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At least 811 records · Page 45

Comparison Testings between Two High-temperature Strain Measurement Systems

An experimental evaluation was conducted at NASA Lewis Research Center to compare and contrast the performance of a newly developed resistance strain gage, the PdCr temperature-compensated wire strain gage, to that of a conventional high-temperature extensometry. The evaluation of the two strain measurement systems was conducted through the application of various thermal and mechanical loading spectra using a high-temperature thermomechanical uniaxial testing system equipped with quartz lamp heating. The purpose of the testing was not only to compare and contrast the two strain sensors but also to investigate the applicability of the PdCr strain gage to the testing environment typically employed when characterizing the high-temperature mechanical behavior of structural materials. Strain measurement capabilities to 8OO C were investigated with a nickel base superalloy IN100 substrate material, and application to titanium matrix composite (TMC) materials was examined with the SCS-6/Ti-15-3 08 system. PdCr strain gages installed by three attachment techniques, namely, flame spraying, spot welding and rapid infrared joining were investigated.

Lei, J.-F.↗

Thermal Control System Development to Support the Crew Exploration Vehicle and Lunar Surface Access Module

All space vehicles or habitats require thermal management to maintain a safe and operational environment for both crew and hardware. Active Thermal Control Systems (ATCS) perform the functions of acquiring heat from both crew and hardware within a vehicle, transporting that heat throughout the vehicle, and finally rejecting that energy into space. Almost all of the energy used in a space vehicle eventually turns into heat, which must be rejected in order to maintain an energy balance and temperature control of the vehicle. For crewed vehicles, Active Thermal Control Systems are pumped fluid loops that are made up of components designed to perform these functions. NASA has recently evaluated all of the agency s technology development work and identified key areas that must be addressed to aid in the successful development of a Crew Exploration Vehicle (CEV) and a Lunar Surface Access Module (LSAM). The technologies that have been selected and are currently under development include: fluids that enable single loop ATCS architectures, a gravity insensitive vapor compression cycle heat pump, a sublimator with reduced sensitivity to feedwater contamination, an evaporative heat sink that can operate in multiple ambient pressure environments, a compact spray evaporator, and lightweight radiators that take advantage of carbon composites and advanced optical coatings.

Anderson, Molly↗

Examining Graphite Degradation in Molten Salt Environments: A Chemical, Physical, and Material Analysis

