Both of these procedures increased the visible absorptance. There was no change in the infrared reflectance for the dull-nickel - black-chrome combination from that reported for the bright-nickel - black-chrome combination. However, the bright-nickel - black-chrome coating plated on rough surfaces indicated a slight decrease in infrared reflectance. As integrated over the solar spectrum for air mass 2, the reflectance of the dull-nickel - black-chrome coating was 0.077, of the bright-nickel - black-chrome coating plated on a 0.75-micron (30-microinch) surface was 0.070, of the bright-nickel - black-chrome coating plated on a 2.5 micron (100-microinch) surface was 0.064. The corresponding values for the bright-nickel - black-chrome coating on a 0.0125-micron (0.5-microinch) surface, two samples of black nickel, and two samples of Nextrel black paint were 0.132, 0.123, 0.133, and 0.033, respectively.

Mcdonald, G. E.↗
NASA NTRS1993

Comparison of inversion models using AIRSAR data for Death Valley, California

Polarimetric Airborne Synthetic Aperture Radar (AIRSAR) data were collected for the Geologic Remote Sensing Field Experiment (GRSFE) over Death Valley, California, USA, in September 1989. AIRSAR is a four-look, quid-polarizaiton, three frequency instrument. It collects measurements at C-band (5.66 cm), L-band (23.98 cm), and P-band (68.13 cm), and has a GIFOV of 10 meters and a swath width of 12 kilometers. Because the radar measures at three wavelengths, different scales of surface roughness are measured. Also, dielectric constants can be calculated from the data. The scene used in this study is in Death Valley, California and is located over Trail Canyon alluvial fan, the valley floor, and Artists Drive alluvial fan. The fans are very different in mineralogic makeup, size, and surface roughness. Trail Canyon fan is located on the west side of the valley at the base of the Panamint Range and is a large fan with older areas of desert pavement and younger active channels. The source for the material on southern part of the fan is mostly quartzites and there is an area of carbonate source on the northern part of the fan. Artists Drive fan is located at the base of the Black Mountains on the east side of the valley and is a smaller, young fan with its source mostly from volcanic rocks. The valley floor contains playa and salt deposits that range from smooth to Devil's Golf course type salt pinnacles.

Kierein-Young, Kathryn S.↗
NASA NTRS1996

Application of the kappa-omega Turbulence Model to Quasi-Three-Dimensional Turbomachinery Flows

Many computational fluid dynamics codes for turbomachinery use the Baldwin-Lomax (B-L) turbulence model. It is easy to implement in two dimensions and works well for predicting overall turbomachinery performance. However, it is awkward to implement in three dimensions, often has difficulty finding the length scale, has a crude transition model, and neglects freestream turbulence, surface roughness, and mass injection. The kappa-omega model developed by Wilcox is an appealing alternative for several reasons. First, it is the only two-equation model that can be integrated to the wall without requiring damping functions or the distance to the wall, and hence, should behave well numerically. Second, the effects of freestream turbulence, surface roughness, and mass injection are easily included in the model. Finally, transition can be simulated using the low Reynolds number version of the model. Menter applied the kappa-model to external flows and showed very good results for flows with adverse pressure gradients. Liu and Zheng described their implementation of the kappa-model in a cascade code that included an area change term to account for endwall convergence. They validated the model for a flat plate, and compared the B-L and kappa-models to measured surface pressures for a low-pressure turbine cascade. Since they did not use the low Reynolds number version of the model, their results showed problems resulting from early transition. In this Note the low Reynolds number kappa-model was incorporated in the author's quasi-three-dimensional turbomachinery analysis code. The code includes the effects of rotation, radius change, and stream-surface thickness variation, and also includes the B-L turbulence model. The kappa-omega model was implemented using many of Menter's recommendations and an implicit approximate-factorization scheme described by Baldwin and Barth. The model was tested for a transonic compressor with rotation and variable stream-surface radius and height, and for a transonic turbine vane with transition and heat transfer. Results were compared to the B-L model and to experimental data.

Chima, Rodrick V.↗
NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗
NASA NTRS2018

Characterizing Performance of Additively Manufacturing Regenerative Cooled Combustion Chambers Through Hot Fire Testing

NASA Marshall Space Flight Center (MSFC) has developed several additive manufactured regenerative cooled combustion chambers from 2014 to present. Chambers have been constructed using the Selective Laser Melting (SLM) powder bed additive manufacturing (AM) technique. The materials used for the chambers has varied from Inconel 718, Inconel 625, GRCop-84, and C18150 metal alloys. The surface finish and build techniques used to successfully manufacture combustion chambers using the SLM AM result in as built surface finish and off nominal geometric features. This paper discusses and reviews the effects of surface roughness, flow area, and hydraulic performance of regenerative cooled combustion chambers. The thrust chambers designs tested ranged from 200 to 1,400 psia producing 1,000 to 35,000 lbf thrust. Empirical data from four test campaigns will be reviewed and related to design modeling parameters such as pressure drop, surface roughness, and actual fluid flow geometry. Correlation results with simple 2-D CFD modeling will also be presented. The goal of the work is to better understand how the finished additive manufactured component characteristics inside internal features can effect regenerative cooling chamber design. Adjustments to design methodology will be discussed and recommended based on the above results.

