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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 NTRS2021

Investigation of Ionic Liquids Isolated Iron for Ductile Iron Castings

As research continues for missions beyond low-Earth orbit, in-situ resource utilization (ISRU) methods are critical. For Lunar and Martian colonization, the ability to manufacture mechanical and structural components with local resources is essential. Ionic liquids (IL) are being studied at NASA Marshall Space Flight Center (MSFC) to harvest elemental metals from meteorites and regolith oxides. In this investigation, the viability of casting ductile iron using ionic liquids sourced iron and nickel was explored given ductile iron’s range of applications and performance as an as-cast alloy. Ingots were produced using commercial elements to simulate the use of IL iron with carbon sourced from the by-products of a life support system currently tested at MSFC. Samples were cast and compared to commercial ductile iron with phase transformation diagrams,microstructures, and hardness. Results showed ionic liquids sourced elements are a viable source of elemental alloying materials for a range of ductile iron alloys.

Ionic Liquids↗
NASA NTRSDate not supplied

Parameter, Post-Processing Sensitivities, and Qualification Approach of Laser Powder Bed Fusion Hydrogen Resistant Alloy NASA HR-1

Metal additive manufacturing (AM) processes are being used to enable economical manufacturing of legacy alloys as well as advancing new alloys. Laser powder bed fusion (L-PBF) is a metal AM process that has high maturity and being used to produce a variety of parts for space applications including complex propulsion components. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. NASA HR-1 is a high strength Fe-Ni based superalloy designed to resist high pressure hydrogen environment embrittlement (HEE), oxidation, and corrosion that has been successfully adapted to laser powder directed energy deposition (LP-DED). Insights gained from the NASA HR-1 development for LP-DED have guided the development process for L-PBF. However, adapting NASA HR-1 to L-PBF posed new challenges due to the distinct differences between the additive manufacturing processes. During parameter development, sensitivities were observed in post-processing that necessitated additional optimization of heat treatments. Additionally, the variations in thickness and how it influenced the microstructural response during heat treatment was characterized. Understanding these sensitivities is important to qualification of the material in a L-PBF machine. This ensures that the microstructures and properties of the material maintain consistency in production. This presentation will cover parameter development along with post-processing challenges and solutions will be discussed in addition to key material properties as it pertains to application performance and qualification per NASA-STD-6030. Improvements made by developing a derivative alloy, NASA HR-2, will be highlighted through preliminary small scale parameter development, material characterization, and initial property testing.

NASA HR-1↗
NASA NTRS2025

Potential Health Impacts, Treatments, and Countermeasures of Martian Dust on Future Human Space Exploration

The challenges of human space exploration produce some of humanity’s greatest technological and scientific advances, not excluding innovations in medicine. The microgravity environment causes a whole host of physiological changes, and exposure to dust on the Moon caused considerable pulmonary distress to astronauts during the Apollo missions. As the National Aeronautics and Space Administration (NASA)and other space organizations prepare for long duration exploration missions to Mars, the hazards and consequences of the Martian surface need to be accounted for. This review investigates how substances analogous to the hazardous components of Martian dust have caused disease in people on Earth. Because of the small grain size of Martian dust, dust on Mars is more likely to cause lung irritation, absorb into the bloodstream, and lead to diseases in astronauts. Toxic components of Martian dust to astronaut health include perchlorates, silica, nanophase iron oxides, and gypsum in addition to trace amounts of toxic metals whose abundances are debated: chromium, beryllium, arsenic, and cadmium. Predicted effects of dust exposure ranges from asymptomatic to life threatening, with many substances being carcinogenic and most damage impacting the pulmonary system. The longer transit time for astronauts to return home makes the operations of performing emergency medical treatment more difficult and increases both the likelihood and consequences of developing chronic disease. Exposure mitigation needs to be prioritized; however, supplements may be taken to prevent disease from breakthrough exposures and treatment regimens could lessen morbidity and mortality. Treatments and equipment need to be carefully thought out and transported with the astronauts to be prepared for all possible scenarios.

