Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “PROCESS HEAT”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Sodium Heat Pipe Module Processing For the SAFE-100 Reactor Concept

To support development and hardware-based testing of various space reactor concepts, the Early Flight Fission-Test Facility (EFF-TF) team established a specialized glove box unit with ancillary systems to handle/process alkali metals. Recently, these systems have been commissioned with sodium supporting the fill of stainless steel heat pipe modules for use with a 100 kW thermal heat pipe reactor design. As part of this effort, procedures were developed and refined to govern each segment of the process covering: fill, leak check, vacuum processing, weld closeout, and final "wet in". A series of 316 stainless steel modules, used as precursors to the actual 321 stainless steel modules, were filled with 35 +/- 1 grams of sodium using a known volume canister to control the dispensed mass. Each module was leak checked to less than10(exp -10) std cc/sec helium and vacuum conditioned at 250 C to assist in the removal of trapped gases. A welding procedure was developed to close out the fill stem preventing external gases from entering the evacuated module. Finally the completed modules were vacuum fired at 750 C allowing the sodium to fully wet the internal surface and wick structure of the heat pipe module.

Martin, James↗
DOE OSTI2012

West Village Community: Quality Management Processes and Preliminary Heat Pump Water Heater Performance

West Village, a multi-use project underway at the University of California Davis, represents a ground-breaking sustainable community incorporating energy efficiency measures and on-site renewable generation to achieve community-level Zero Net Energy (ZNE) goals. When complete, the project will provide housing for students, faculty, and staff with a vision to minimize the community’s impact on energy use by reducing building energy use, providing on-site generation, and encouraging alternative forms of transportation. This focus of this research is on the 192 student apartments that were completed in 2011 under Phase I of the West Village multi-year project. The numerous aggressive energy efficiency measures implemented result in estimated source energy savings of 37% over the B10 Benchmark. There are two primary objectives of this research. The first is to evaluate performance and efficiency of the central heat pump water heaters as a strategy to provide efficient electric water heating for net-zero all-electric buildings and where natural gas is not available on site. In addition, effectiveness of the quality assurance and quality control processes implemented to ensure proper system commissioning and to meet program participation requirements is evaluated. Recommendations for improvements that could improve successful implementation for large-scale, high performance communities are identified.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1985

Heat flow and thermal processes in the Jornada delMuerto, New Mexico

Most heat flow data in rifts are uncertain largely because of hydrologic disturbances in regions of extensive fracturing. Estimates of heat flow in deep petroleum tests within a large basin of the Rio Grande rift, which has suffered little syn-rift fracturing, may begin to provide clearer insight into the relationships between high heat flow and crustal thinning processes. The Jornada del Muerto is a large basin located in the Rio Grande rift of south central New Mexico. The region of interest within the Jornada del Muerto is centered about 30 km east of the town of Truth or Consequences, and is approximately 60 km north-south by 30 km east-west. High heat flows are estimated for the region. Values increase from about 90 mWm(-2) in the northern part of the study area to about 125 mWm(-2) in the southern part. These high heat flows are rather enigmatic because in the immediate vicinities of the sites there is little evidence of Cenozoic volcanism or syn-rift extensional tectonics. It is suggested that the geothermal anomaly in the southern Jornada del Muerto (approx. 125 to approx. 95 mWm(-2) results from some type of mass movement-heat transfer mechanism operating in the crust just below the elastic layer. This conclusion is consistent with the geologic and geophysical data which describe a thin crust, apparently devoid of features indicative of extensional-tectonics in the upper part of the lastic crust.

Reiter, M.↗
DOE OSTI2024

A Gaussian Process-Based extended Goldak heat source model for finite element simulation of laser powder bed fusion additive manufacturing process

In this study, laser powder bed fusion (L-PBF) additive manufacturing (AM) is a key enabling technology to manufacture highly complex and integrated metallic structures. In L-PBF AM process, the melting of the metal powders and the layers underneath can be governed by either “conduction mode” or “keyhole mode”, with the keyhole mode reportedly leading to porosity and decreased strength and ductility by many studies. In part scale simulations, finite element (FE) model is often used to study the temperature distribution during printing and to predict the residual stress, where a volumetric heat flux with a Gaussian or a double ellipsoidal (Goldak) distribution is often applied as the laser heat source. However, the above heat source models can only capture the melt pool shape in the conduction mode, and fail to capture the transition to keyhole melting mode when the process parameters change. To overcome this inaccuracy, an extended Goldak heat source model is proposed by introducing a laser penetration term as a function of laser parameters obtained from a Gaussian-Process (GP) model. The model is validated by “2D pad” AlSi10Mg L-PBF experiments under a wide range of laser power, scan speed, and laser focus offset, and the results show the model successfully captures the measured melt pool shape in all conditions.

