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At least 883 records · Page 49

Damage Accumulation and Failure of Plasma-Sprayed Thermal Barrier Coatings under Thermal Gradient Cyclic Conditions

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. A fundamental understanding of the sintering and thermal cycling induced delamination of thermal barrier coating systems under engine-like heat flux conditions will potentially help to improve the coating temperature capability. In this study, a test approach is established to emphasize the real-time monitoring and assessment of the coating thermal conductivity, which can initially increase under the steady-state high temperature thermal gradient test due to coating sintering, and later decrease under the thermal gradient cyclic test due to coating cracking and delamination. Thermal conductivity prediction models have been established for a ZrO2-(7- 8wt%)Y2O3 model coating system in terms of heat flux, time, and testing temperatures. The coating delamination accumulation is then assessed based on the observed thermal conductivity response under the combined steady-state and cyclic thermal gradient tests. The coating thermal gradient cycling associated delaminations and failure mechanisms under simulated engine heat-flux conditions will be discussed in conjunction with the coating sintering and fracture testing results.

Zhu, Dongming↗

High-Temperature Adhesives for Thermally Stable Aero-Assist Technologies

Aero-assist technologies are used to control the velocity of exploration vehicles (EVs) when entering Earth or other planetary atmospheres. Since entry of EVs in planetary atmospheres results in significant heating, thermally stable aero-assist technologies are required to avoid the high heating rates while maintaining low mass. Polymer adhesives are used in aero-assist structures because of the need for high flexibility and good bonding between layers of polymer films or fabrics. However, current polymer adhesives cannot withstand temperatures above 400 C. This innovation utilizes nanotechnology capabilities to address this need, leading to the development of high-temperature adhesives that exhibit high thermal conductivity in addition to increased thermal decomposition temperature. Enhanced thermal conductivity will help to dissipate heat quickly and effectively to avoid temperature rising to harmful levels. This, together with increased thermal decomposition temperature, will enable the adhesives to sustain transient high-temperature conditions.

Eberts, Kenneth↗

Thermal analysis of the vertical bridgman semiconductor crystal growth technique

The quality of semiconductor crystals grown by the vertical Bridgman technique is strongly influenced by the axial and radial variations of temperature within the charge. The relationship between the thermal parameters of the vertical Bridgman system and the thermal behavior of the charge are examined. Thermal models are developed which are capable of producing results expressable in analytical form and which can be used without recourse to extensive computer work for the preliminary thermal design of vertical Bridgman crystal growth systems. These models include the effects of thermal coupling between the furnace and the charge, charge translation rate, charge diameter, thickness and thermal conductivity of the confining crucible, thermal conductivity change and liberation of latent heat at the growth interface, and infinite charge length. The hot and cold zone regions, considered to be at spatially uniform temperatures, are separated by a gradient control region which provides added thermal design flexibility for controlling the temperature variations near the growth interface.

Jasinski, T. J.↗

Silica-Aerogel Composites Opacified with La(0.7)Sr(0.3)MnO3

As part of an effort to develop improved lightweight thermal-insulation tiles to withstand temperatures up to 1,000 C, silica aerogel/fused-quartz-fiber composite materials containing La0.7Sr0.3MnO3 particles as opacifiers have been investigated as potentially offering thermal conductivities lower than those of the otherwise equivalent silica-aerogel composite materials not containing La(0.7)Sr(0.3)MnO3 particles. The basic idea of incorporating opacifying particles into silica-aerogels composite to reduce infrared radiative contributions to thermal conductivities at high temperatures is not new: it has been reported in a number of previous NASA Tech Briefs articles. What is new here is the selection of La(0.7)Sr(0.3)MnO3 particles as candidate opacifiers that, in comparison with some prior opacifiers (carbon black and metal nanoparticles), are more thermally stable. The preparation of a composite material of the present type includes synthesis of the silica-aerogel component in a sol-gel process. The La(0.7)Sr(0.3)MnO3 particles, made previously in a separate process, are mixed into the sol, which is then cast onto fused-quartz-fiber batting. Then the aerogel-casting solution is poured into the mold, where it permeates the silica fiber felt. After the sol has gelled, the casting is aged and then subjected to supercritical drying to convert the gel to the final aerogel form. The separate process for making the La(0.7)Sr(0.3)MnO3 particles begins with the slow addition of corresponding proportions of La(CH3COOH)3, Mn(CH3COOH)3, and Sr(NO3)2 to a solution of H2O2 in H2O. The solution is then peptized by drop-wise addition of NH4OH to obtain a sol. Next, the sol is dried in an oven at a temperature of 120 C to obtain a glassy solid. The solid is calcined at 700 C to convert it to La(0.7)Sr(0.3)MnO3. Then La(0.7)Sr(0.3)MnO3 particles are made by ball-milling the calcined solid. The effectiveness of La(0.7)Sr(0.3)MnO3 particles as opacifiers and thermal-conductivity reducers depends on the statistical distribution of particle sizes as well as the relative proportions of La(0.7)Sr(0.3)MnO3 and aerogel. For experiments performed thus far, samples of aerogel/fiber composites were formulated to have, variously, silica target density of 0.07 or 0.14 g/cu cm and to contain 30 percent of La(0.7)Sr(0.3)MnO3 in average particle size of 0.3 or 3 microns. The thermal conductivities of the samples containing the 3 micron La(0.7)Sr(0.3)MnO3 particles were found to be lower than those of the samples containing the 0.3 micron La(0.7)Sr(0.3)MnO3 particles. The optimum particle size is believed to be between 1 and 5 microns.

