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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 811 records · Page 45

Crystal Growth in the SUBSA furnace in MSG: 2002 to 2022

In 2002, the investigation “Solidification Using a Baffle In Sealed Ampoules (SUBSA)” was the first investigation to utilize the Microgravity Science Glovebox (MSG) Facility on the International Space Station (ISS). The SUBSA furnace was designed for growth of indium antimonide. It features a transparent section, which allows a side view of the melt, the solid-liquid (SL) interface and the growing crystal. In 2002, four Te-doped and three Zn-doped InSb crystals were grown in microgravity. Subsequently, the SUBSA furnace was used in several materials science investigations, including growing the radiation detector materials, InI and Cs2LiYCl6:Ce from the melt and vapor phase (2017 to 2019) and “Brazing of Aluminum alloys in Space (BRAINS)”. A review of the SUBSA furnace features and parameters will be presented, including the design of the growth ampoules, charge preparation, and the procedures used to grow InSb (in 2002) and InI (in 2019).

Aleksandar Ostrogorsky↗

Prometheus and Constellation Materials Research and Testing Overview

Outline - New Technologies and New Materials meet Flight Program - Reactor Materials Selection - Material Radiation Resistance - Testing in four different radiation environments - Superalloy Creep Testing - Superalloy-Refractory Alloy Joining - Superalloy, Stainless Steel, Copper Brazing - Superalloy-Refractory Cross Contamination - Na and NaK Compatibility - Radiator Panel Materials Selection

nuclear power↗

Crystal Growth in the SUBSA furnace at the International Space Station (ISS)

In 2002, our investigation Solidification Using a Baffle In Sealed Ampoules (SUBSA) was the first investigation to utilize the Microgravity Science Glovebox (MSG) Facility on the International Space Station (ISS). The SUBSA furnace was designed for growth of indium antimonide. It features a transparent section, which allows a side view of the melt, the solid-liquid (SL) interface and the growing crystal. In 2002, four Te- doped and three Zn-doped InSb crystals were grown in microgravity. Subsequently, the SUBSA furnace was used in several other materials science investigations, including growing the radiation detector materials InI and Cs2LiYCl6:Ce from the melt and vapor phase (2017 to 2019) and Brazing of Aluminum alloys in Space (BRAINS). A review of the SUBSA furnace features and parameters will be presented, including the design of the growth ampoules, charge preparation, and the procedures used to grow InSb (in 2002) and InI (in 2019).

A.G. Ostrogorsk↗

Development of Large-Scale Thrust Chambers using Laser Powder Directed Energy Deposition

Historical manufacturing methods for liquid propulsion combustion chambers have relied on series of tube-walls or slotted channel walls (subsequently brazed or plated) for regenerative cooling paths. Large-scale additive manufacturing techniques offer strong potential to minimize manufacturing lead times and cost for developing liquid propulsion chambers, while maintaining performance metrics of traditionally manufactured hardware. The benefits expand beyond traditional combustion chambers to lesser considered nuclear thermal propulsion chambers where radiation energizes the singular incoming propellant stream instead of an exothermic chemical reaction. While each subset of liquid propulsion chambers reaps similar benefit, the geometric challenges in each design can vary substantially. This manuscript discusses the challenges of large contraction ratio propulsion chambers, bimetallic liners and closeout jackets, and material selection when considering laser powder directed energy deposition. LP-DED presently offers build volumes unattainable by L-PBF systems, required for large diameter thrust chambers. LP-DED typically has faster deposition time and is capable of overhang angles without support material (due to the ability to tilt the build plate and minimize the actual build angle). These benefits come at the cost of feature resolution. Designers and manufacturers should consider the effects of thick-wall features printed parallel to the primary surface versus perpendicular due to distortion. Thick-wall and thin-wall features printed in the same plane can substantially increase build time. Where large-scale L-PBF overlaps in size, there may be limited benefit in the quantity of powder required for the build due to the low capture rate of LP-DED and a case-by-case examination is required.