Justin L Wang↗
NASA NTRS2013

Composite Aerogel Multifoil Protective Shielding

New technologies are needed to survive the temperatures, radiation, and hypervelocity particles that exploration spacecraft encounter. Multilayer insulations (MLIs) have been used on many spacecraft as thermal insulation. Other materials and composites have been used as micrometeorite shielding or radiation shielding. However, no material composite has been developed and employed as a combined thermal insulation, micrometeorite, and radiation shielding. By replacing the scrims that have been used to separate the foil layers in MLIs with various aerogels, and by using a variety of different metal foils, the overall protective performance of MLIs can be greatly expanded to act as thermal insulation, radiation shielding, and hypervelocity particle shielding. Aerogels are highly porous, low-density solids that are produced by the gelation of metal alkoxides and supercritical drying. Aerogels have been flown in NASA missions as a hypervelocity particle capture medium (Stardust) and as thermal insulation (2003 MER). Composite aerogel multifoil protective shielding would be used to provide thermal insulation, while also shielding spacecraft or components from radiation and hypervelocity particle impacts. Multiple layers of foil separated by aerogel would act as a thermal barrier by preventing the transport of heat energy through the composite. The silica aerogel would act as a convective and conductive thermal barrier, while the titania powder and metal foils would absorb and reflect the radiative heat. It would also capture small hypervelocity particles, such as micrometeorites, since it would be a stuffed, multi-shock Whipple shield. The metal foil layers would slow and break up the impacting particles, while the aerogel layers would convert the kinetic energy of the particles to thermal and mechanical energy and stop the particles.

Jones, Steven M.↗
NASA NTRS1975

Heat conduction in metal-filled polymers - The role of particle size, shape, and orientation

This paper presents a new type of analysis for predicting the thermal conductivity of disperse composites from the properties of the component phases and elementary characterizations of particle shapes and orientation. This analysis successfully predicted the sensitivity to particle shape which was confirmed by experiments also reported in this paper. These results suggest that highly elongated particles may be used to achieve dramatic modifications of thermal conductivity and the analysis presented here may be a useful tool in the design or development of disperse composites of specific thermal conductivity. The analysis may also apply to other properties such as electrical conductivity or magnetic permeability.

Hansen, D.↗
NASA NTRS1979

Thermal stress analysis of ceramic gas-path seal components for aircraft turbines

Stress and temperature distributions were evaluated numerically for a blade-tip seal system proposed for gas turbine applications. The seal consists of an abradable ceramic layer on metallic backing with intermediate layers between the ceramic layer and metal substrate. The most severe stresses in the seal, as far as failure is concerned, are tensile stresses at the top of the ceramic layer and shear and normal stresses at the layer interfaces. All these stresses reach their maximum values during the deceleration phase of a test engine cycle. A parametric study was carried out to evaluate the influence of various design parameters on these critical stress values. The influences of material properties and geometric parameters of the ceramic, intermediate, and backing layers were investigated. After the parametric study was completed, a seal system was designed which incorporated materials with beneficial elastic and thermal properties in each layer of the seal. An analysis of the proposed seal design shows an appreciable decrease in the magnitude of the maximum critical stresses over those obtained with earlier configurations.

Kennedy, F. E.↗
NASA NTRS2002

New Approach to Ultrasonic Spectroscopy Applied to Flywheel Rotors

Flywheel energy storage devices comprising multilayered composite rotor systems are being studied extensively for use in the International Space Station. A flywheel system includes the components necessary to store and discharge energy in a rotating mass. The rotor is the complete rotating assembly portion of the flywheel, which is composed primarily of a metallic hub and a composite rim. The rim may contain several concentric composite rings. This article summarizes current ultrasonic spectroscopy research of such composite rings and rims and a flat coupon, which was manufactured to mimic the manufacturing of the rings. Ultrasonic spectroscopy is a nondestructive evaluation (NDE) method for material characterization and defect detection. In the past, a wide bandwidth frequency spectrum created from a narrow ultrasonic signal was analyzed for amplitude and frequency changes. Tucker developed and patented a new approach to ultrasonic spectroscopy. The ultrasonic system employs a continuous swept-sine waveform and performs a fast Fourier transform on the frequency spectrum to create the spectrum resonance spacing domain, or fundamental resonant frequency. Ultrasonic responses from composite flywheel components were analyzed at Glenn to assess this NDE technique for the quality assurance of flywheel applications.