Rhine, Wendell↗

Heat transfer analysis of the Bridgman-Stockbarger configuration for crystal growth. Part 1: Analytical treatment of the axial temperature distribution

All first order effects on the axial temperature distribution in a solidifying charge in a Bridgman-Stockbarger configuration for crystal growth are analyzed on the basis of a one dimensional model whose validity can be verified through comparison with published finite difference ana;uses of two dimensional models. The model presented includes an insulated region between axially aligned heat pipes and considers the effects of charge diameter, charge motion, thickness, and thermal conductivity of a confining crucible, thermal conductivity change at the crystal-melt interface, generation of latent heat at the interface, and finite charge length. Results are primarily given in analytical form and can be used without recourse to computer work for both improve furnace design and optimization of growth conditions in a given thermal configuration.

Jasinski, T. J.↗

Thermal Design, Test and Analysis of PharmaSat, a Small Class D Spacecraft with a Biological Experiment

Small spacecraft have been increasing in popularity because of their low cost, short turnaround and relative efficiency. In the past, small spacecraft have been primarily used for technology demonstrations, but advances in technology have made the miniaturization of space science possible [1,2]. PharmaSat is a low cost, small three cube size spacecraft, with a biological experiment on board, built at NASA (National Aeronautics and Space Administration) Ames Research Center. The thermal design of small spacecraft presents challenges as their smaller surface areas translate into power and thermal constraints. The spacecraft is thermally designed to run colder in the Low Earth Orbit space environment, and heated to reach the temperatures required by the science payload. The limited power supply obtained from the solar panels on small surfaces creates a constraint in the power used to heat the payload to required temperatures. The pressurized payload is isolated with low thermally conductance paths from the large ambient temperature changes. The thermal design consists of different optical properties of section surfaces, Multi Layer Insulation (MLI), low thermal conductance materials, flexible heaters and thermal spreaders. The payload temperature is controlled with temperature sensors and flexible heaters. Finite Element Analysis (FEA) and testing were used to aid the thermal design of the spacecraft. Various tests were conducted to verify the thermal design. An infrared imager was used on the electronic boards to find large heat sources and eliminate any possible temperature runaways. The spacecraft was tested in a thermal vacuum chamber to optimize the thermal and power analysis and qualify the thermal design of the spacecraft for the mission.

Diaz-Aguado, Millan F.↗

Thermal grease replacement for the modular power subsystem

A comparative thermal conductance test was conducted to evaluate thermal interface materials for use on the Modular Power Subsystem. Materials tested included three thermal pads, four RTV adhesives, bare metal, and one thermal grease. The tests were conducted in a bell jar at vacuum conditions using a 1400 square centimeter footprint and two relatively low contact pressures, 207 kPa and 620 kPa. Power inputs ranged from 100 to 500 watts, and the thermal interface conductance values ranged from 100 to 1700 W/m2 C for the interstitial materials tested. In general, the thermal pads performed a little better than bare metal, while the RTV adhesives performed significantly better than the bare metal and comparable to the thermal grease.

Lapinski, John R., Jr.↗

Electrically-conducting thermal-control coating

Coating comprised mainly of zinc and aluminum oxides is characterized by high thermal emittance, low thermal absorption, and high electrical conductivity. Originally developed to protect spacecraft, coating can be used to prevent charge buildup on components in other applications. Mixture is stable under ultraviolet and X-ray radiation and under bombardment by ionizing particles. It can be applied to aluminum, stainless steel, epoxy/fiberglass, and other substrates. When exposed to equivalent of 1,000 Sun-hours illumination, coating remained stable and retained its optical properties.