36 MATERIALS SCIENCE↗
NASA NTRS2011

Method for Selective Cleaning of Mold Release from Composite Honeycomb Surfaces

Honeycomb structures are commonly employed as load- and force-bearing structures as they are structurally strong and lightweight. Manufacturing processes for heat-molded composite honeycomb structures commence with the placement of pre-impregnated composite layups over metal mandrels. To prevent permanent bonding between the composite layup and the metal mandrels, an agent, known as a mold release agent, is used. Mold release agents allow the molded composite material to be removed from mandrels after a heat-forming process. Without a specific removal process, mold release agents may continue to adhere to the surface of the composite material, thereby affecting the bonding of other materials that may come into contact with the composite surface in later stages of processing A constituent common to commercially available household cleaning agents is employed for the removal of mold release agents common to the manufacturing of heat-formed composite materials. The reliability of the solvent has been proven by the longevity and reliability of commercial household cleaners. At the time of this reporting, no one has attempted using constituent for this purpose. The material to be cleaned is immersed in the solution, vertically removed so that the solution is allowed to drain along cell walls and into a solvent bath, and then placed on a compressed airflow table for drying.

Pugel, Diane↗
DOE OSTI2019

Estimation of and barriers to waste heat recovery from harsh environments in industrial processes

This paper discusses the industrial potential for waste heat recovery (WHR) in harsh environments – defined as a waste heat stream having either a temperature of at least 650 °C or containing reactive constituents that complicate heat recovery. The analysis covers five industries (steel, aluminum, glass, cement, and lime), chosen based on volume of production, discharge of exhaust gases containing components that present harsh environments, possibility of recovering considerably more heat than currently recovered, and current lack of acceptable WHR options. The total potential energy savings identified in harsh environment waste heat streams from these industries is equal to 15.4% (113.6 TWh) of the process heat energy lost in U.S. manufacturing. Existing technologies and materials for these industries are evaluated and the recoverable waste heat from harsh environment gas for each industrial sector is estimated. Finally, an in-depth summary of each waste heat source shows exactly where waste heat can be recovered and what specific issues must be addressed. The most potential lies within steel blast furnaces (46 TWh/year). Other waste heat streams considered include steel electric arc furnaces (14.1 TWh/year), flat glass (3.6 TWh/year), container glass (5.7 TWh/year), glass fiber (1.1 TWh/year), specialty glass (2.2 TWh/year), aluminum melting furnaces (4.7 TWh/year), cement (17.1 TWh/year), and lime (10.5 TWh/year). Furthermore attempts to recover waste heat in harsh environments have been mostly unsuccessful, advances in research and technology could unlock an enormous potential for energy and cost savings.

42 ENGINEERING↗
DOE OSTI2021

Experimental investigation of elemental and isotopic evaporation processes by laser heating in an aerodynamic levitation furnace

In this report we carried out evaporation experiments on a B-type calcium–aluminium-rich inclusion (CAI) melt in a gas-mixing aerodynamic levitation laser furnace, at 1873 K and an oxygen partial pressure of 10 -9.1 atm, for durations ranging from 60 to 600 s. Evaporation of SiO 2 and MgO follow the same trend as those observed in vacuum furnace experiments at the same temperature and starting composition, showing that their evaporation relative to one another from the melt is independent of pressure, oxygen fugacity, and hydrodynamical regime specific to the furnace. Isotopic ratios of Mg and Si in evaporation residues are used to derive fractionation factors of α 26/24 Mg vap-liq = 0.9906± 0.0004 and α 30/28 Si vap-lip = 0.9943±0.0003, which are both significantly closer to unity than those found for evaporation in a vacuum, which translates to less isotope fractionation. The residues are also less isotopically fractionated than expected for cases in which transport of the gas species away from the melt is diffusion-controlled at 1-atm. By analysing the flow regimes in our furnace, we find that advection by the levitating gas is the primary mode of mass transport away from the melt surface, as opposed to diffusion-limited transport in a vacuum or 1-atm tube furnace. A modified Hertz–Knudsen–Langmuir formulation accounts for this process, and shows that isotopic fractionation of both Si and Mg reflect a saturation factor (ratio of the pressure of the evaporating species to vapour saturation pressure) equal to 0.75. This is in perfect accord with recent measurements of Cu isotopic fractionation using a similar furnace. The fact that three elements (Mg, Si, Cu) with varying equilibrium vapour pressures, activity coefficients in the liquid, and diffusion coefficients in the gas have the same scaling behaviour to saturation pressure is a strong indication that the mechanism controlling evaporation is driven by the hydrodynamical regime imposed in the furnace. Therefore, this class of experiments can be used to constrain processes in which advection dominates over diffusion, such as (but not limited to) planetary ejecta, tektites, giant impacts, nebular condensation in a turbulent flow, or nuclear fallout material. Finally, the possibility to reach high temperatures (in excess of 3500 K) in this furnace allows it to be used to evaluate the activity coefficients of melt components in extreme conditions relevant to molten planetary interiors (i.e., magma oceans), with a specific focus on refractory elements.

