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NASA NTRS2004

Temperature Distributions in Hollow Cathode Emitters

Life-limiting processes in hollow cathodes are determined largely by the temperature of the emitter. To support development of cathode life models we have developed a noncontact temperature measurement technique which employs a stepper motor-driven fiber optic probe. The probe is driven inside the hollow cathode and collects light radiated by the hot interior surface of the emitter. Ratio pyrometry is used determine the axial temperature profile. Thermocouples on the orifice plate provide measurements ofthe external temperature during cathode operation and are used to calibrate the pyrometer system in situ with a small oven enclosing the externally heated cathode. Initial measurements of the temperature distribution in a hollow cathode with the same geometry as a cathode that failed after operating at 12 A emission current for 27800 hours are discussed.

ratio pyrometer system↗

NASA NTRS2011

High-Temperature Thermometer Using Cr-Doped GdAlO3 Broadband Luminescence

A new concept has been developed for a high-temperature luminescence-based optical thermometer that both shows the desired temperature sensitivity in the upper temperature range of present state-of-the-art luminescence thermometers (above 1,300 C), while maintaining substantial stronger luminescence signal intensity that will allow these optical thermometers to operate in the presence of the high thermal background radiation typical of industrial applications. This objective is attained by using a Cr-doped GdAlO3 (Cr:GdAlO3) sensor with an orthorhombic perovskite structure, resulting in broadband luminescence that remains strong at high temperature due to the favorable electron energy level spacing of Cr:GdAlO3. The Cr:GdAlO3 temperature (and pressure) sensor can be incorporated into, or applied onto, a component s surface when a non-contact surface temperature measurement is desired, or alternatively, the temperature sensor can be attached to the end of a fiber-optic probe that can then be positioned at the location where the temperature measurement is desired. In the case of the fiber-optic probe, both the pulsed excitation and the luminescence emission travel through the fiber-optic light guide. In either case, a pulsed light source provides excitation of the luminescence, and the broadband luminescence emission is collected. Real-time temperature measurements are obtain ed using a least-squares fitting algorithm that determines the luminescence decay time, which has a known temperature dependence established by calibration. Due to the broad absorption and emission bands for Cr:GdAlO3, there is considerable flexibility in the choice of excitation wavelength and emission wavelength detection bands. The strategic choice of the GdAlO3 host is based on its high crystal field, phase stability, and distorted symmetry at the Cr3+ occupation sites. The use of the broadband emission for temperature sensing at high temperatures is a key feature of the invention and is novel since broadband luminescence emission normally shows severe thermal quenching. The tightly bound AlO6 octahedra in GdAlO3 results in a larger energy barrier to nonradiative decays than in other materials and therefore makes using broadband emission for temperature sensing possible at high temperatures. This approach results in a substantial increase in temperature capability. For example, the most commonly used Cr-doped crystal used for luminescence-based temperature measurements, ruby, has only been demonstrated up to 600 C, whereas the Cr:GdAlO3 optical thermometer under development has already been shown to exhibit useful luminescence up to 1,300 C. Because GdAlO3 is non-reactive and is stable in harsh, high-temperature environments, sensors composed of Cr:GdAlO3 will be very well suited for remote high-temperature measurements in engine or industrial environments where its intense high-temperature luminescence will stand out above significant thermal radiation background levels.