LP-DED↗

Expanding the Capability of A Legacy Combustion Flametube to Test High Temperature Engine Materials in Relevant Environments

New materials and component designs are needed to advance gas turbine engine technology and provide the performance and efficiency needs for future applications. In order to advance these materials, testing in combustion environments is a critical step prior to engine testing. In this work, we detail the design and the fabrication of a materials test sector in a flametube combustor facility. The facility simulates a combustion environment similar to that experienced by components in gas turbine engines. The flow regime is characterized by a combination of high-temperature, high-velocity, high-heat flux, and high-velocity that components experience in gas turbine engines. Exposure of components in this facility allows for the study of combined environmental effects and the impact on both coating and substrate durability. The test facility may operate across a wide range of pressures from 275-400 psig (1,896-2,758 kPa) and an air flow rate of 5 lb/s (2.27 kg/s). While combustion gas temperature is expected in excess of 3,000°F (1,649°C), 900°F (482°C) cooling air may be supplied to the backside of components or test articles. The flametube combustor was previously used to evaluate fuel injectors and combustion products, and the new test configuration will also allow for materials exposure to complex, engine-like conditions. The interior of the Test Section was additively manufactured from GRCop-84 and cryogenically fit and brazed to a stainless steel 304 housing. The use of a copper liner minimizes welds and with active cooling, is expected to provide better durability over traditional hardware using stainless steel or Inconel with a ceramic liner. The Test Section has two opposing removable windows approximately 230 mm x 80 mm that can accommodate articles up to 85 mm tall. This modular design allows for custom platforms to hold coupons, panels, or airfoil shapes to be tested with minimal re-engineering or fabrication. The bolted joint and sealing remains consistent, so any new testing only needs to work within the existing design footprint. This paper will provide an overview of the facility capabilities, design considerations, as well as thermal and structural analysis of the hardware. Future testing of ceramic matrix composite (CMC) airfoils and advanced environmental barrier coatings (EBCs) will also be discussed.

Combustion↗

Thermal Cycle and Capacitance Testing of Mezzo Industries Phase Changer Material Heat Capacitor

Effective Thermal management is essential for the safety and performance of human spacecraft, especially during long-duration missions with fluctuating heat loads. Phase Change Material (PCM) heat exchangers offer a compact, efficient solution by storing and releasing thermal energy through latent heat during phase transitions. This allows PCM systems to buffer transient thermal loads without immediate heat rejection, reducing the need for oversized radiators – particularly critical during ascent and re-entry when radiators are stowed. By maintaining stable temperatures in crew cabins and equipment bays, PCM technology enhances crew comfort, protects sensitive systems, and supports long-term mission sustainability with minimal mass and volume impact. A phase change material heat capacitor prototype, designed and built under a NASA Small Business Innovation Research grant by Mezzo Technologies, utilizes a laser welding microtube manufacturing process that promises increased reliability and performance over current manufacturing methods like brazing. This heat exchanger was tested through coolant thermal cycling within the expected flow rates and temperature range of the Orion spacecraft, the crewed spacecraft taking NASA astronauts to the moon under the Artemis Program. The useful heat storage capacitance was measured and compared to Orion spacecraft requirements.

Active Thermal Control Systems↗

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity↗

Electrode array for neural stimulation

An electrode array for neural stimulation is disclosed which has particular applications for use in a retinal prosthesis. The electrode array can be formed as a hermetically-sealed two-part ceramic package which includes an electronic circuit such as a demultiplexer circuit encapsulated therein. A relatively large number (up to 1000 or more) of individually-addressable electrodes are provided on a curved surface of a ceramic base portion the electrode array, while a much smaller number of electrical connections are provided on a ceramic lid of the electrode array. The base and lid can be attached using a metal-to-metal seal formed by laser brazing. Electrical connections to the electrode array can be provided by a flexible ribbon cable which can also be used to secure the electrode array in place.