Molten-salt reactors (MSRs) are Generation IV nuclear reactors that use liquid salt as a coolant and/or fuel. In several MSR designs, graphite serves as a moderator and/or reflector. However, due to limited experimental data and operational experience, our understanding of graphite behavior in molten salt environments remains incomplete. This report aims to identify the degradation mechanisms of nuclear graphite in MSRs, detail the mechanisms of each factor, and provide an initial assessment of their impact on the structural integrity of graphite components. This assessment is based on an extensive literature review and insights from subject matter experts. Furthermore, given the limited data, a modeling strategy using existing Grizzly software is proposed for a more thorough analysis where appropriate. Additionally, it presents mitigation strategies where applicable. The report covers physical degradation mechanisms such as infiltration, erosion, and abrasion, as well as chemical degradation mechanisms including fluorination, intercalation, corrosion, and oxidation. Molten salt can infiltrate the porous structure of graphite, leading to several detrimental effects. Entrapment of fissile products within the graphite pores can cause radiation damage and could pose challenges in the handling and disposal of contaminated components. The differential thermal expansion between the infiltrated salt and graphite, along with internal stress from pressurized molten salt and volumetric heating, can compromise the structural integrity of graphite. To mitigate these effects, employing ultra-fine graphite grades and applying sealants and coatings are effective strategies. A computational model based on coupled solid mechanics and heat transfer phenomena could be used to predict the internal stresses using Grizzly software. In pebble-bed MSRs, graphite fuel pebbles can cause abrasion against reactor components due to friction and wear. The severity of wear is influenced by various factors such as temperature, environment, and the presence of lubricants. Tribological studies reveal that higher temperatures and molten salt environments, such as FLiBe, significantly reduce wear rates compared to dry conditions. Additionally, the chemical composition of the salt can further optimize graphite's tribological performance. Long-term wear effects can be modeled by incorporating surface defects into the geometry and predict stresses under thermal and radiation effects using Grizzly software. Chemical degradation of graphite in a molten salt environment can occur through fluorination and intercalation. Fluorination can occur via replacement of hydrogen or oxygen atoms, or at the active sites, but does not cause structural degradation. Intercalation, on the other hand, can lead to exfoliation, where layers of graphite separate and peel away, damaging the graphite. Protective coatings can enhance graphite's resistance to intercalation. Graphite generally exhibits good chemical stability in molten salt environments, though it can corrode under specific conditions, particularly in the presence of impurities or oxidants. Studies have shown that protective coatings, such as plasma-sprayed partially stabilized zirconia (PSZ), can effectively prevent such degradation. Corrosion behavior varies significantly with different graphite grades and coating applications, underscoring the need for detailed studies on uncoated and coated graphite to understand and mitigate corrosion mechanisms in MSRs. Research indicates that the presence of oxidants and impurities can accelerate graphite degradation in molten salts, making it essential to explore acceptable impurity limits. Oxidation is another critical degradation mechanism, leading to weight loss and structural damage due to the formation of CO and CO 2 from the reaction of carbon atoms with oxygen. This process creates new porosity and compromises graphite's integrity. While extensive research on graphite oxidation has been conducted for gas-cooled reactors, studies specific to MSRs are limited. Findings from the coal industry suggest that molten alkali metal salts can significantly accelerate graphite oxidation, a hypothesis worth exploring for fluoride salts in MSRs. Understanding oxidation behavior in MSRs is vital for developing protective measures. The analysis of post-irradiated graphite from the MSRE experiment demonstrated exceptional chemical compatibility with molten fluoride salt, suggesting that the extent of chemical attack on graphite largely depends on the salt's infiltration capability. Therefore, the use of ultra-fine grade graphite could help mitigate chemical degradation effects. Existing oxidation modeling capabilities in Grizzly, which use reaction-diffusion equations to model graphite-air interactions, could be adapted to simulate the chemical degradation effects of graphite in molten salt environments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Properties of plasma sprayed bond coats

Increasing bond coat oxidation resistance has been clearly linked to increasing durability of the ceramic layer of TBC's. However, recent studies have shown that significant differences in TBC life can be achieved for different bond coats that have little or no difference in oxidation behavior. These results suggest bond coat properties other than oxidation resistance can also influence TBC life. A determination of which properties affect TBC life and an understanding of how these properties affect TBC life could be valuable in designing new, more durable TBC's. Unfortunately, there is little existing information on the physical and mechanical properties of bond coat materials and there are fewer comparative studies that can be used to determine which properties are important to TBC life. This paper compares the properties of three bond coat compositions that have similar oxidation behavior but different TBC lives. Analysis of the properties indicates that the coefficient of thermal expansion and stress relaxation (creep) behavior of the three alloys are strongly correlated to the observed differences in TBC life.

Brindley, W. J.↗

The effect of substrate temperature on the critical velocity in microparticle impact bonding

A number of nascent coating and micromanufacturing processes involve particles sprayed at a high velocity, which impact a substrate, deform, and adhere. Successful bonding between the particles and the substrate requires impact velocities higher than the so-called critical adhesion velocity. This critical velocity is influenced by the temperature of the substrate, a variable that we isolate in this work by conducting single-particle impacts on a variable-temperature substrate for three systems (Al–Al, Sn–Sn, and Ti–Ti) with particles individually selected within a narrow size distribution. Our results quantitatively connect the increase in substrate temperature to a significant lowering of the critical velocity, which we attribute to the lower dynamic strength of the thermally softened substrate. The data are generally consistent with expectations for bonding being controlled by a hydrodynamic process of jetting upon impact.