Eldridge, Jeffrey↗

NASA NTRS2001

Mars Array Technology Experiment Developed to Test Solar Arrays on Mars

Solar arrays will be the power supply for future missions to the planet Mars, including landers, rovers, and eventually human missions to explore the Martian surface. Until Mars Pathfinder landed in July 1997, no solar array had been used on the surface. The MATE package is intended to measure the solar energy reaching the surface, characterize the Martian environment to gather the baseline information required for designing power systems for long-duration missions, and to quantify the performance and degradation of advanced solar cells on the Martian surface. To measure the properties of sunlight reaching the Martian surface, MATE incorporates two radiometers and a visible/NIR spectrometer. The radiometers consist of multiple thermocouple junctions using thin-film technology. These devices generate a voltage proportional to the solar intensity. One radiometer measures the global broadband solar intensity, including both the direct and scattered sunlight, with a field of view of approximately 130. The second radiometer incorporates a slit to measure the direct (unscattered) intensity radiation. The direct radiometer can only be read once per day, with the Sun passing over the slit. The spectrometer measures the global solar spectrum with two 256-element photodiode arrays, one Si sensitive in the visible range (300 to 1100 nm), and a second InGaAs sensitive to the near infrared (900 to 1700 nm). This range covers 86 percent of the total energy from the Sun, with approximately 5-nm resolution. Each photodiode array has its own fiber-optic feed and grating. Although the purpose of the MATE is to gather data useful in designing solar arrays for Mars surface power systems, the radiometer and spectrometer measurements are expected to also provide important scientific data for characterizing the properties of suspended atmospheric dust. In addition to measuring the solar environment of Mars, MATE will measure the performance of five different individual solar cell types and two different solar cell strings, to qualify advanced solar cell types for future Mars missions. The MATE instrument, designed for the Mars-2001 Surveyor Lander mission, contains a capable suite of sensors that will provide both scientific information as well as important engineering data on the operation of solar power systems on Mars. MATE will characterize the intensity and spectrum of the solar radiation on Mars and measure the performance of solar arrays in the Mars environment. MATE flight hardware was built and tested at the NASA Glenn Research Center and is ready for flight.

Landis, Geoffrey A.↗

NASA NTRS2012

Active Piezoelectric Vibration Control of Subscale Composite Fan Blades

As part of the Fundamental Aeronautics program, researchers at NASA Glenn Research Center (GRC) are investigating new technologies supporting the development of lighter, quieter, and more efficient fans for turbomachinery applications. High performance fan blades designed to achieve such goals will be subjected to higher levels of aerodynamic excitations which could lead to more serious and complex vibration problems. Piezoelectric materials have been proposed as a means of decreasing engine blade vibration either through a passive damping scheme, or as part of an active vibration control system. For polymer matrix fiber composite blades, the piezoelectric elements could be embedded within the blade material, protecting the brittle piezoceramic material from the airflow and from debris. To investigate this idea, spin testing was performed on two General Electric Aviation (GE) subscale composite fan blades in the NASA GRC Dynamic Spin Rig Facility. The first bending mode (1B) was targeted for vibration control. Because these subscale blades are very thin, the piezoelectric material was surface-mounted on the blades. Three thin piezoelectric patches were applied to each blade two actuator patches and one small sensor patch. These flexible macro-fiber-composite patches were placed in a location of high resonant strain for the 1B mode. The blades were tested up to 5000 rpm, with patches used as sensors, as excitation for the blade, and as part of open- and closed-loop vibration control. Results show that with a single actuator patch, active vibration control causes the damping ratio to increase from a baseline of 0.3% critical damping to about 1.0% damping at 0 RPM. As the rotor speed approaches 5000 RPM, the actively controlled blade damping ratio decreases to about 0.5% damping. This occurs primarily because of centrifugal blade stiffening, and can be observed by the decrease in the generalized electromechanical coupling with rotor speed.