47 OTHER INSTRUMENTATION↗

Ultrahigh heat flux plasma-facing components for magnetic fusion energy

Sandia and Ultramet partnered to design and test refractory metal plasma-facing components and heat exchangers for advanced, high-temperature power conversion systems. These devices consisted of high-temperature helium-to-helium and lithium-to-helium heat exchangers that operate with high efficiency due to the porous foam inserts used in the gas stream, which promote turbulence and provide extended surface area for enhanced convection. Single- and multi-channel helium panels and the Li-He heat exchanger were fabricated from either pure molybdenum, TZM, or tungsten. The design was carried out through an Ultramet subcontractor. The flow path was carefully tailored to minimize the pressure drop while maximizing the heat transfer. The single- and multi-channel helium panels were tested at Sandia's PMTF using an electron beam system and the closed helium flow loop. In 2006, a single-channel tungsten tube was successfully tested to an average heat flux of 14 MW/m{sup 2} with a localized peak of 22 MW/m{sup 2} along the axial centerline at the outer radius. Under this CRADA, multiple square-channel molybdenum components were successfully tested to heat flux levels approaching 8.5 MW/m{sup 2}. The three multi-channel prototypes experienced mechanical failure due to issues related to the design of the large unsupported span of the heated faceplates in combination with prototype material and braze selection. The Li-He heat exchanger was both designed and partially tested at the PMTF for helium and lithium flow.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Technological Issues and High Gradient Test Results on X-Band Molybdenum Accelerating Structures

Two 11.424 GHz single cell standing wave accelerating structures have been fabricated for high gradient RF breakdown studies. Both are brazed structures: one made from copper and the other from sintered molybdenum bulk. The tests results are presented and compared to those of similar devices constructed at SLAC (Stanford Linear Accelerator Center) and KEK (Ko Enerugi Kasokuki Kenkyu Kiko). The technological issues to build both sections are discussed.

43 PARTICLE ACCELERATORS↗

Sealed joint structure for electrochemical device

Several members make up a joint in a high-temperature electrochemical device, wherein the various members perform different functions. The joint is useful for joining multiple cells (generally tubular modules) of an electrochemical device to produce a multi-cell segment-in-series stack for a solid oxide fuel cell, for instance. The joint includes sections that bond the joining members to each other; one or more seal sections that provide gas-tightness, and sections providing electrical connection and/or electrical insulation between the various joining members. A suitable joint configuration for an electrochemical device has a metal joint housing, a first porous electrode, a second porous electrode, separated from the first porous electrode by a solid electrolyte, and an insulating member disposed between the metal joint housing and the electrolyte and second electrode. One or more brazes structurally and electrically connects the first electrode to the metal joint housing and forms a gas tight seal between the first electrode and the second electrode.

30 DIRECT ENERGY CONVERSION↗

Evaluation of Static Mixer Flow Enhancements for Cryogenic Viscous Compressor Prototype for ITER Vacuum System

As part of the U.S. ITER contribution to the vacuum systems for the ITER fusion project, a cryogenic viscous compressor (CVC) is being designed and fabricated to cryopump hydrogenic gases in the torus and neutral beam exhaust streams and to regenerate the collected gases to controlled pressures such that they can be mechanically pumped with controlled flows to the tritium reprocessing facility. One critical element of the CVC design that required additional investigation was the determination of flow rates of the low pressure (50 to 1000 Pa) exhaust stream that would allow for complete pumping of hydrogenic gases while permitting trace levels of helium to pass through the CVC to be pumped by conventional vacuum pumps. A sub-scale prototype test facility was utilized to determine the effectiveness of a static mixer pump tube concept, which consisted of a series of rotated twisted elements brazed into a 2-mm thick, 5-cm diameter stainless steel tube. Cold helium gas flow provided by a dewar and helium transfer line was used to cool the exterior of the static mixer pump tube. Deuterium gas was mixed with helium gas through flow controllers at different concentrations while the composition of the exhaust gas was monitored with a Penning gauge and optical spectrometer to determine the effectiveness of the static mixer. It was found that with tube wall temperatures between 6 K and 9 K, the deuterium gas was completely cryopumped and only helium passed through the tube. These results have been used to design the cooling geometry and the static mixer pump tubes in the full-scale CVC prototype

Duckworth, Robert C↗

Low Activation Joining of SiC/SiC Composites for Fusion Applications: Tape Casting TiC+Si Powders

The use of SiC composites in fusion environments likely requires joining of plates using reactive joining or brazing. One promising reactive joining method uses solid-state displacement reactions between Si and TiC to produce Ti3SiC2 + SiC. We continue to explore the processing envelope for this joint for the TITAN collaboration in order to produce optimal joints to undergo irradiation studies in HFIR. One noted feature of the joints produced using tape-calendared powders of TiC+Si has been the large void regions that have been apparently unavoidable. Although the produced joints are very strong, these voids are undesirable. In addition, the tapes that were made for this joining were produced about 20 years ago and were aging. Therefore, we embarked on an effort to produce some new tape cast powders of TiC and Si that could replace our aging tape calendared materials.

