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At least 1,063 records · Page 59

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NASA NTRS2010

Advanced Vacuum Plasma Spray (VPS) for a Robust, Longlife and Safe Space Shuttle Main Engine (SSME)

In 1984, the Vacuum Plasma Spray Lab was built at NASA/Marshall Space Flight Center for applying durable, protective coatings to turbine blades for the space shuttle main engine (SSME) high pressure fuel turbopump. Existing turbine blades were cracking and breaking off after five hot fire tests while VPS coated turbine blades showed no wear or cracking after 40 hot fire tests. Following that, a major manufacturing problem of copper coatings peeling off the SSME Titanium Main Fuel Valve Housing was corrected with a tenacious VPS copper coating. A patented VPS process utilizing Functional Gradient Material (FGM) application was developed to build ceramic lined metallic cartridges for space furnace experiments, safely containing gallium arsenide at 1260 degrees centigrade. The VPS/FGM process was then translated to build robust, long life, liquid rocket combustion chambers for the space shuttle main engine. A 5K (5,000 Lb. thrust) thruster with the VPS/FGM protective coating experienced 220 hot firing tests in pristine condition with no wear compared to the SSME which showed blanching (surface pulverization) and cooling channel cracks in less than 30 of the same hot firing tests. After 35 of the hot firing tests, the injector face plates disintegrated. The VPS/FGM process was then applied to spraying protective thermal barrier coatings on the face plates which showed 50% cooler operating temperature, with no wear after 50 hot fire tests. Cooling channels were closed out in two weeks, compared to one year for the SSME. Working up the TRL (Technology Readiness Level) to establish the VPS/FGM process as viable technology, a 40K thruster was built and is currently being tested. Proposed is to build a J-2X size liquid rocket engine as the final step in establishing the VPS/FGM process TRL for space flight.

Holmes, Richard R.↗

DOE OSTI2022

Cooling-induced reactivation of distant faults during long-term geothermal energy production in hot sedimentary aquifers

Deep geothermal energy (DGE) represents an opportunity for a sustainable and carbon-free energy supply. One of the main concerns of DGE is induced seismicity that may produce damaging earthquakes, challenging its widespread exploitation. It is widely believed that the seismicity risk can be controlled by using doublet systems circulating water to minimize the injection-induced pressure changes. However, cold water reinjection may also give rise to thermal stresses within and beyond the cooled region, whose potential impacts on fault reactivation are less well understood. Here, we investigate by coupled thermo-hydro-mechanical modeling the processes that may lead to fault reactivation in a hot sedimentary aquifer (HSA) in which water is circulated through a doublet. We show that thermal stresses are transmitted much ahead of the cooled region and are likely to destabilize faults located far away from the doublet. Meanwhile, the fault permeability mainly controls the fault reactivation timing, which entails the importance of employing appropriate characterization methods. This investigation is crucial for understanding the mechanisms controlling induced seismicity associated with DGE in a HSA and allows the success of future DGE projects.

15 GEOTHERMAL ENERGY↗

NASA NTRS1992

Cooling of the magma ocean due to accretional disruption of the surface insulating layer

Planetary accretion has been considered as a process to heat planets. Some fraction of the kinetic energy of incoming planetesimals is trapped to heat the planetary interior (Kaula, 1979; Davies, 1984). Moreover, blanketing effect of a primary atmosphere (Hayashi et al., 1979; Sasaki, 1990) or a degassed atmosphere (Abe and Matsui, 1986; Zahnle et al., 1988) would raise the surface temperature of the Earth-size planets to be higher than the melting temperature. The primordial magma ocean was likely to be formed during accretion of terrestrial planets. In the magma ocean, if crystallized fractions were heavier than melt, they would sink. But if solidified materials were lighter than the melt (like anorthosite of the lunar early crust) they would float to form a solid shell surrounding the planet. (In an icy satellite, solidified water ice should easily float on liquid water because of its small density.) The surface solid lid would prevent efficient convective heat transfer and slow the interior cooling. Consider that the accretion of planetesimals still continues in this cooling stage. Shock disruption at planetesimal impact events may destroy the solid insulating layer. Even if the layer survives impacts, the surface layer is finally overturned by Rayleigh-Taylor instability, since accreting materials containing metals are heavier than the surface solidified lid of silicates.