58 GEOSCIENCES↗
DOE OSTI2013

Diffusion-Welded Microchannel Heat Exchanger for Industrial Processes

The goal of next generation reactors is to increase energy ef?ciency in the production of electricity and provide high-temperature heat for industrial processes. The ef?cient transfer of energy for industrial applications depends on the ability to incorporate effective heat exchangers between the nuclear heat transport system and the industrial process. The need for ef?ciency, compactness, and safety challenge the boundaries of existing heat exchanger technology. Various studies have been performed in attempts to update the secondary heat exchanger that is downstream of the primary heat exchanger, mostly because its performance is strongly tied to the ability to employ more ef?cient industrial processes. Modern compact heat exchangers can provide high compactness, a measure of the ratio of surface area-to-volume of a heat exchange. The microchannel heat exchanger studied here is a plate-type, robust heat exchanger that combines compactness, low pressure drop, high effectiveness, and the ability to operate with a very large pressure differential between hot and cold sides. The plates are etched and thereafter joined by diffusion welding, resulting in extremely strong all-metal heat exchanger cores. After bonding, any number of core blocks can be welded together to provide the required ?ow capacity. This study explores the microchannel heat exchanger and draws conclusions about diffusion welding/bonding for joining heat exchanger plates, with both experimental and computational modeling, along with existing challenges and gaps. Also, presented is a thermal design method for determining overall design speci?cations for a microchannel printed circuit heat exchanger for both supercritical (24 MPa) and subcritical (17 MPa) Rankine power cycles.

42 ENGINEERING↗
DOE OSTI2017

Microstructure Evolution During Continuous Cooling in AISI 5140 Steel Processed by Induction Heating Chromizing

In this study, induction heating chromizing (IHC) and box-type furnace heating chromizing (BFHC) were conducted on commercial AISI 5140 steels, respectively. Microstructure, microhardness and wear resistance of the chromized samples were characterized. The results show that the IHC samples have thicker Cr coating layer and stronger interface bond due to pre-compressive stress among the packed powders. Three kinds of microstructures including alloyed cementite (AC-layer), fine pearlite zone (FP-zone) and carbon-poor zone (CP-zone) are formed near the interface in the IHC samples. The main reason given for this is that different contents of Cr and C have different effects on pearlite phase and morphology. The IHC sample shows better wear properties due to its stronger interface bonding strength than that of the BFHC sample. The formation mechanism of CP-zone and its influences on microhardness and wear resistance are also discussed.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Improved silicon carbide for advanced heat engines. I - Process development for injection molding

Alternate processing methods have been investigated as a means of improving the mechanical properties of injection-molded SiC. Various mixing processes (dry, high-sheer, and fluid) were evaluated along with the morphology and particle size of the starting beta-SiC powder. Statistically-designed experiments were used to determine significant effects and interactions of variables in the mixing, injection molding, and binder removal process steps. Improvements in mechanical strength can be correlated with the reduction in flaw size observed in the injection molded green bodies obtained with improved processing methods.

Whalen, Thomas J.↗
NASA NTRS1995

A probabilistic model of a porous heat exchanger

This paper presents a probabilistic one-dimensional finite element model for heat transfer processes in porous heat exchangers. The Galerkin approach is used to develop the finite element matrices. Some of the submatrices are asymmetric due to the presence of the flow term. The Neumann expansion is used to write the temperature distribution as a series of random variables, and the expectation operator is applied to obtain the mean and deviation statistics. To demonstrate the feasibility of the formulation, a one-dimensional model of heat transfer phenomenon in superfluid flow through a porous media is considered. Results of this formulation agree well with the Monte-Carlo simulations and the analytical solutions. Although the numerical experiments are confined to parametric random variables, a formulation is presented to account for the random spatial variations.