Duffy, Kirsten P.↗

NASA NTRS2005

Texturing Blood-Glucose-Monitoring Optics Using Oxygen Beams

A method has been invented for utilizing directed, hyperthermal oxygen atoms and ions for texturing tips of polymeric optical fibers or other polymeric optical components for use in optical measurement of concentration of glucose in blood. The required texture of the sensory surface of such a component amounts to a landscape of microscopic hills having high aspect ratios (hills taller than they are wide), with an average distance between hills of no more than about 5 m. This limit on the average distance between hills is chosen so that blood cells (which are wider) cannot enter the valleys between the hills, where they could obstruct optical sensing of glucose in the blood plasma. On the other hand, the plasma is required to enter the valleys, and a high aspect ratio is intended to maximize the hillside and valley surface area in contact with the plasma, thereby making it possible to obtain a given level of optical glucose- measurement sensitivity with a relatively small volume of blood. The present method of texturing by use of directed, hyperthermal (particle energy >1 eV) oxygen atoms and ions stands in contrast to a prior method of texturing by use of thermal monatomic oxygen characterized by a temperature of the order of 0.5 eV. The prior method yields low-aspect- ratio (approximately hemispherical) craters that are tens of microns wide . too wide to exclude blood cells. The figure schematically depicts parts of a typical apparatus for texturing according to the present method. One or more polymeric optical components to be textured (e.g., multiple optical fibers bundled together for simultaneous processing) are mounted in a vacuum chamber facing a suitable ion- or atom-accelerating device capable of generating a beam of oxygen atoms and/or ions having kinetic energies >1 eV. Typically, such a device includes a heated cathode, in which case it is desirable to interpose a water-cooled thermal-radiation shield to prevent melting of the polymeric component(s) to be textured. In operation, the chamber is evacuated to a pressure .10.5 torr (less than or equal to approximately 1.3 mPa), then the beam is turned on. The resulting texture is characterized by approximately conical hills having aspect ratios greater than 1. In experiments, it was demonstrated that separations between adjacent hills can be made .1 m and that the separations and heights of the hills can be varied by varying the fluence of monatomic oxygen and/or oxygen ions.

Banks, Bruce↗

DOE OSTI2020

Prediction for Pressure Differential Across HEPA Filter Media Based on Media Characteristics and Particle Size Distribution

A new method for predicting the pressure drop across High Efficiency Particulate Air (HEPA) filter media is proposed based upon mass deposited onto the filter and known physical characteristics of the filter media. Detailed are the methods used in conjunction with current filter loading models to predict the pressure drop, as well as tests conducted to validate the methods. The benefit of a prediction model for practical use lies in the manufacturing and service life of nuclear grade HEPA filters. HEPA filters for use in nuclear facilities have a prescribed expiration date and a maximum allowable operating pressure drop. Therefore, the ability to predict the pressure drop across a filter and relate it to an expected length of service time can enable a reduction in wasted filters. This will allow for more informed decisions to be made based upon the dictated life cycle of the filters. Also, understanding and predicting how the pressure drop of HEPA filter media behaves as a function of physical characteristics and loaded mass can assist in future design and manufacturing of filter media. Currently, most existing pressure drop models are either computationally based or analytical methods relying on data gathered during tests. Neither are practical for prediction; the computational methods are difficult to implement, and the current analytical methods are more useful as tools for analysis. The current analytical model developed by Bergman et al. is based upon the pressure drop from each media fiber and modeling the deposited particles as newly formed fibers. Using Bergman's model and the media properties, air properties, and known aerosol particle size distribution, a pressure drop curve as a function of loaded mass can be created. This curve implies initial loading in the depth of the filter media with a transition to pure surface loading on the filter face, and a sensitivity to an evolving particle size distribution as mass continues to load onto the filter. To implement the predictive model, knowledge of the mean filter fiber diameter and porosity of the filter media is required. Traditionally, the mean fiber diameter is calculated as an effective diameter from prior media testing, however, in this study a Scanning Electron Microscope (SEM) technique is used to acquire this variable. Validation of the predictive model is provided by flat sheet media tests under a controlled environment with a measured particle size distribution of the challenge aerosol and shows reasonable preliminary agreement.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Dimensional stability of low-cost thermoplastic composite molds