Shai, M. C.↗

Advanced Oxide Material Systems For 1650 C Thermal/Environmental Barrier Coating Applications

Advanced thermal/environmental barrier coatings (T/EBCs) are being developed for low emission SiC/SiC ceramic matrix composite (CMC) combustor and vane applications to extend the CMC liner and vane temperature capability to 1650 C (3000 F) in oxidizing and water-vapor containing combustion environments. The 1650 C T/EBC system is required to have better thermal stability, lower thermal conductivity, and improved sintering and thermal stress resistance than current coating systems. In this paper, the thermal conductivity, water vapor stability and cyclic durability of selected candidate zirconia-/hafnia-, pyrochlore- and magnetoplumbite-based T/EBC materials are evaluated. The test results have been used to downselect the T/EBC coating materials, and help demonstrate advanced 1650OC coatings feasibility with long-term cyclic durability.

Zhu, Dongming↗

AGR-5/6/7 Thermal Model with Non-uniform Gas Gaps

The daily as-run thermal analysis for the Advanced Gas Reactor (AGR)-5/6/7 experiment was documented in ECAR-5633 (Hawkes 2021). A finite element model was created for the entire test train, which consisted of five capsules. The fuel compacts, graphite holders, stainless-steel capsule walls, and all other major components were individually modeled, including all thermocouples (TCs). Daily heat rates for each compact and component in the model were input from daily as-run physics analyses. Daily gas compositions for each capsule were also input. The thermal conductivity of the compacts and graphite holders varied with fast neutron fluence. Gas mixture thermal conductivity was implemented using experimentally attained values from the literature. Fluence and temperature-dependent thermal conductivity was used for the graphite components and the fuel compacts. Radiation heat transfer was implemented. The model was tuned in an attempt to match the TC readings during the first cycle by adjusting the Neolube (graphite lubricant) thickness.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Molecular dynamics simulation of hydrodynamic transport coefficients in plasmas

Molecular dynamics simulations are used to calculate transport coefficients in a two-component plasma interacting through a repulsive Coulomb potential. The thermal conductivity, electrical conductivity, electrothermal coefficient, thermoelectric coefficient, and shear viscosity are computed using the Green–Kubo formalism over a broad range of Coulomb coupling strength, 0.01 ≤ Γ ≤ 140. Emphasis is placed on testing standard results of the Chapman–Enskog solution in the weakly coupled regime (Γ ≪ 1) using these first-principles simulations. As expected, the results show good agreement for Γ ≲ 0.1. However, this agreement is only possible if careful attention is paid to the definitions of linear constitutive relations in each of the theoretical models, a point that is often overlooked. For example, the standard Green–Kubo expression for thermal conductivity is a linear combination of thermal conductivity, electrothermal, and thermoelectric coefficients computed in the Chapman–Enskog formalism. Meaningful results for electrical conductivity are obtained over the full range of coupling strengths explored, but it is shown that potential and virial components of the other transport coefficients diverge in the strongly coupled regime (Γ ≫ 1). In this regime, only the kinetic components of the transport coefficients are meaningful for a classical plasma.

Electrical conductivity↗

Development and Testing of an Innovative Two-Arm Focal-Plane Thermal Strap (TAFTS)

Maintaining temperature stability in optical focal planes comes with the intrinsic challenge of creating a pathway that is both extremely flexible mechanically and highly conductive thermally. The task is further complicated because science‐caliber optical focal planes are extremely delicate, yet their mechanical resiliency is rarely tested and documented. The mechanical engineer tasked with the thermo‐mechanical design must then create a highly conductive thermal link that minimizes the tensile and shear stresses transmitted to the focal plane without design parameters on an acceptable stiffness. This paper will describe the development and testing of the thermal link developed for the Portable Remote Imaging Spectrometer (PRISM) instrument. It will provide experimentally determined mechanical stiffness plots in the three axes of interest. Analytical and experimental thermal conductance results for the two‐arm focal‐plane thermal strap (TAFTS), from cryogenic to room temperatures, are also presented. The paper also briefly describes some elements of the fabrication process followed in developing a novel design solution, which provides high conductance and symmetrical mechanical loading, while providing enhanced flexibility in all three degrees of freedom.

flexible thermal strap↗

Suppressing thermal transport in nonporous polymer hybrids by limiting thermally accessible vibrational modes

