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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 955 records · Page 53
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

Solar energy in California industry - Applications, characteristics and potential

Results of a survey to determine the potential applicability of solar thermal energy to industrial processes in California are presented. It is found that if the heat for all industrial processes at temperatures below 212 F were supplied by solar energy, total state energy consumption could be reduced by 100 trillion Btus (2%), while the use of solar energy in processes between 212 and 350 F could displace 500 trillion Btus. The issues and problems with which solar energy must contend are illustrated by a description of fluid milk processing operations. Solar energy application is found to be technically feasible for processes with thermal energy requirements below 212 F, with design, and degree of technical, economic and management feasibility being site specific. It is recommended that the state provide support for federal and industrial research, development and demonstration programs in order to stimulate acceptance of solar process heat application by industry.

Barbieri, R. H.↗
NASA NTRS1991

Variation of superheat with subcooling in nucleate pool boiling

An analysis is presented that explains the variation of superheat with subcooling that has been observed by a number of researchers investigating nucleate boiling heat transfer at constant heat flux. It is shown that superheat initially increases with increasing subcooling near saturated conditions because of the way in which changes in active site density and average bubble frequency with increasing subcooling affect the rate of heat removal from the heater surface by enthalpy transport and microlayer evaporation. As subcooling increases further, natural convection begins to play an increasingly important role in the heat transfer process. Ultimately, natural convection is able to accommodate the entire imposed heat flux, after which superheat decreases as subcooling increases. The success of the analysis in explaining the variation of superheat with subcooling suggests that the rate of the heat removal from the heater surface is completely determined by the mechanisms of enthalpy transport, natural convection, and microlayer evaporation.

Judd, R. L.↗
NASA NTRS2002

Radiation Effects in a Semitransparent Gray Coating Heated by Convection and Cooled by Radiation

A parametric study using a one dimensional model of a semitransparent gray thermal barrier coating was performed to gain an understanding of the role thermal radiation can play in the heat transferred. Some ceramic materials are semitransparent in the wavelength ranges were thermal radiation is important. Therefore, absorption, emission, and scattering of thermal radiation can affect the he at transfer through the coating. In this paper, a one dimensional layer was used to model the heat transfer process occurring, in a burner test rig. The semitransparent layer is heated by a hot gas flowing over its surface. The layer and substrate at a cooled by radiation to the surroundings. The back side of the substrate is insulated. The coating is assumed to be gray (absorption and scattering coefficients are not function of wavelength). An absorption coefficient of 0.3/cm and scatter a rig coefficients of 0 (no scattering) and 100/cm (isotropic scattering) were used. The thickness and thermal conductivity of the layer are varied. The results show that the temperatures are affected by the properties of the semitransparent .ever and the emissivity of the substrate. The substrate and surface temperatures are presented. The apparent temperature an optical pyrometer would read for the emitted energy is also given. An apparent thermal conductivity was calculated for the layer.

Spuckler, Charles M.↗
NASA NTRS2011

Shape Memory Characteristics of Ti(sub 49.5)Ni(sub 25)Pd(sub 25)Sc(sub 0.5) High-Temperature Shape Memory Alloy After Severe Plastic Deformation

A Ti(49.5)Ni25Pd25Sc(0.5) high-temperature shape memory alloy is thermomechanically processed to obtain enhanced shape-memory characteristics: in particular, dimensional stability upon repeated thermal cycles under constant loads. This is accomplished using severe plastic deformation via equal channel angular extrusion (ECAE) and post-processing annealing heat treatments. The results of the thermomechanical experiments reveal that the processed materials display enhanced shape memory response, exhibiting higher recoverable transformation and reduced irrecoverable strain levels upon thermal cycling compared with the unprocessed material. This improvement is attributed to the increased strength and resistance of the material against defect generation upon phase transformation as a result of the microstructural refinement due to the ECAE process, as supported by the electron microscopy observations.

Atli, K. C.↗
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗
DOE OSTI2019

Numerical Simulation of Critical Factors Controlling Heat Extraction from Geothermal Systems Using a Closed-Loop Heat Exchange Method