Agrawal, O. P.↗
NASA NTRSDate not supplied

Multi-Anvil Experimentation Applied to Planetary Differentiation

Planets undergo differentiation that includes segregation of metal from silicate at high temperatures and pressures ranging from deep planetary core pressures (>300 GPa for Earth)to very shallow conditions of asteroids (<100 MPa).The multi-anvil solid media apparatus accesses the middle part of this range from 3 to 30 GPa –pressure relevant to the interior of Mercury, Venus, Earth, Earth’s Moon, and Mars. Early planets are thought to have experienced high temperatures from a combination of heat sources including radioactive decay, gravitational and accretional heating, and impact processes. These heating events led to melting of mantles and cores, thus requiring an understanding of solid-liquid equilibria in metal-silicate systems. In 2006 we established a multi-anvil facility at NASA-JSC combining an 880 ton press and a Kawai/Walker type module from Rockland Research. Our high PT work has been greatly facilitated by use of the COMPRES multi-anvil assemblies (1). Our recent work has included studies of element partitioning between liquid metal and liquid silicate(e.g., 2), as well as between minerals and melts(e.g., 3), both of which have led to better constraints on the timing and conditions of planetary differentiation(e.g. 4). Several examples involving sustained efforts will be summarized below and for the presentation. The distribution of siderophile (iron-loving) elements between core and mantle is controlled by metal-silicate equilibrium across a wide range of pressures. Therefore, experimentation across this pressure range helps to calibrate elemental partitioning models that can be applied to planets, and used to predict mantle chemistry and composition during planetary differentiation. Our studies have focused on a wide range of siderophile elements (refractory Ni, Co, W, Mo; volatile P, Ga, Cu, Sn, Sb; highly siderophile Au, Pd) that have constrained partitioning, valence, and isotopic fractionation, and applied to Earth, Moon, and Mars. When molten mantles (magma oceans) cool enough to initiate crystallization, the solids precipitate at depth and in large planets this involves high pressure phases like garnet, majorite, akimotoite, and ringwoodite. As these solids precipitate they can segregate from liquid by density contrasts, thus causing elemental fractionation which can be used to decipher timing of differentiation. Mineral/melt and metal/silicate equilibria in our lab have helped to better understand high pressure fractionation of isotopic parent/daughter pairs Hf/W, Mn/Cr, Pd/Ag, Pt/Os, Re/Os, and U/Pb, and their application to Earth, Moon and Mars. There remains great potential for multi-anvil experimentation to shed light on many pressure–dependent aspects of planetary evolution such as core formation, high pressure phase equilibria, redox equilibria, and volatile evolution and storage. References1. Leinenweber, K., et al.(2012) American Mineralogist,97, 353–368. 2.Righter, K., et al.(2020) Geochem. Persp. Lett.15, 1-6.3. Righter, K., et al.(2020) Met. Planet. Sci 55, 2741-2757.4. Righter, K., et al.(2020)Earth and Planetary Science Letters,552, 116590.

pressure↗
DOE OSTI2020

Advanced cast aluminum alloys for automotive engine application with superior high-temperature properties

A high fatigue strength aluminum alloy comprises in weight percent copper 3.0-3.5%, iron 0-1.3%, magnesium 0.24-0.35%, manganese 0-0.8%, silicon 6.5-12.0%, strontium 0-0.025%, titanium 0.05-0.2%, vanadium 0.20-0.35%, zinc 0-3.0%, zirconium 0.2-0.4%, a maximum of 0.5% other elements and balance aluminum plus impurities. The alloy defines a microstructure having an aluminum matrix with the Zr and the V in solid solution after solidification. The matrix has solid solution Zr of at least 0.16% after heat treatment and solid solution V of at least 0.20% after heat treatment, and both Cu and Mg are dissolved into the aluminum matrix during the heat treatment and subsequently precipitated during the heat treatment. A process for heat treating an Al—Si—Cu—Mg—Fe—Zn—Mn—Sr-TMs alloy comprises heat treating the alloy to produce a microstructure having a matrix with Zr and V in solid solution after solidification.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Numerical study of plasma generation process and internal antenna heat loadings in J-PARC RF negative ion source

A numerical model of plasma transport and electromagnetic field in the J-PARC (Japan Proton Accelerator Research Complex) radio frequency ion source has been developed to understand the relation between antenna coil heat loadings and plasma production/transport processes. From the calculation, the local plasma density increase is observed in the region close to the antenna coil. Electrons are magnetized by the magnetic field line with absolute magnetic flux density 30–120 Gauss which leads to high local ionization rate. The results suggest that modification of magnetic configuration can be made to reduce plasma heat flux onto the antenna.

43 PARTICLE ACCELERATORS↗