Harmon, Laura M.↗
NASA NTRS2010

Performance Testing of Molten Regolith Electrolysis with Transfer of Molten Material for the Production of Oxygen and Metals on the Moon

Previously, we have demonstrated the production of oxygen by electrolysis of molten regolith simulants at temperatures near 1600 C. Using an inert anode and suitable cathode, direct electrolysis (no supporting electrolyte) of the molten silicate is carried out, resulting in the production of molten metallic products at the cathode and oxygen gas at the anode. Initial direct measurements of current efficiency have confirmed that the process offer potential advantages of high oxygen production rates in a smaller footprint facility landed on the moon, with a minimum of consumables brought from Earth. We now report the results of a scale-up effort toward the goal of achieving production rates equivalent to 1 metric ton O2/year, a benchmark established for the support of a lunar base. We previously reported on the electrochemical behavior of the molten electrolyte as dependent on anode material, sweep rate and electrolyte composition in batches of 20-200g and at currents of less than 0.5 A. In this paper, we present the results of experiments performed at currents up to 10 Amperes) and in larger volumes of regolith simulant (500 g - 1 kg) for longer durations of electrolysis. The technical development of critical design components is described, including: inert anodes capable of passing continuous currents of several Amperes, container materials selection, direct gas analysis capability to determine the gas components co-evolving with oxygen. To allow a continuous process, a system has been designed and tested to enable the withdrawal of cathodically-reduced molten metals and spent molten oxide electrolyte. The performance of the withdrawal system is presented and critiqued. The design of the electrolytic cell and the configuration of the furnace were supported by modeling the thermal environment of the system in an effort to realize a balance between external heating and internal joule heating. We will discuss the impact these simulations and experimental findings have on the design of a suitable prototype for lunar applications

Sibille, Laurent↗
NASA NTRS1976

Compound solder joints

Joining technique prevents contamination, may be used to join dissimilar metal tubes, minimizes fluid and gas entrapment, expedites repairs, and can yield joints having leakage rates less than 0.000001 standard cubic cm He/min. Components of joint are solder sleeve, two solder rings, Teflon sleeve, and tubing to be joined.

Batista, R. I.↗
NASA NTRS1976

Ultrasonic measurement of stress in 2219-T87 aluminum plate

The basic relationship of ultrasonic signal velocity to directional subsurface stress is reviewed. Inappropriateness of dependency on a single correlative value of constant for a three dimensional stress field in metallic materials is discussed. Implementation of conventional ultrasonic nondestructive testing capabilities integrated to provide a composite technique for the measurement of orthogonal stress components is described, and the procedures for performing the preparatory calibration and subsequent stress field measurements are presented. In conclusion, the prime effect of stress on ultrasonic signal velocity occurs only in the direction of material excitation or particle motion.

Clotfelter, W. N.↗
NASA NTRS1977

The NASA thermionic-conversion /TEC-ART/ program

The NASA program for applied research and technology in thermionic energy conversion is described, and the approaches used to obtain the goal of reduced interelectrode losses, improved emitters, and improved collectors are indicated. The current emphasis on out-of-core thermionics allows materials and designs previously prohibited by in-core nucleonics and geometrics. Since high-temperature material effects are important for several components, tungsten, 25%-rhenium technology is a subject of research. Emitter-vaporization, collector-deposition effects were studied, and improvements in metallic-fluid heat pipes are considered. Some required characteristics of electrodes are examined.

Morris, J. F.↗
NASA NTRS1979

High-energy-density cylindrical capacitors

Manufacturing technique produces high quality metalized-film cylindrical capacitors of energy density greater than 0.1 J/g uncased, using either 24-gage polyvinylidene flouride or 14-gage polycarbonate film. Components are wound wrinkle-free on hollow PTFE cores, using winding machine that applies constant dynamically controlled tension to film during winding operation.