Sasaki, Sho↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Additive Manufacturing↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

DED↗

DOE OSTI2024

Co-treating flue gas desulfurized effluent and produced water enables novel waste management and recovery of critical minerals

Herein this study reports a novel approach of resource recovery from co-managing two geographically co-located and chemically complementary wastewaters using a pilot-scale treatment process. Designed to treat flue gas desulfurized (FGD) effluent from combustion powerplants and produced water (PW) from energy industries, the process consists of soda-ash softening, nanofiltration (NF), and reverse osmosis (RO). Recovered products are barite, calcite, and low-salinity water. Using field-collected waters, the results show that softening at pH 8.5 produces calcite (yield: 30 kg/m 3 treated water), a chemical used as SO ₂(g) scrubbers. NF treatment under an applied pressure of 3.5 MPa yields a permeate stream laden with monovalent ions (water recovery 60%) and a concentrate stream with a sulfate concentration 1.8 times of the feedwater concentration. Mixing the NF concentrate and PW at a volumetric ratio of 1.0 precipitates a high-density barite material (4.1 g/cm 3 , yield: ~7.5 kg/m 3 mixture) – a critical mineral commonly used as a weighting agent in drilling. The RO treatment recovers >64% water as the permeate, which can be readily used as cooling make-up water at the powerplants. The RO concentrate stream can be further processed in a thermal evaporative system for additional water recovery and brine production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2013

20 K Helium Refrigeration System for NASA-JSC Chamber-A

A new 20 K helium refrigerator installed at NASA Johnson Space Center's Space Environment Simulation Laboratory (SESL) was successfully commissioned and tested in 2012. The refrigerator is used to create a deep space environment within SESL s Chamber A to perform ground testing of the James Webb Space Telescope. The chamber previously and currently still has helium cryopumping panels (CPP) and LN2 shrouds used to create Low Earth Orbit environments. Now with the new refrigerator and new helium shrouds (45 x 65 ) the chamber can create a deep space environment. The process design, system analysis, specification development, and commissioning oversight were performed by the cryogenics department at Jefferson Labs, while the contracts and system installation was performed by the ESC group at JSC. Commissioning data indicate a inverse coefficient of performance better than 70 W/W for a 18 KW load at 20 K (accounting for liquid nitrogen precooling power) that remains essentially constant down to 1/3 of this load. Even at 10 percent of the maximum capacity, the performance is better than 140 W/W at 20K. The refrigerator exceeded all design goals and demonstrated the ability to support a wide load range from 10kW at 15 K to 100 kW at 100K. The refrigerator is capable of operating at any load temperature from 15K to ambient with tight temperature stability. The new shroud (36 tons of aluminum) can be cooled from room temperature to 20 K in 24 hours. This paper will outline the process design and commissioning results.

Homan, J.↗

NASA NTRS1978

Analysis of data user's needs for performance evaluation of solar heating and cooling systems

In a successful data acquisition program, the information needs must be evaluated, the design and cost factors of the program must be determined, and a data management loop must be organized and operated in order to collect, process, and disseminate the needed information in useable formats. This paper describes each of these program elements in detail as an aid for the solar heating and cooling data manager and user to implement effective data acquisition and monitoring systems. Consideration is given to the development of evaluation techniques which will aid in the determination of solar energy systems performances.

Christensen, D. L.↗

NASA NTRS1987

Growth of Triglycine Sulfate (TGS) crystals aboard Spacelab-3

An experiment to study the growth of single crystals of triglycine sulfate (NH2CH2COOH)3 H2SO4 (TGS) was successfully carried out on the Spacelab-3 mission during April 29 to May 6, 1985. Two crystals of TGS were grown during the flight, using a specially developed cooled sting technique of solution crystal growth. For the first time in any flight experiment the growth was monitored on-board as well as on ground by video-schlieren technique. Hundreds of holograms were taken for the solution/crystal interaction during the growth process. Preliminary results indicate that the optical system worked very well and the quality of reconstructed holograms is satisfactory. The cooled sting technique was successfully demonstrated. Holographic interferograms indicate convection free, diffusion limited growth. Some of the preliminary results of crystal quality are also presented.