36 MATERIALS SCIENCE↗

Exploring the Effects of Piston Bowl Geometry and Injector Included Angle on Dual-Fuel and Single-Fuel RCCI

Abstract Reactivity control compression ignition (RCCI) is a low-temperature combustion technique that has been proposed to meet the current demand for high thermal efficiency and low engine-out emissions. However, its requirement of two separate fuel systems (i.e., a low-reactivity fuel system and a high-reactivity fuel system) has been one of its major challenges in the last decade. This leads to the single-fuel RCCI concept, where the secondary fuel (reformates of diesel) is generated from the primary fuel (diesel) through catalytic partial oxidation reformation. Following the in-depth analysis of the reformate fuel (reformates of diesel) and its benefit as the low-reactivity fuel with diesel, the effects of the start of injection (SOI) timing of diesel and the energy-based blend ratio were also studied in detail. In this study, the effects of piston profile and the injector included angles were experimentally examined using both conventional fuel pairs (gasoline—diesel and natural gas—diesel) and reformate RCCI. A validated computational fluid dynamics (CFD) model was also used for a better understanding of the experimental trends. Comparing a reentrant bowl piston with a shallow bowl piston at a constant compression ratio and SOI, the latter showed better thermal efficiency, regardless of the fuel combination, due to its 10% lower surface area for the heat transfer. Comparing the 150-degree included angle and 60-degree included angle on the shallow bowl piston, the latter showed better combustion efficiency, regardless of the fuel combination, due to its earlier combustion phasing (at constant SOI timing). The effect was particularly prominent on reformate RCCI because of its incredibly high diluent concentration, which retards the combustion further for the 150-deg injector. Later, using convergecfd, seven different injector included angles were studied at a constant SOI. With the change in injector included angle, the region of the cylinder targeted by the fuel spray varies significantly, and it was found to have a significant impact on the combustion efficiency and the engine-out emissions. As the injector included angle changed from 60-deg to 150-deg, the combustion efficiency increased by 15% and the CO, NOx, and HC emissions decreased by 96%, 70%, and 86%, respectively.

Engineering↗

Gravity Effects Observed In Partially Premixed Flames

Partially premixed flames (PPFs) contain a rich premixed fuel air mixture in a pocket or stream, and, for complete combustion to occur, they require the transport of oxidizer from an appropriately oxidizer-rich (or fuel-lean) mixture that is present in another pocket or stream. Partial oxidation reactions occur in fuel-rich portions of the mixture and any remaining unburned fuel and/or intermediate species are consumed in the oxidizer-rich portions. Partial premixing, therefore, represents that condition when the equivalence ratio (phi) in one portion of the flowfield is greater than unity, and in another section its value is less than unity. In general, for combustion to occur efficiently, the global equivalence ratio is in the range fuel-lean to stoichiometric. These flames can be established by design by placing a fuel-rich mixture in contact with a fuel-lean mixture, but they also occur otherwise in many practical systems, which include nonpremixed lifted flames, turbulent nonpremixed combustion, spray flames, and unwanted fires. Other practical applications of PPFs are reported elsewhere. Although extensive experimental studies have been conducted on premixed and nonpremixed flames under microgravity, there is a absence of previous experimental work on burner stabilized PPFs in this regard. Previous numerical studies by our group employing a detailed numerical model showed gravity effects to be significant on the PPF structure. We report on the results of microgravity experiments conducted on two-dimensional (established on a Wolfhard-Parker slot burner) and axisymmetric flames (on a coannular burner) that were investigated in a self-contained multipurpose rig. Thermocouple and radiometer data were also used to characterize the thermal transport in the flame.

Puri, Ishwar K.↗

Soot and PAH formation in high pressure spray pyrolysis of gasoline and diesel fuels

Time-resolved soot and PAH formation from gasoline and diesel spray pyrolysis are visualized and quantified using diffuse back illumination (DBI) and laser induced fluorescence (LIF) at 355 nm, respectively, in a constant-volume vessel at 60 bar from 1400 to 1700 K for up to 30 ms. The delay, maximum formation rate, and yield of soot and PAHs are compared across fuels and temperatures and correlated with the yield sooting indices on either the mass or mole basis. The delays generally decrease with increasing temperature, and the formation rates of both PAHs and soot generally increase with temperature. The apparent PAH-LIF yield may decrease with temperature due to PAH growth and conversion into larger species, signal trapping, and thermal quneching. Soot yield generally increases with temperature. The mass-based YSI correlates reasonably well with soot delay, but YSI does not correlate well with soot yield. Here, the mass-based YSI is a more appropriate predictor of sooting propensity than the mole-based YSI.