This report addresses a key question for using additively manufactured tooling from carbon fiber reinforced thermoplastic composites. How does the distortion of the molded part change with the print orientation used in the manufacture of tooling? The objective of this research was to discuss the distortion of parts molded with such tooling, in relation to the deflections in the tooling during the compression molding process. This was achieved through both model simulations and experimental molding runs. A vertical orientation was used in printing the mold with a distinctly non-planar surface: this orientation allowed for higher performance along the press closing direction -- higher thermal conductivity, higher stiffness, and lower coefficient of thermal expansion. Epoxy-carbon fiber twill weave fabric prepreg was then compression molded in this mold. The thermomechanical properties of the tooling material and the molded part were measured and used in simulation of mold deformation as well as part distortion. The thermomechanical anisotropy of the mold is quite different from that of the molded part because in the mold, the stiffest direction is the z-axis, while in the molded thermoset part, the z-axis is the weakest direction. The connection between mold deformation during the compression molding process and the final part distortion can be seen from the simulation results. The simulation results for the case where the mold was four times as stiff as the part along the press closing direction compared well with experiment. When the mold stiffness was lowered in relation to the part stiffness, the mold deformation during the compression molding increased; but this led to a smaller extent of part distortion.

36 MATERIALS SCIENCE↗

NASA NTRS1997

Thermal and Mechanical Durability of Graphite-Fiber-Reinforced PMR-15 Composites

Earlier work, which reported relationships between compression properties and elevated temperature aging times and weight losses, also pointed out the apparent influence of surface layer formation and growth on the retention of compression properties during extended aging times. Since that time, studies have been directed toward evaluating the growth of the surface layer. This layer was found to change in its composition and features as the aging temperature changed. Microcracks and small voids initiated and advanced inward at all temperatures. Visible oxidation at the surface occurred only at temperatures above 260 C. Relationships between layer thickness and aging time and temperature were evaluated and empirically formulated. Then, the compression properties were graphically related to the surface layer thickness with excellent correlation. The surface layer was observed to influence the compression strength of thin samples only.

Bowles, Kenneth J.↗

NASA NTRS1998

Thermal and Mechanical Durability of Graphite-Fiber-Reinforced PMR-15 Composites

Earlier work, which reported relationships between compression properties and elevated temperature aging times and weight losses, also pointed out the apparent influence of surface layer formation and growth on the retention of compression properties during extended aging times. Since that time, studies have been directed toward evaluating the growth of the surface layer. This layer was found to change in its composition and features as the aging temperature changed. Microcracks and small voids initiated and advanced inward at all temperatures. Visible oxidation at the surface occurred only at temperatures above 260 deg. C. Relationships between layer thickness and aging time and temperature were evaluated and empirically formulated. Then, the compression properties were graphically related to the surface layer thickness with excellent correlation. The surface layer was observed to influence the compression strength of thin samples only.

Bowles, Kenneth J.↗

DOE OSTI2025

Direct measurement of thermal Knudsen forces in rarefied gas environments

At micro- and nanoscales, momentum transfer between surfaces is influenced by various physical mechanisms, including quantum fluctuations, electromagnetic interactions, electric charges, and the dynamics of (rarefied) gases. Under non-isothermal conditions, rarefied gases give rise to thermal Knudsen forces whose magnitudes strongly depend on the gas species and surface characteristics. Knudsen forces are particularly relevant in nanotechnology, optical manipulation, and aerospace systems, where gas rarefaction occurs due to highly confined geometries, sub-micrometer length scales, and reduced particle densities. Despite their significance, predictive modeling of Knudsen forces is limited by a lack of comprehensive experimental data across diverse materials and surface morphologies. Here, in this work, we present a highly sensitive and adaptable measurement platform capable of directly quantifying Knudsen forces using a suspended, interchangeable micro-cantilever within controlled rarefied helium and nitrogen environments. The system integrates optical fiber interferometry to precisely capture out-of-plane displacements at sub-micrometer resolution, driven by Knudsen forces. From the empirical data, we derive a robust correlation linking the magnitudes of Knudsen forces to energy accommodation coefficients, offering deeper insights into the underlying gas–surface interaction mechanisms.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2021