Achieving low thermal conductivity in nonporous polymer materials without compromising mechanical integrity remains a longstanding challenge. Conventional strategies, such as introducing porosity, are inherently limited in dense systems. Here, in this study, we demonstrate that thermal transport in polymer–organic filler hybrids is closely associated with the engineered availability of thermally accessible vibrational modes, rather than individual interfacial resistance or porosity. Using PU/organic filler hybrids as a model system, we show that incorporating rigid organic motifs shifts the vibrational density of states toward higher frequencies, where vibrational modes are weakly thermally populated at ambient conditions. This limits the number of heat-carrying channels, leading to suppressed thermal conductivity despite negligible individual interfacial resistance (∼10 −9 m 2 K W −1 ). These findings provide initial evidence that vibrational mode engineering may offer a promising molecular-level route for reducing thermal conductivity in dense polymer–organic hybrid systems.

36 MATERIALS SCIENCE↗

Braze Development of Graphite Fiber for Use in Phase Change Material Heat Sinks

Hamilton Sundstrand (HS), together with NASA Johnson Space Center, developed methods to metallurgically join graphite fiber to aluminum. The goal of the effort was to demonstrate improved thermal conductance, tensile strength and manufacturability compared to existing epoxy bonded techniques. These improvements have the potential to increase the performance and robustness of phase change material heat sinks that use graphite fibers as an interstitial material. Initial work focused on evaluating joining techniques from 4 suppliers, each consisting of a metallization step followed by brazing or soldering of one inch square blocks of Fibercore graphite fiber material to aluminum end sheets. Results matched the strength and thermal conductance of the epoxy bonded control samples, so two suppliers were down-selected for a second round of braze development. The second round of braze samples had up to a 300% increase in strength and up to a 132% increase in thermal conductance over the bonded samples. However, scalability and repeatability proved to be significant hurdles with the metallization approach. An alternative approach was pursued which used nickel and active braze allows to prepare the carbon fibers for joining with aluminum. This approach was repeatable and scalable with improved strength and thermal conductance when compared with epoxy bonding.

Quinn, Gregory↗

Braze Development of Graphite Fiber for Use in Phase Change Material Heat Sinks

Hamilton Sundstrand (HS), together with NASA Johnson Space Center, developed methods to metallurgically join graphite fiber to aluminum. The goal of the effort was to demonstrate improved thermal conductance, tensile strength and manufacturability compared to existing epoxy bonded techniques. These improvements have the potential to increase the performance and robustness of phase change material heat sinks that use graphite fibers as an interstitial material. Initial work focused on evaluating joining techniques from four suppliers, each consisting of a metallization step followed by brazing or soldering of one inch square blocks of Fibercore graphite fiber material to aluminum end sheets. Results matched the strength and thermal conductance of the epoxy bonded control samples, so two suppliers were down-selected for a second round of braze development. The second round of braze samples had up to a 300% increase in strength and up to a 132% increase in thermal conductance over the bonded samples. However, scalability and repeatability proved to be significant hurdles with the metallization approach. An alternative approach was pursued which used a nickel braze allow to prepare the carbon fibers for joining with aluminum. Initial results on sample blocks indicate that this approach should be repeatable and scalable with good strength and thermal conductance when compared with epoxy bonding.

Quinn, Gregory↗

Secondary processing of chondrules and refractory inclusions (CAIs) by gasdynamic heating

Results of calculations performed to determine the conditions necessary for producing the opaque rims on chondrules and CAI rims by high-speed entry into the transient atmosphere of an accreting meteorite parent body are presented. The sensitivity of these results to variations in critical parameters is investigated. The range of entry velocities which can produce such rims is shown to depend on the size, melting temperature, and thermal conductivity of the particles. For particles greater than 2 mm in radius, with thermal conductivities of 20,000 ergs/sm s K or lower, entry velocities of about 3 km/s suffice. For particle sizes less than 1 mm in radius, the range of encounter velocities that can produce rims is narrow or vanishing, regardless of the thermal conductivity, unless the melting temperature in the outer part of the chondrule has been reduced by compositional heterogeneity.