Closed-loop heat exchange for geothermal energy production involves injecting working fluid down a well that extends through the geothermal resource over a significant length to absorb heat by conduction through the well pipe. The well then needs to return to the surface for energy recovery and fluid re-injection to complete the cycle. We have carried out mixed convective-conductive fluid-flow modeling using a wellbore flow model for TOUGH2 called T2Well to investigate the critical factors that control closed-loop geothermal energy recovery. T2Well solves a mixed explicit-implicit set of momentum equations for flow in the pipe with full coupling to the implicit three-dimensional integral finite difference equations for Darcy flow in the porous medium. T2Well has the option of modeling conductive heat flow from the porous medium to the pipe by means of a semi-analytical solution which makes the computation very efficient because the porous medium does not have to be discretized. When the fully three-dimensional option is chosen, the porous medium is discretized and heat flow to the pipe is by conduction and convection, depending on reservoir permeability and other factors. Simulations of the closed-loop system for a variety of parameter values have been carried out to elucidate the heat recovery process. To the extent that convection may occur to aid in heat delivery to the pipe, the permeability of the geothermal reservoir, whether natural or stimulated, is an important property in heat extraction. The injection temperature and flow rate of the working fluid strongly control the ultimate energy recovery. Pipe diameter also plays a strong role in heat extraction, but is correlated with flow rate. Similarly, the choice of working fluid plays an important role, with water showing better heat extraction than CO2 for certain flow rates, while the CO2 has higher pressure at the production wellhead which can aid in surface energy recovery. In general, we find complex interactions between the critical factors that will require advanced computational approaches to fully optimize.

Oldenburg, Curtis↗
NASA NTRS1999

Consistency Between Tropical Divergent Circulations from Reanalysis Data Sets and Satellite-Derived Precipitation, Radiation, and Surface Fluxes

Large-scale divergent circulations are part of the atmospheric dynamic response to diabatic heating from condensation, radiative processes, and surface heat fluxes. Vertical motion and the associated divergent wind is thus intimately tied to the hydrologic cycle and the global heat balance. Vertical motions are recovered diagnostically from reanalyses and, as such, are subject to shortcommings in model physics, numerics, and data availability. We use several Global Energy and Water Cycle Experiment (GEWEX) Earth Observation System (EOS) data sets derived from satellite data to assess interannual divergent flow anomalies in the National Centers for Environmental Prediction (NCEP), Goddard Space Flight Center (GSFC), and GSFC Data Assimilation Office (DAO) analyses. Among the data sets are monthly, 2.5 degree gridded precipitation (Microwave Sounding Unit (MSU) and Special Sensor Microwave Imager (SSM/I-based)), Top or the atmosphere (TOA) radiative fluxes from ERBS, surface radiative fluxes from the SRB project, and surface latent and sensible flux estimates from SSM/I. These data sets can be considered as independent of the reanalysis fields. We focus largely on the period 1987-1989 encompassing a strong El Nino / la Nina couplet. Consequently we emphasize interannual changes as well as climatological aspects of the reanalyses. In the processes of this study we use simple integral constraints enforced through the satellite-derived data sets to derive corrections to the divergent circulation produced from the reanalyses. We examine the implications of these corrections in describing how perturbations to the tropical heat balance evolve during a warm / cool couplet. In particular the perturbations to the planetary scale water vapor transport, and the resulting changes in TOA and surface radiative fluxes are considered.

Robertson, Franklin R.↗
NASA NTRS2014

Processing of Packing Foams Using Heat Melt Compaction

Foam is used extensively as packing material for items sent to the International Space Station (ISS). Although lightweight, foam is bulky and can occupy a large fraction of the limited ISS volume. Four chemically distinct foams have been used on the ISS. In descending order of current usage, these are Plastazote Zotek Minicel Pyrell. Processing foam with the Heat Melt Compactor (HMC), a solid waste treatment system, has been proposed to reduce the volume of foams stored on spacecraft. Prior to HMC testing, Thermogravimetric Analyses were conducted on the four foams as a precaution to ensure that the thermal decomposition temperatures were not within range of HMC operation (180C). Pyrell was not tested with the HMC because it is known to release toxic compounds and comprises less than 1.5 of total foam usage on ISS resupply flights. Zotek, Minicel, Plastazote LD24FR (low density), and Plastazote LD45FR (high density) were processed with the HMC at 130, 150 and 170C. Volume was reduced by 82.6 on average (n19; std dev4.88). Hydrocarbons and several other compounds emitted during foam processing were measured using a Total Hydrocarbon Analyzer and FTIR. Effects of process temperature and foam type on exhaust composition are discussed. Feeding of foams into the limited size opening of the HMC compaction chamber is likely to be a challenge, particularly in microgravity. Some suggestions are proposed to facilitate feeding foam into the HMC. Processing packing foam with the HMC has been shown to substantially reduce foam volume, and also has the potential benefit of producing radiation-shielding foam tiles.