Fusion↗

Thermal Performance Benchmarking; NREL (National Renewable Energy Laboratory)

This project proposes to seek out the SOA power electronics and motor technologies to thermally benchmark their performance. The benchmarking will focus on the thermal aspects of the system. System metrics including the junction-to-coolant thermal resistance and the parasitic power consumption (i.e., coolant flow rates and pressure drop performance) of the heat exchanger will be measured. The type of heat exchanger (i.e., channel flow, brazed, folded-fin) and any enhancement features (i.e., enhanced surfaces) will be identified and evaluated to understand their effect on performance. Additionally, the thermal resistance/conductivity of the power module’s passive stack and motor’s laminations and copper winding bundles will also be measured. The research conducted will allow insight into the various cooling strategies to understand which heat exchangers are most effective in terms of thermal performance and efficiency. Modeling analysis and fluid-flow visualization may also be carried out to better understand the heat transfer and fluid dynamics of the systems.

30 DIRECT ENERGY CONVERSION↗

Electron beam gun with kinematic coupling for high power RF vacuum devices

An electron beam gun for a high power RF vacuum device has components joined by a fixed kinematic coupling to provide both precise alignment and high voltage electrical insulation of the components. The kinematic coupling has high strength ceramic elements directly bonded to one or more non-ductile rigid metal components using a high temperature active metal brazing alloy. The ceramic elements have a convex surface that mates with concave grooves in another one of the components. The kinematic coupling, for example, may join a cathode assembly and/or a beam shaping focus electrode to a gun stem, which is preferably composed of ceramic. The electron beam gun may be part of a high power RF vacuum device such as, for example, a gyrotron, klystron, or magnetron.

36 MATERIALS SCIENCE↗

Materials and Manufacturing Challenges for Compact Heat Exchangers of Supercritical CO2 Power Cycles

The supercritical CO2 (sCO2) power cycles rely heavily on heat recuperation to increase efficiency. Compact heat exchangers are proposed to reduce equipment size and enhance heat transfer between heat source and sCO2. Microchannel architectures in these heat exchangers are typically formed by a lamination process wherein channels are formed in layers of sheet material, which are then stacked and joined together using diffusion bonding, brazing, or transient-liquid-phase bonding (TLPB). TLPB of Ni-based superalloy (Alloy 230) sheets into stacks was investigated. Electron microscopy identified solidification shrinkage porosity on the bond line as the most common defect in the TLP bonded stacks. Tensile yield strengths of 76-86 % of the base alloy strength were obtained on bonded stacks. Scanning electron microscopy on the fracture surfaces indicated ductile failure mode in the bonded zone. Environmental stability of joined regions in Alloy 230 stacks was investigated by exposing to CO2 at 700°C for 1500 hours. Mass change and post-exposure microscopic analysis showed a corrosion behavior similar to the base material.

14 SOLAR ENERGY↗

Hermetic edge-connect headers and corresponding connectors

A hermetically-sealed edge-connect header that can withstand high temperatures, high pressures (or high vacuum levels), and high vibration environments, along with two corresponding connectors are disclosed. After brazing the edge-connect header components, the assembly is machined to form a slot with a portion of each of a plurality of electrical conductors removed in the machining process, resulting in a header with a high pin density. During the process of mating the first connector design to the edge-connect header, a plurality of wipers in the connector deflect, thereby causing the wipers to extend from the connector and contact the corresponding electrical conductors in the header. During the process of mating the second connector design to the edge-connect header, each of a plurality of wipers formed of low-mass, compliant metal wool, forms multiple contact points with a corresponding electrical conductor in the header.

Kellogg, Rick A.↗

High temperature substrate heater for use in high and ultra-high vacuum systems

A braze-free substrate heating device including a heater block body, a heater block lid, and a heating element. The heating element sits inside the heater block body. The heater block lid is on the heating element, such that the heating element is sandwiched between the heater block lid and the floor of the heater block body. The heating element is held in place by compressing the heater block lid into the heater block body and attaching the heater block lid to the top of the heater block body so that the heating element is fully supported over its surface area, and can maintain uniform thermal contact with the heater block lid and heater block body over its entire surface area.

Dowden, Paul↗