Podolak, M.↗

Sensitivity analysis of thermal contact conductance modeling to inform MiniFuel irradiation capsule designs

The MiniFuel irradiation platform has been developed by Oak Ridge National Laboratory as a flexible, high-throughput separate effects testing capability within the High Flux Isotope Reactor (HFIR). Finite element thermal models are relied upon to design MiniFuel experiments to achieve a specific time-averaged irradiation temperature for experimental objectives. A previous study identified that uncertainty in the component heat generation rates and thermal contact conductance (TCC) model are the most significant contributors to predicted fuel temperature variance. To address both sources of uncertainty, this work performs sensitivity analysis on the TCC model to identify high-impact, high-uncertainty parameters that contribute to fuel temperature variance. The TCC model is analyzed in increasing detail, first using a standalone Python code, then again after coupling Python to the BISON fuel performance code. Furthermore, the parameters with the largest contributions to fuel temperature variance which can be reduced through design changes are identified as the initial subcapsule gas pressure, contact pressure between the fuel and dish, and the effective surface roughness of the interface. A set of design recommendations for future capsule designs has been established and applied to reduce the previously quantified average fuel temperature uncertainty ranges of ± 40 °C in the HFIR vertical experiment facilities (VXF) and ± 80 °C in the removable beryllium (RB) reflector to approximately ± 32 °C and ± 53 °C, respectively. This equates to a 21 % and 33 % reduction in the uncertainty range of the average fuel temperature for VXF and RB, respectively.

BISON↗

Study of a Solar X-Ray Telescope

The highly structured nature of the outer solar atmosphere seems to be intimately linked to the presence, at the solar surface, of magnetic fields that have been generated inside the Sun and have emerged to the surface. The corona is brightest (and also hottest) at just those locations where the magnetic field has emerged from inside the Sun. Dynamo theory predicts that strong magnetic fields will be generated deep in the solar interior and that bundles or 'ropes' of magnetic flux will float to the surface. When this happens, a magnetically bipolar region will become visible, extending above the surface in a three-dimensional structure. The field lines penetrate through the surface, showing two magnetic poles, and also exhibit a three-dimensional structure above the surface. The structure created by the field emergence is rooted in the (relatively) cool photosphere and extends through the chromosphere and transition region to the corona. Thus, the magnetic field creates a region, called an active region, which contains portions at temperatures from less than 10(exp 4) K to greater than 10(exp 6) K, and is therefore visible at wavelengths from the infrared through x-rays. The locations where the magnetic field leaves and reenters the visible surface are called the 'footpoints' of the coronal structures associated with the magnetic field. The magnetic fields themselves are not directly visible. However, the hot coronal plasma is, for the most part, constrained to follow the direction of the magnetic field lines in the atmosphere. Now, 100 years after the discovery of x-rays by Wilhelm Roentgen in 1896, we can routinely make observations of the solar corona from outside the Earth's atmosphere in this region of the electromagnetic spectrum. As shown by comparing x-ray images with magnetograms, the bright corona over these bipolar magnetic regions consists of closed structures that seem to follow the orientation of the magnetic field. Although we can see down to the photosphere at x-ray wavelengths when observing the disk of the Sun, this part of the solar atmosphere emits so little that far from the peak of its Planck curve it appears dark in x-ray images. This impression of hot plasma following the magnetic field direction is further strengthened by quantitative studies that calculate coronal magnetic field strength and direction based on photospheric measurements and compare them with the observed brightness and location of the x-ray emitting structures. Such comparisons make it clear that, for the most part, the hot plasma conforms to the geometry of the magnetic field and that the coronal brightness is strongly linked to the strength of the magnetic fields which have erupted to the solar surface from the interior. It is also the case that the larger-scale, fainter corona, as well as coronal holes, are strongly influenced by the large-scale solar magnetic field. We may get a small hint of the reason that the coronal plasma outlines the direction of B by examining the thermal conductivity of a hot plasma in the presence of a magnetic field. This quantity has enormously different values in the directions parallel and perpendicular to the field for a coronal temperature of 10(exp 6) K, a particle density of 10(exp 9)/cu cm and a magnetic field strength of 100 G, the conductivity along the field is approximately 13 orders of magnitude greater than that perpendicular to the field. It is therefore not surprising that a parcel of plasma which is locally heated would conduct that heat preferentially in the direction of the field. We also note that the thermal conductivity parallel to the magnetic field increases with temperature T, while the perpendicular conductivity decreases. To the extent that the loop aspect ratio, i.e., the ratio of loop length to loop width, is determined by the thermal conductivity, we would expect that higher temperature loops are longer and thinner than cooler ones. However, if the loop width becomes smaller than the spatial resolution of the observing instrument, this effect will not be directly observable. For organizational purposes, we provide a listing of some scientific objectives for a Solar-B x-ray telescope, arranged in terms of identifiable features in the corona.

Golub, Leon↗