Harris, Linden↗
DOE OSTI2013

Inverse bremsstrahlung heating rate for dense plasmas in laser fields

We report a theoretical analysis of inverse bremsstrahlung heating rate in the eikonal approximation. The present analysis is performed for a dense plasma using the screened electron-ion interaction potential for the ion charge state Z{sub i} = 1 and for both the weak and strong plasma screening cases. We have also compared the eikonal results with the first Born approximation (FBA) [M. Moll et al., New J. Phys. 14, 065010 (2012)] calculation. We find that the magnitudes of inverse bremsstrahlung heating rate within the eikonal approximation (EA) are larger than the FBA values in the weak screening case (κ = 0.03 a.u.) in a wide range of field strength for three different initial electron momenta (2, 3, and 4 a.u.). But for strong screening case (κ = 0.3 a.u.), the heating rates predicted by the two approximations do not differ much after reaching their maximum values. Furthermore, the individual contribution of photoemission and photoabsorption processes to heating rate is analysed for both the weak and strong screening cases. We find that the single photoemission and photoabsorption rates are the same throughout the field strength while the multiphoton absorption process dominates over the multiphoton emission process beyond the field strength ≈ 4×10{sup 8} V/cm. The present study of the dependence of heating rate on the screening parameter ranging from 0.01 to 20 shows that whereas the heating rate predicted by the EA is greater than the FBA up to the screening parameter κ = 0.3 a.u., the two approximation methods yield results which are nearly identical beyond the above value.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Collaborative Technology Assessments Of Transient Field Processing And Additive Manufacturing Technologies As Applied To Gas Turbine Components

ORNL partnered with GE Power & Water to investigate the effect of thermomagnetic processing on the microstructure and mechanical properties of GE Power & Water newly developed wrought Ni-Fe-Cr alloys. Exploration of the effects of high magnetic field process during heat treatment of the alloys indicated conditions where applications of magnetic fields yields significant property improvements. The alloy aged using high magnetic field processing exhibited 3 HRC higher hardness compared to the conventionally-aged alloy. The alloy annealed at 1785 F using high magnetic field processing demonstrated an average creep life 2.5 times longer than that of the conventionally heat-treated alloy. Preliminary results show that high magnetic field processing can improve the mechanical properties of Ni-Fe-Cr alloys and potentially extend the life cycle of the gas turbine components such as nozzles leading to significant energy savings.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Development of CFD-Based Simulation Tools for In-Situ Thermal Processing of Oil Shale/Sands

In our research, we are taking the novel approach of developing and applying high performance computing, computational fluid dynamics (CFD)-based simulation tools to a modified in-situ process for production of oil from oil shale. The simulation tools being developed capture the relevant physical processes and data from a large-scale system. The modified in-situ application is a pilot-scale heat transfer process inside Red Leaf Resources EcoShale capsule. We demonstrate the need to understand fluid flow behavior in the convective channels of the rubblized shale bed as convective heating greatly decreases the time required to heat the oil shale to the production temperature when compared with conductive heating alone. We have developed and implemented a geometry creation strategy for a representative section of the EcoShale capsule, developed a meshing approach to deal with the complicated geometry and produce a well-behaved mesh, analyzed the effects of boundary conditions on the simulation results, and devised a new operator splitting solution algorithm that reduces computational costs by taking advantage of the differing convective and conductive time scales occurring in the simulation. These simulation tools can be applied to a wide range of processes involving convective fluid flow heating in rubblized beds.

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2025

The effect of heat treatment on the defect evolution in LPBF 316H stainless steel

This work investigates the effect of processing and heat treatment on defect evolution and irradiation response of laser powder bed fusion (LPBF) 316H stainless steel, with comparisons to LPBF 316L and wrought 316L/316H. Using in-situ and ex-situ ion irradiations across a wide parameter space—temperature (300–675 °C), dose (0.2–25 dpa), dose rate (10 -3 –10 -5 dpa/s), and helium co-implantation (20–2500 appm)—we correlated void swelling, dislocation loop evolution, and segregation behavior with pre-irradiation microstructures (as-built, stress-relieved, solution-annealed, and cold-worked). Results show that swelling is strongly controlled by dislocation density: intermediate densities maximize swelling, while solution annealing or cold working reduce susceptibility to levels comparable to wrought alloys. Low dose rates and helium both promote cavity nucleation and lower the incubation barrier, with helium suppressing the role of dislocation density and driving swelling behavior toward wrought-like response. Loop evolution in SA LPBF 316H resembles wrought 316L but shows localized denuded zones near low-angle grain boundaries. STEM-EDS mapping further revealed Ni segregation at voids and sparse Al-rich oxides, without evidence of Ni–Si precipitates. Collectively, these findings identify dislocation density, helium content, and dose rate as the factors governing swelling in LPBF 316H and provide mechanistic datasets for model validation, supporting LAIN and the qualification of AM austenitic steels for nuclear service.