42 ENGINEERING↗

A thermally-limited bubble growth model for the relaxation time of superheated fuels

Here, we propose a novel approach to evaluate the relaxation time of vapor bubble growth in the context of the flash boiling of a superheated liquid. In alternative to the empirical correlation derived from superheated water experiments almost fifty years ago, the new model describes the thermally-dominated growth of vapor bubbles in terms that are dependent on the local Jakob number (the ratio of sensible heat to latent heat during phase change) and the number density of vapor bubbles. The model is tested by plugging the resulting relaxation time into the Homogenous Relaxation Model (HRM). Flash-boiling simulations carried out with HRM are compared with n-pentane (C 5 H 12 ) injection and boil-off experiments conducted with a real-size, axial-hole, transparent gasoline injector discharging into a constant-pressure vessel. The long-distance microscopy images from the experiments, processed to derive the projected liquid volume (PLV) of the spray, provide a unique set of time-resolved validation data for direct fuel injection simulations. At conditions ranging from flaring to mild and minimal flash boiling, we show that switching to the new relaxation time improves the agreement with the measured PLV profiles with respect to the standard empirical model. Particularly at flaring conditions, the predicted increase in gas cooling caused by rapid vapor production is shown to be more consistent with the observed boil-off.

42 ENGINEERING↗

Molecular films associated with LDEF

The molecular films deposited on the surface of the Long Duration Exposure Facility (LDEF) originated from the paints and room-temperature-vulcanized (RTV) silicone materials intentionally used on the satellite and not from residual contaminants. The high silicone content of most of the films and the uniformity of the films indicates a homogenization process in the molecular deposition and suggests a chemically most favored composition for the final film. The deposition on interior surfaces and vents indicated multiple bounce trajectories or repeated deposition-reemission cycles. Exterior surface deposits indicated a significant return flux. Ultraviolet light exposure was required to fix the deposited film as is indicated by the distribution of the films on interior surfaces and the thickness of films at the vent locations. Thermal conditions at the time of exposure to ultraviolet light seems to be an important factor in the thickness of the deposit. Sunrise facing (ram direction) surfaces always had the thicker film. These were the coldest surfaces at the time of their exposure to ultraviolet light. The films have a layered structure suggesting cyclic deposition. As many as 34 distinct layers were seen in the films. The cyclic nature of the deposition and the chemical uniformity of the film one layer to the next suggest an early deposition of the films though there is evidence for the deposition of molecular films throughout the nearly six year exposure of the satellite. A final 'spray' of an organic material associated with water soluble salts occurred very late in the mission. This may have been the result of one of the shuttle dump activities.

Crutcher, E. R.↗

Active Thermal Control System Development for Exploration

All space vehicles or habitats require thermal management to maintain a safe and operational environment for both crew and hardware. Active Thermal Control Systems (ATCS) perform the functions of acquiring heat from both crew and hardware within a vehicle, transporting that heat throughout the vehicle, and finally rejecting that energy into space. Almost all of the energy used in a space vehicle eventually turns into heat, which must be rejected in order to maintain an energy balance and temperature control of the vehicle. For crewed vehicles, Active Thermal Control Systems are pumped fluid loops that are made up of components designed to perform these functions. NASA has been actively developing technologies that will enable future missions or will provide significant improvements over the state of the art technologies. These technologies have are targeted for application on the Crew Exploration Vehicle (CEV), or Orion, and a Lunar Surface Access Module (LSAM). The technologies that have been selected and are currently under development include: fluids that enable single loop ATCS architectures, a gravity insensitive vapor compression cycle heat pump, a sublimator with reduced sensitivity to feedwater contamination, an evaporative heat sink that can operate in multiple ambient pressure environments, a compact spray evaporator, and lightweight radiators that take advantage of carbon composites and advanced optical coatings.