Garcia, C. P.↗
DOE OSTI2022

Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls

Thin-walled features can be difficult to produce with traditional machining methods which often rely on excess stock material for stiffness. This challenge is increased in hybrid manufacturing where the feature is already near net shape before machining. Significant workpiece deflection can result in poor geometric and surface finish tolerances on the finished part. A potential solution to this problem is to implement sacrificial support structures to the as-printed geometry. The supports are then machined away during the finishing portion of the hybrid process. In the present work, several different design parameters for these sacrificial supports were evaluated to determine their impact on the quality of representative thin wall geometry samples. The angle, height, and spacing of triangular support structures were varied for each sample and then machined and examined. The addition of these supports relative to an unsupported configuration provided a deflection reduction of around 0.2 mm. Surface roughness was improved by approximately 1.5 µm. Increasing values of support height were found to correspond to reduced wall deflection. Similarly, decreasing values of support angle and support spacing improved geometric accuracy. Efficiency comparisons showed that increases in print time corresponded to rapidly diminishing gains in geometric accuracy but continued to improve surface roughness. Implications for hybrid finishing of additively manufactured thin-walled structures is briefly discussed.

36 MATERIALS SCIENCE↗
NASA NTRS1961

Heat Transfer and Boundary-Layer Transition on a Highly Polished Hemisphere-Cone in Free Flight at Mach Numbers Up to 3.14 and Reynolds Numbers Up to 24 x 10(exp 6)

A highly polished hemisphere-cone having a ratio of nose radius to base radius of 0.74 and a half-angle of 14.5 was flight tested at Mach numbers up to 4.70. Temperature and pressure data were obtained at Mach numbers up to 3.14 and a free-stream Reynolds number of 24 x 10(exp 6) based on body diameter. The nose of the model had a surface roughness of 2 to 5 microinches as measured with an interferometer. The measured Stanton numbers were in good agreement with theory. Transition Reynolds numbers based on the laminar boundary-layer momentum thickness at transition ranged from 2,190 to 794. Comparison with results from previous tests of blunt shapes having a surface roughness of 20 to 40 microinches showed that the high degree of polish was instrumental in delaying the transition from laminar to turbulent flow.

Buglia, James J.↗
DOE OSTI2020

Interactions between atmospheric pressure plasmas and metallic catalyst particles in packed bed reactors

Atmospheric-pressure plasmas sustained in packed bed reactors (PBRs) are being investigated for chemical conversion of gases and pollution control. Metallic catalysts added to the surfaces of the dielectric beads of PBRs can increase the energy efficiency and selectivity of chemical processes by reducing operating temperature and providing additional reaction pathways. In this paper, results from a computational investigation of plasma surface interactions between micron-scale metallic catalysts and humid-air plasmas in PBRs are discussed. Here we found that high plasma density regions form in the proximity of the metallic catalysts. These higher-density plasma regions were confirmed experimentally using ICCD imaging. The intense plasmas result from geometrical electric field enhancement and redistribution of charges within the conductive particles, leading to further enhancement. The high electric field at the triple points of the catalysts can produce electric field emission of electrons, which provides a pre-ionization source or additional source of electrons. These regions of high electric field and sources of electrons guide discharges towards the catalysts and increases fluxes of excited species, ions, electrons and photons to their surfaces. These fluxes are focused primarily at the triple points between the metal, dielectric and gas. As a result, the catalyst is locally heated, which could lead to further increased rates of thermocatalytic reactions on the surface. Surface roughness of the metal inclusions can lead to additional electric field enhancement, which changes the character of the discharges in the vicinity of the catalysts while reducing breakdown voltage.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1961

Local Aerodynamic Heat Transfer and Boundary-Layer Transition on Roughened Sphere-Ellipsoid Bodies at Mach Number 3.0

A wind-tunnel investigation was made to determine heat-transfer distributions on three steel sphere-ellipsoid bodies with surface roughnesses of 5, 100, and 200 microinches. Tests were conducted in the Langley 9- by 6-foot thermal structures tunnel at a Mach number of 3.0, free-stream Reynolds numbers (based on model spherical diameter) of 4.25 x 10(exp 6) and 2.76 x l0(exp 6), and at a stagnation temperature of 650 F. Pressure distributions were obtained also on a fourth model. The results indicated that the combination of surface roughness and boundary-layer cooling tended to promote early transition and nullify the advantages attributable to the blunt shape of the model for reducing local temperatures. Good correlation between experimental heating rates and those calculated from laminar theory was achieved up to the start of boundary-layer transition. The correlation also was good with the values predicted by turbulent theory for surface stations downstream from the 45 deg. station.

Deveikis, William D.↗