316 stainless steel↗
DOE OSTI2025

Friction Self-piercing Riveting Process for 3T Configuration of AA7075-AA7075-AA6022

Friction self-piercing riveting (F-SPR), as a solid-state joining process that generates frictional heat during the process, was utilized to join a 3 T configuration of low-ductility AA7075-AA7075-AA6022 sheets. A multi-step F-SPR process was employed to precisely control the mechanical interlocking and solid-state joining, ensuring a strong joint formation. With control of the plunge depth when the transition from rivet penetration to rivet flaring, two joining conditions were developed to assess mechanical joint integrity: one bearing deep penetration with a smaller interlock, and the other yielding a shallow penetration with a larger interlock. Both strategies met the criteria for a sound rivet joint. Customized lap shear tensile configurations were designed to assess the joint strength at interface between first and second layers, as well as between second and third layers. Both conditions demonstrated great joint strength between the first and second layers, while deeper penetration approach showed stronger solid-state joint, leading to improved joint strength between the second and third layers.

Wang, Tianzhao [ORNL] (ORCID:0000000315337602)↗
DOE OSTI2018

Study on Corrosion Behavior of 7075 Aluminum Alloy with Retrogression and Reaging Using Taguchi Method

The corrosion resistance and mechanical properties of 7075 aluminum alloy are improved by retrogression and reaging (RRA) heat treatment. Due to the complex process of RRA heat treatment, a Taguchi L25 orthogonal array is designed to optimize the process parameters of RRA heat treatment. In this work, analysis of variance was performed to find out the significant heat treatment parameters. Microstructure, mechanical properties, intergranular corrosion, exfoliation corrosion and stress corrosion cracking behaviors of 7075 aluminum alloy after RRA heat treatment were investigated by tensile test, slow strain rate test, transmission electron microscope and scanning electron microscope. Results showed that the RRA treatment involving preaging at 120 °C for 16 h, retrogression at 200 °C for 8 min and reaging at 120 °C for 24 h resulted in a desired combination of corrosion resistance and mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Dynamics of laser induced metal nanoparticle and pattern formation

Discontinuous metal films are converted into either almost round, isolated, and randomly distributed nanoparticles (NPs) or fringed patterns of alternate non transformed film and NPs by exposure to single pulses (20 ns pulse duration and 193 nm wavelength) of homogeneous or modulated laser beam intensity. The dynamics of NPs and pattern formation is studied by measuring in real time the transmission and reflectivity of the sample upon homogeneous beam exposure and the intensity of the diffraction orders 0 and 1 in transmission configuration upon modulated beam exposure. The results show that laser irradiation induces melting of the metal either completely or at regions around intensity maxima sites for homogeneous and modulated beam exposure, respectively, within ≤10 ns. The aggregation and/or coalescence of the initially irregular metal nanostructures is triggered upon melting and continues after solidification (estimated to occur at ≤80 ns) for more than 1 μs. The present results demonstrate that real time transmission rather than reflectivity measurements is a valuable and easy-to-use tool for following the dynamics of NPs and pattern formation. They provide insights on the heat-driven processes occurring both in liquid and solid phases and allow controlling in-situ the process through the fluence. They also evidence that there is negligible lateral heat release in discontinuous films upon laser irradiation.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2018

Magnetothermal disc winds in X-ray binaries: poloidal magnetic fields suppress thermal winds

Magnetic, radiation pressure, and thermal driving are the three mechanisms capable of launching accretion disc winds. In X-ray binaries, radiation pressure is often not significant, as in many systems the luminosity is too low for driving due to continuum transitions yet too high for driving due to line transitions. This leaves thermal and magnetic driving as the contender launching mechanisms in these systems. Using ATHENA++, here we perform axisymmetric ideal MHD simulations that include radiative heating and cooling processes appropriate for Compton heated winds to show that the inclusion of magnetic fields into a thermally driven wind has the opposite effect of what one might expect: rather than provide a velocity boost, the thermal wind is suppressed in low-plasma beta regions where the field lines are strong enough to reshape the direction of the flow. Our analysis reveals that magneto-centrifugal launching is present but weak, while the reduction in wind velocity is not due to the change in gravitational potential through the magnetically imposed streamline geometry, but rather due to the increased flow tube area just above the surface of the disc, which is less conducive to acceleration. Finally, our results suggest that for magnetothermal wind models to be successful at producing fast dense outflows in low-mass X-ray binaries, the winds must be magnetically launched well within the Compton radius.

79 ASTRONOMY AND ASTROPHYSICS↗