Global and local texture development during initial plastic deformation of cold-pilgered Zircaloy-4 tubing

In this work we present a thorough characterization of the texture development during the initial step of a cold pilgering process of a Zircaloy-4 TREX tube, on which the axial cross section is reduced by 80% over a 40cm length with an overall Q-ratio of 2.34, followed by a recrystallization thermal treatment. Texture across a tapered specimen representing this working zone was characterized by neutron diffraction and high energy synchrotron x-ray diffraction at 28 positions (4 locations along its length and 7 locations across its thickness with 0.3 mm spatial resolution), and on the deformed end after the thermal treatment. Results show that the starting material (TREX tube) presents a texture gradient through its wall thickness, with the c poles aligned to the hoop direction at the outer surface (with radial and hoop Kearns factors: f R =0.36, f H = 0.50), and gradually rotating around the axial direction to become a quasi-radial orientation (~35 o out of the radial direction) at the inner surface ( f R =0.43, f H =0.35). The overall texture becomes more radial due to the cold pilgering, but the texture gradient remains during the whole deformation process, being always more radial at the inner surface, ( f R =0.53, f H =0.37 at 80%) than at the outer surface ( f R =0.41, f H =0.50at 80%). The most remarkable changes in texture produced by the rolling process is a 30 o rotation of the grains around their c-axis, producing a marked increase of the <11 2 ¯ 0> // axial fiber texture at expenses of the original <10 1 ¯ 0> // axial fiber texture observed in the TREX tube. The observed changes in texture during deformation were correctly explained by visco-plastic self-consistent (VPSC) modelling. This was achieved after the inclusion of the basal <a> slip system, which plays a central role to explain the 30 o rotation around the c-axis during deformation. The texture evolution was correctly described after the inclusion of a drag effect to grain rotation due to the interaction with neighbouring grains. The through thickness texture differences are greatly reduced by the recrystallization thermal treatment, with similar Kearns factors at the inner surface ( f R =0.50, f H =0.28) and the outer surface ( f R =0.48, f H =0.39). The predominance of the <10 1 ¯ 0> // axial fiber texture is recovered after recrystallization.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Oxide evolution on the SiC layer of TRISO particles during extended air oxidation

Tristructural isotropic (TRISO) fuel particles have been primarily developed for high-temperature gas-cooled nuclear reactors and can be subjected to oxidizing environments for extended periods in an off-normal accident scenario. Surrogate TRISO fuel particles were oxidized in air at 1,000 or 1,100 °C for up to 120 h. Here, the oxide scale morphology and thickness were studied via scanning electron microscopy, focused ion beam, and atomic force microscopy. TRISO particles oxidized at 1,100 °C exhibited a highly crystalline oxide scale, which led to significant cracking and irregularly shaped closed porosity, whereas those oxidized at 1,000 °C possessed a primarily amorphous oxide scale, which contained small, rounded internal pores and no larger defects. The observed phenomena deviated from the expected behavior based on models for oxide growth on flat-plate and fiber SiC. The oxidation kinetics of TRISO fuel particles in high-temperature air were investigated without mechanically deforming the surface and were analyzed with respect to oxide morphology.

36 MATERIALS SCIENCE↗

DOE OSTI2026

HYBRID COMPOSITES VIA CO-EXTRUSION ADDITIVE MANUFACTURING-COMPRESSION MOLDING FOR PERFORMANCE OPTIMIZATION

The growing demand for hybrid polymer composites with multifunctional properties has led to the development of various hybridization techniques, such as multi-material compounding and controlled laminate stacking sequence. In this study, a novel hybrid manufacturing approach was used by integrating a multiplexing extrusion system (MExS) based on additive manufacturing with subsequent compression molding process. This technique enabled the co-extrusion of different materials during the additive manufacturing process to fabricate composites with tailored performance. The developed hybrid composite featured a skin layer of glass fiberreinforced polycarbonate (PC/GF) encapsulating a carbon fiber-reinforced acrylonitrile butadiene styrene (CF/ABS) core. The structure was engineered to promote improved thermal and impact resistance at the surface, supported by a stiff core for enhanced overall mechanical integrity. Mechanical, thermal and morphological properties of the hybrid composites were investigated to understand trade-offs in performance compared to a single-material system. The results demonstrate that this approach enables the production of multifunctional composites suitable for applications such as automotive body panels and protective housings, where a balance of weight, mechanical strength, and thermal performance is essential.