Westheimer, David↗

Development of YAG:Dy Thermographic Phosphor Coatings for Turbine Engine Applications

The selection and development of thermographic phosphor coatings were pursued to meet the objective of demonstrating luminescence-decay-based temperature measurements up to 1300C on the surface of a vane in an operating demonstrator turbine engine. To meet this objective, YAG:Dy was selected based on the desirable luminescence performance observed for YAG:Dy powder: (1) excellent temperature sensitivity and intensity at operating turbine engine temperatures, (2) an emission peak at the relatively short wavelength of 456 nm, where the interference from background blackbody radiation is fairly low, and (3) its nearly single exponential decay which makes for a simple, reliable temperature calibration. However, implementation of YAG:Dy for surface temperature measurements required application of YAG:Dy as a coating onto the surface of a superalloy component with a preexisting yttria-stabilized zirconia (YSZ) thermal barrier coating (TBC). An inherent dilemma in producing a YAG:Dy coating is that coating processing is constrained to be performed at temperatures below (less than 1200C) what is considered safe for the superalloy component, much lower than temperatures used to produce the high quality crystalline powder. Therefore, YAG:Dy coatings tend to exhibit lower luminescence performance compared to well prepared YAG:Dy powder, and the luminescence performance of the coating will depend on the method of coating deposition. In this presentation, the luminescence performance of YAG:Dy coatings prepared by the different methods of (1) application of a binder-based YAG:Dy-containing paint, (2) solution precursor plasma spray (SPPS), and (3) electron-beam physical vapor deposition (EB-PVD) and the effect of post-deposition heat treatments will be discussed.

Eldridge, J. I.↗

Aero-thermal Calibration of the NASA Glenn Icing Research Tunnel (2000 Tests)

Aerothermal calibration measurements and flow quality surveys were made in the test section of the Icing Research Tunnel at the NASA Glenn Research Center. These surveys were made following major facility modifications including widening of the heat exchanger tunnel section, replacement of the heat exchanger, installation of new turning vanes, and installation of new fan exit guide vanes. Standard practice at NASA Glenn requires that test section calibration and flow quality surveys be performed following such major facility modifications. A single horizontally oriented rake was used to survey the flow field at several vertical positions within a single cross-sectional plane of the test section. These surveys provided a detailed mapping of the total and static pressure, total temperature, Mach number, velocity, flow angle and turbulence intensity. Data were acquired over the entire velocity and total temperature range of the facility. No icing conditions were tested; however, the effects of air sprayed through the water injecting spray bars were assessed. All data indicate good flow quality. Mach number standard deviations were less than 0.0017, flow angle standard deviations were between 0.3 deg and 0.8 deg, total temperature standard deviations were between 0.5 and 1.8 F for subfreezing conditions, axial turbulence intensities varied between 0.3 and 1.0 percent, and transverse turbulence intensities varied between 0.3 and 1.5 percent. Measurement uncertainties were also quantified.

Gonsalez, Jose C.↗

Integration and software for thermal test of heat rate sensors

A minicomputer controlled radiant test facility is described which was developed and calibrated in an effort to verify analytical thermal models of instrumentation islands installed aboard the space shuttle external tank to measure thermal flight parameters during ascent. Software was provided for the facility as well as for development tests on the SRB actuator tail stock. Additional testing was conducted with the test facility to determine the temperature and heat flux rate and loads required to effect a change of color in the ET tank external paint. This requirement resulted from the review of photographs taken of the ET at separation from the orbiter which showed that 75% of the external tank paint coating had not changed color from its original white color. The paint on the remaining 25% of the tank was either brown or black, indicating that it had degraded due to heating or that the spray on form insulation had receded in these areas. The operational capability of the facility as well as the various tests which were conducted and their results are discussed.

Wojciechowski, C. J.↗

After Math - Foamology and Flight Rationale

The Space Shuttle was developed by NASA to be a largely reusable launch system which could provide frequent access to low earth orbit. Like all previous launch systems, safe reentry for the crew and payload required the use of a thermal protection system (TPS). Unlike previous spacecraft though, the Shuttle's TPS was exposed from launch, making it sensitive to debris which could be generated by the vehicle on ascent. The most likely and potentially destructive source of debris was considered to be ice, which could build-up anywhere on the External Tank (ET) where there was exposed metal. Ice could form during ground operations after the cryogenic propellants had been loaded and then be knocked loose on ascent. In order to prevent both ice build-up and boil-off of the propellants, the entire ET and all protuberances (orbiter attach points, pressurization lines, propellant feed lines, etc.) were covered with a spray on foam insulation (SOFI) type TPS. Unfortunately the foam was also susceptible to liberation during ascent, and posed a debris risk of its own. During the early years of the Shuttle Program engineers spent a good deal of effort characterizing the amount of foam that was shed.