Lal, R. B.↗

NASA NTRS1962

PROGRESS REPORT ON THE DEVELOPMENT OF PROTECTED CONSTRUCTION FOR HYPERSONIC VEHICLES

The structural problems of re-entry occasioned by aerodynamic heating are now generally well known. Typical of these heating problems is the environment experienced by the manned lifting vehicle re-entering from a low altitude orbit. Figure 1 shows typical curves of lower surface temperature as a function of time for a wing loading of 25 Ibs/ft(exp 2), and a lift-drag ratio of 2.5. The two curves cover a practical range of re-entry angles, the lower curve representing an ideal re-entry path with zero dive angle and the upper curve assuming a 2° error in the re-entry angle. Maneuvers for course change or correction are also added to the upper curve. Significant factors from this curve are the relationship between the maximum temperatures and the capabilities of available metallic material, and also the long re-entry time and its effect on total heat load. If a very shallow re-entry is made, maximum lower surface temperatures reach 2000°F which is just within the range of conventional superalloys. To accommodate practical re-entry angles and maneuvers, however, the temperature capability must reach about 2500°F which requires refractory metals. The re-entry time may be as high as 100 minutes, which gives total heat loads of approximately 40,000 BTU/ft(exp 2). A heat load of this magnitude, with equilibrium surface temperatures of the values shown, suggests that a lighter airframe can be constructed by dissipating the heat by radiation from the surface, rather than by absorbing it with a heat sink, or surface cooling, or ablation. Air Force programs to provide airframes for this type of environment have involved the parallel development of a number of different structural concepts. The development to be discussed here was carried out by Bell Aerosystems Company for the Fabrication Branch, Manufacturing Technology Laboratory, Directorate of Materials and Processes, Aeronautical Systems' Division, Wright-Patterson Air Force Base, Ohio, under Contract AF33(600)-40100 (Double-Wall Cooled Structure).

Reentry vehicle↗

DOE OSTI2025

On the numerical sensitivity of cellular automata grain structure predictions to large thermal gradients and cooling rates

Cellular automata (CA) models of as-solidified grain structure, originally developed and applied to casting, have become a common means of predicting grain structure resulting from Additive Manufacturing (AM) processes. The majority of these models are based on the decentered octahedron approach, which attempts to correct for the effect of grid anisotropy on the prediction of competitive solidification of dendritic grains. However, AM solidification occurs under cooling rates ($\dot{T}$) and thermal gradients (G) that are orders of magnitude larger than those encountered in casting, and no systematic investigation on the effect of the CA model cell size (Δx) and time step (Δt) on AM microstructure predictions has been performed. Here, in this study, such an investigation is first performed via simulation of individual grains of various crystallographic orientations with a fixed, unidirectional G, showing that CA prediction of the steady-state undercooling matched the expected values based on the interfacial response function at small G and deviated from the expected values at large G. Simulation of competitive growth of multiple grains showed a weakening of the predicted texture as G and Δx became large. Simulation of solidification under AM conditions, where G and $\dot{T}$ vary spatially across the melt pools, showed that not only does grain selection weaken and deviate from expectations at large Δx, but grains with crystallographic $\langle$100$\rangle$ aligned with the grid directions are more adversely affected by the temperature field discontinuities than grains with other crystallographic orientations. Despite the fact that the exact grain competition results depended on Δt, the overall texture development was notably less sensitive to Δt than Δx, provided that a reasonable value of Δt is selected based on the ratio of Δx to the maximum local solidification velocity in the simulation domain. Finally, from the directional solidification and AM simulation results, an analysis of computational cost compared to simulation resolution is performed based on an equation derived to quantify the relatively inaccuracy in grain selection based on the model and temperature field inputs. From this analysis, it is concluded that there is a need for algorithmic improvements to improve CA grain competition accuracy for large G processing conditions as sufficiently small Δx to resolve the necessary competition is intractable for many AM processing conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2020