Wasti, Sanjita [ORNL]↗

NASA NTRS1977

Two-dimensional hygrothermal diffusions into a finite width composite laminate

Two dimensional hygroscopic diffusion into composite laminates with free edges was obtained through the use of a second order finite difference scheme. A computer program was developed for the transient nonlinear coupled hygrothermal diffusion into finite width laminates with varying surface conditions along two edges. The formulation permits the diffusion coefficient to be a function of temperature, moisture concentration, and fiber orientation. The moisture distributions thus obtained are necessary for analysis of the moisture induced interlaminar stresses in the vicinity of free edges. It is shown that large diffusion times tend to eliminate the significance of stacking sequence, but gradients within and between layers are significant for all diffusion times.

Farley, G. L.↗

NASA NTRS1979

Space Shuttle status

Hardware considerations and the orbital flight test program of the Space Shuttle are discussed, including reference to the Space Shuttle main engine, payload bay doors, TV cameras for flight inspection, and launch crew escape schemes. Particular attention is given to the thermal protection system consisting of 32,000 tiles composed of approximately 3% pure silica fibers and 97% air, which has a design requirement of keeping the basic aluminum skin below 350 F for a surface temperature of 2700 F.

Slayton, D. K.↗

NASA NTRS1985

Fractography of the interlaminar fracture of carbon-fibre epoxy composites

The failed surfaces of interlaminar fracture (mode I) specimens of AS4/3501-6 were examined using scanning electron microscopy. The principal fracture features were fiber pull-out (bundles and single fibers), hackle markings, and regions of smooth resin fracture. Considerable (30 to 50 percent) relaxation of the deformed resin occurred when the specimens were heated above the matrix glass transition temperature. This relaxation was taken as evidence of extensive shear yielding of the resin during the fracture process. Some of the fractography features are discussed in terms of transverse tensile stresses and peeling stresses acting on the fibers. In some instances these localized stresses focus failure close to the resin-fiber interface, which can be mistakenly interpreted as interfacial failure and low fiber-resin adhesion.

Bascom, W. D.↗

NASA NTRS1991

Thermal shock of fiber reinforced ceramic matrix composites

Monolithic silicon carbide and silicon nitride and a Nicalon fiber reinforced silicon carbide composite were subjected to severe thermal shock conditions via impingement of a hydrogen-oxygen flame. Surface heating rates of 1000 C/sec to 2500 C/sec were generated. The performance of the monolithic reference materials are compared and contrasted to the significantly greater thermal shock resistance of the composite. Ultrasonic and radiographic NDE techniques were used to evaluate the integrity of the composite subsequent to thermal shock. Tensile tests were performed to determine the residual tensile strength and modulus. Physical property changes are discussed as a function of number and severity of thermal shock cycles.

Eckel, Andrew J.↗

NASA NTRS1991

Survey of results from the Boeing modules on the M0003 experiment on LDEF

The Boeing modules on the M0003 experiment included fiber optics, ceramic materials, a variety of electronic piece parts, composites and thermal control paints, fasteners, thin film lubricants, anodized surfaces, and adhesives. These materials were flown on the leading and trailing edge exteriors, and on the interior portion of LDEF M0003 providing exposure under three distinct environments. The condition of each of these material types is described. Results of optical, surface, and mechanical properties are presented.

Pippin, H. Gary↗