Parker, R. D.↗
NASA NTRS1980

A computer program for cyclic plasticity and structural fatigue analysis

A computerized tool for the analysis of time independent cyclic plasticity structural response, life to crack initiation prediction, and crack growth rate prediction for metallic materials is described. Three analytical items are combined: the finite element method with its associated numerical techniques for idealization of the structural component, cyclic plasticity models for idealization of the material behavior, and damage accumulation criteria for the fatigue failure.

Kalev, I.↗
NASA NTRS1988

Improved "Green" Forming Of Silicon Nitride

Advanced processing techniques reduce incidence of critical flaws. Critical flaws reduced by processing of powders to avoid organic and metallic contamination and combination of colloidal techniques with innovative slurry-pressing technique avoiding agglomeration. Silicon nitride considered for many applications ranging from components of turbine engines to industrial heat exchangers.

Freedman, Marc R.↗
NASA NTRS1991

Ceramic regenerator program

The feasibility of fabricating an Air Turbo Ramjet (ATR) regenerator containing intricate hydraulic passages from a ceramic material in order to allow operation with high temperature combustion gas and to reduce weight as compared with metallic materials was demonstrated. Platelet technology, ceramic tape casting, and multilayer ceramic packaging techniques were used in this fabrication of subscale silicon nitride components. Proof-of-concept demonstrations were performed to simulate a methane cooled regenerator for an ATR engine. The regenerator vane was designed to operate at realistic service conditions, i.e., 600 psi in a 3500 R (3040 F), 500 fps combustion gas environment. A total of six regenerators were fabricated and tested. The regenerators were shown to be able to withstand internal pressurization to 1575 psi. They were subjected to testing in 500 fps, 3560 R (3100 F) air/propane combustion products and were operated satisfactorily for an excess of 100 hr and 40 thermal cycles which exceeded 2460 R (2000 F).

Franklin, Jerrold E.↗
NASA NTRS1959

Materials Problems in Chemical Liquid-Propellant Rocket Systems

With the advent of the space age, new adjustments in technical thinking and engineering experience are necessary. There is an increasing and extensive interest in the utilization of materials for components to be used at temperatures ranging from -423 to over 3500 deg F. This paper presents a description of the materials problems associated with the various components of chemical liquid rocket systems. These components include cooled and uncooled thrust chambers, injectors, turbine drive systems, propellant tanks, and cryogenic propellant containers. In addition to materials limitations associated with these components, suggested research approaches for improving materials properties are made. Materials such as high-temperature alloys, cermets, carbides, nonferrous alloys, plastics, refractory metals, and porous materials are considered.

Gilbert, L. L.↗
NASA NTRS1999

SiC/SiC Leading Edge Turbine Airfoil Tested Under Simulated Gas Turbine Conditions

Silicon-based ceramics have been proposed as component materials for use in gas turbine engine hot-sections. A high pressure burner rig was used to expose both a baseline metal airfoil and ceramic matrix composite leading edge airfoil to typical gas turbine conditions to comparatively evaluate the material response at high temperatures. To eliminate many of the concerns related to an entirely ceramic, rotating airfoil, this study has focused on equipping a stationary metal airfoil with a ceramic leading edge insert to demonstrate the feasibility and benefits of such a configuration. Here, the idea was to allow the SiC/SiC composite to be integrated as the airfoil's leading edge, operating in a "free-floating" or unrestrained manner. and provide temperature relief to the metal blade underneath. The test included cycling the airfoils between simulated idle, lift, and cruise flight conditions. In addition, the airfoils were air-cooled, uniquely instrumented, and exposed to the same internal and external conditions, which included gas temperatures in excess of 1370 C (2500 F). Results show the leading edge insert remained structurally intact after 200 simulated flight cycles with only a slightly oxidized surface. The instrumentation clearly suggested a significant reduction (approximately 600 F) in internal metal temperatures as a result of the ceramic leading edge. The object of this testing was to validate the design and analysis done by Materials Research and Design of Rosemont, PA and to determine the feasibility of this design for the intended application.

Robinson, R. Craig↗