In Situ Analysis of Laser Powder Bed Fusion Using Simultaneous High-Speed Infrared and X-ray Imaging

Laser powder bed fusion is a metal additive manufacturing technique that has received significant scientific and industrial attention over the past decades. However, the quality and reproducibility of parts manufactured by this technique is still a problem. Overcoming this issue requires an understanding of multiple complex physical phenomena which occur simultaneously during the process. Here, we illustrate a powerful new technique which synchronizes high-speed x-ray imaging with high-speed infrared imaging to study laser powder bed fusion processes in real time. Using this technique, we demonstrate the simultaneous observation of multiple phenomena including three-dimensional melt pool visualization, vapor plume dynamics, spatter formation, thermal history, and point cooling rates. The paired observation of these dynamic phenomena is critical to understanding the fundamentals of laser powder bed fusion, and the overall impact of process parameters on print quality.

36 MATERIALS SCIENCE↗

NASA NTRS2012

Demonstration of Passive Fuel Cell Thermal Management Technology

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA Exploration program. The passive thermal management system relies on heat conduction within highly thermally conductive cooling plates to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack. Using the passive approach eliminates the need for a coolant pump and other cooling loop components within the fuel cell system which reduces mass and improves overall system reliability. Previous development demonstrated the performance of suitable highly thermally conductive cooling plates and integrated heat exchanger technology to collect the heat from the cooling plates (Ref. 1). The next step in the development of this passive thermal approach was the demonstration of the control of the heat removal process and the demonstration of the passive thermal control technology in actual fuel cell stacks. Tests were run with a simulated fuel cell stack passive thermal management system outfitted with passive cooling plates, an integrated heat exchanger and two types of cooling flow control valves. The tests were run to demonstrate the controllability of the passive thermal control approach. Finally, successful demonstrations of passive thermal control technology were conducted with fuel cell stacks from two fuel cell stack vendors.

Burke, Kenneth A.↗

NASA NTRS2016

Atmospheric Diabatic Heating in Different Weather States and the General Circulation

Analysis of multiple global satellite products identifies distinctive weather states of the atmosphere from the mesoscale pattern of cloud properties and quantifies the associated diabatic heating/cooling by radiative flux divergence, precipitation, and surface sensible heat flux. The results show that the forcing for the atmospheric general circulation is a very dynamic process, varying strongly at weather space-time scales, comprising relatively infrequent, strong heating events by ''stormy'' weather and more nearly continuous, weak cooling by ''fair'' weather. Such behavior undercuts the value of analyses of time-averaged energy exchanges in observations or numerical models. It is proposed that an analysis of the joint time-related variations of the global weather states and the general circulation on weather space-time scales might be used to establish useful ''feedback like'' relationships between cloud processes and the large-scale circulation.

Cooling↗

DOE OSTI2024

Roles of the atmosphere and ocean in the projected north atlantic warming hole

There exists a warming deficit in sea surface temperatures (SST) over the subpolar North Atlantic in response to quadrupled CO 2 , referred to as the projected North Atlantic warming hole (WH). This study employs a partial coupling technique to accurately verify the relative roles of oceanic and atmospheric processes in the formation of the projected WH within an atmosphere-ocean coupled framework. By decomposing the SST anomalies in the subpolar North Atlantic into two components: those induced by atmospheric processes (i.e., the atmosphere-forced component) and those driven by changes in ocean circulation (i.e., the ocean-driven component), we find that the projected WH is primarily driven by changes in ocean circulation, with almost no contribution from atmospheric processes. Specifically, the slowdown of the Atlantic Meridional Overturning Circulation (AMOC) results in a cooling of SST in the WH region due to reduced northward ocean heat transport into this region. This study further quantifies the influence of a positive coupled feedback through surface heat flux (SHF) on the AMOC response under greenhouse gas forcing within this self-consistent framework. It is found that the AMOC slowdown leads to a negative SST anomaly in the subpolar North Atlantic and subsequently a positive ocean-driven SHF anomaly, which in turn further weakens the AMOC. In conclusion, this positive feedback through the SHF contributes about 50% to the total AMOC slowdown in response to quadrupled CO 2 .