Steva, Thomas↗

Challenges in the development of the orbiter active thermal control subsystem

A number of major challenges were faced in the design and development of the Orbiter Active Thermal Control Subsystem (ATCS). At the system level, the initial challenges were to define an approach that would interface dual Freon coolant loops with multiple coolant loops from other vehicle subsystems with the lowest weight penalty to the Orbiter; and to provide highly responsive vehicle heat rejection throughout all of the Orbiter mission phases. Optimized heat exchangers, representing an advance in the state-of-the-art in heat exchanger design, were developed to transfer heat between the orbiter Freon coolant loops and five other vehicle systems. Flash evaporation was selected as a highly efficient and responsive means for cooling the Orbiter Freon loops during ascent and entry. The Flash Evaporator Subsystem (FES) utilizes cyclic water spray cooling in a chamber maintained at or below the water triple point pressure. A summary of the basic heat transfer research conducted to identify the fundamental heat transfer processes involved in water spray cooling in support of the FES design is given. The high fidelity dynamic analytical model of the FES that was generated to aid in the design of control logic, evaluate performance and simulate ground test and flight anomalies is discussed. A description of the FES and Integrated ATCS testing conducted in the SESL chamber A at NASA-JSC is also presented.

Nason, J. R.↗

Cryogenic Flow Boiling Parabolic Flight Experiment and Universal Correlations for Cryogens

Cryogenic fluids are employed in many industries and play crucial roles in space applications, including nuclear thermal propulsion systems, LOX/LCH4 ascent and descent stage feedlines, LOX/LH2 transfer lines for in-space fuel depots, and LHe transfer lines that cool space experiments. Due to the ultra-low boiling point of cryogens, phase change is inevitable in these systems, which leads to complex boiling behavior in reduced gravity. For cost-effective design and sizing of the aforementioned systems, accurate knowledge of two-phase parameters such as pressure drop, heat transfer coefficient (HTC), and critical heat flux (CHF) is desired. Since 2018, researchers from Purdue University and NASA Glenn Research Center (GRC) have been collaborating to investigate the effects of reduced gravity on cryogenic pool boiling, flow boiling ins tubes, and spray cooling. Using a variety of both terrestrial and parabolic flight experimental rigs, extensive LN2 data have been amassed and combined with cryogenic data from World literature to develop both ‘universal’ empirical correlations and CFD models, which are expected to serve as foundation for design of future space systems involving cryogenic fluids. This presentation will provide an overview of both the experimental work and predictive tools that have resulted from the joined Purdue-Glenn studies.

Flow Boiling↗

A computational parametric study of ducted fuel injection implementation in a heavy-duty diesel engine

Experiments have shown that ducted fuel injection (DFI) effectively reduces soot emissions from direct-injection diesel engines. Although many computational studies have evaluated DFI’s spray development and soot reduction mechanisms in constant volume chambers, only limited computational work on internal combustion engines exists. The DFI duct assembly changes the engine’s in-cylinder flow, spray, and combustion development. Therefore, current production engine designs might not be optimal for achieving the best engine performance with DFI. Here, this work conducted an extensive numerical study to evaluate how parameter changes affect DFI performance. The parameters include swirl ratio, piston geometry, compression ratio (CR), number of injector orifices, split injection strategy, and exhaust gas recirculation (EGR) in a heavy-duty diesel engine utilizing DFI. The combustion and soot emission data from the Sandia compression ignition optical research engine were used for model validation. Simulations showed that an increased swirl ratio resulted in more intense jet flame-piston interaction, slowing down the combustion heat release during the late combustion stage and leading to lower indicated thermal efficiency (ITE) due to higher exhaust losses. A piston-bowl design with a reentrant inner piston edge yielded the highest thermal efficiency, due to the reduced cylinder head heat transfer loss. Additional injector orifices led to higher efficiency owing to a more advanced combustion phasing. Nevertheless, the maximum pressure rise rate (MPRR) and oxides of nitrogen (NO x ) emissions also increased with the number of injector orifices due to more rapid heat release and higher combustion temperature. Implementation of a split injection strategy combined with a higher EGR rate effectively inhibited the excessive MPRR and NO x formation. In general, the study concluded that DFI is not sensitive to most parameter changes but will benefit from future parameter optimization.

33 ADVANCED PROPULSION SYSTEMS↗