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Hydrodynamic behavior of wrapped coil water heater tank

In this work, a numerical investigation using computational fluid dynamics (CFD) has been carried out to analyze the thermal behavior of a water tank integrated to a heat pump water heating system (HPWH). The heat pump condenser is a long coil wrapped around the water tank and insulated from outside from which heat is transferred from the heat pump cycle into the water stored inside the tank. The simulated water tank has a capacity of about 170 L with the charging inlet located at the bottom segment of the tank and the discharging outlet located at the top segment of the tank like commercially available water heaters. The tank was simulated during charging/discharging process with isothermal boundary condition at the tank wall to represent the majority of the process for refrigerant condensation inside the heat pump condenser (excluding superheated and sub-cooled section). Three flow rates were selected to represent low, medium and high flow pattern. Both mean and turbulent flow properties were calculated and analyzed. Heat transfer mechanisms inside the tank are quantified by calculating Richardson and Péclet numbers to show the relative contribution of driving forces. The calculations show that advection is dominant over diffusion. Mixing factor is calculated and presented. It is found that the rate of increase of mixing is nonlinear with the increase in flow rate. Mixing increased by a factor of four when the flow rate increased by a factor of two.

stratification↗

DOE OSTI2022

Revealing temperature-dependent polymer aggregation in solution with small-angle X-ray scattering

We report that improving the morphology of bulk heterojunction active layers remains a primary challenge for organic photovoltaics (OPVs), and much research has been devoted to achieving this through modifying OPV casting solutions to control film formation and crystallinity. Yet, the solution conformation of conjugated polymers used in OPVs is largely unknown. Here, we report observations of temperature dependent aggregation (TDA) through small-angle X-ray scattering (SAXS) investigations of polymer conformation in chlorobenzene:dichlorobenzene casting solvent as a function of temperature for PffBT4T-2OD, a polymer known to display TDA, and its derivative PffBT3T-2OD which displays significantly reduced TDA. We find that, upon cooling below 80 °C, PffBT4T-2OD forms large crystalline aggregates in solution, while its derivative PffBT3T-2OD forms mostly amorphous aggregates of similar size with some evidence of short-range order. This change in solution aggregation behavior is reflected in the lack of gelation by PffBT3T-2OD upon film deposition by spin coating. Grazing-incidence wide-angle X-ray scattering (GIWAXS) revealed a preferred face-on π–π stacking orientation for PffBT3T-2OD films while PffBT4T-2OD's π–π stacking peak was isotropic. We combine these findings to suggest that the presence of crystalline seed aggregates in PffBT4T-2OD solution quickly form an isotropic crystallite network upon cooling while PffBT3T-2OD's amorphous aggregates more slowly crystallize resulting in improved processability of PffBT3T-2OD.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Collective Thomson scattering measurement of plasma evolution during the current pulse in a laser-triggered switch

High-voltage laser-triggered switches (HV-LTSs) are used in pulsed-power applications where low jitter and precise timing are required. The switches allow operation in the megaampere, megavolt regime while maintaining low insertion losses. Currently, there is a lack of detailed plasma measurements in these switches, yet such measurements are needed to elucidate the detailed physics, which include a range of processes such as laser breakdown, streamer formation and growth, current flow, plasma evolution, and cooling. Detailed spatially- and temporally resolved measurements of plasma properties within the switches could contribute to validating and advancing numeric models of these systems. This contribution presents laser Thomson scattering measurements of the electron number density and temperature evolution in a HV-LTS. The switch was operated at 6 kV with current flow for a duration of 145 ns and a peak current density of 0.2 MA/cm2 into a matched load. The Thomson scattering diagnostic system uses a 532 nm probe from an Nd:YAG laser allowing a temporal resolution of ∼10 ns. We find that during the switch current pulse, the plasma electron temperature rose from a starting value of 8.1 ± 1.6 eV (due to cooling of the earlier trigger laser plasma) to a peak value of 26 ± 5 eV with an associated increase in the electron density from 8.6 ± 1.7 × 1017 to 3.1 ± 0.6 × 1018 cm−3.

Gottfried, Jacob A. (ORCID:0000000290058841)↗