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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Passive Rocket Diffuser Testing: Reacting Flow Performance of Four Second-Throat Geometries

Second-throat diffusers serve to isolate rocket engines from the effects of ambient back pressure. As one of the nation's largest rocket testing facilities, the performance and design limitations of diffusers are of great interest to NASA's Stennis Space Center. This paper describes a series of tests conducted on four diffuser configurations to better understand the effects of inlet geometry and throat area on starting behavior and boundary layer separation. The diffusers were tested for a duration of five seconds with a 1455-pound thrust, LO2/GH2 thruster to ensure they each reached aerodynamic steady state. The effects of a water spray ring at the diffuser exits and a water-cooled deflector plate were also evaluated. Static pressure and temperature measurements were taken at multiple axial locations along the diffusers, and Computational Fluid Dynamics (CFD) simulations were used as a tool to aid in the interpretation of data. The hot combustion products were confirmed to enable the diffuser start condition with tighter second throats than predicted by historical cold-flow data or the theoretical normal shock method. Both aerodynamic performance and heat transfer were found to increase with smaller diffuser throats. Spray ring and deflector cooling water had negligible impacts on diffuser boundary layer separation. CFD was found to accurately capture diffuser shock structures and full-flowing diffuser wall pressures, and the qualitative behavior of heat transfer. However, the ability to predict boundary layer separated flows was not consistent.

Jones, Daniel R.↗
NASA NTRS1983

Study of lubricant jet flow phenomena in spur gears: Out of mesh condition

The penetration depth onto the tooth flank of a jet of oil at different velocities pointed at the pitch line on the outgoing side of mesh was determined. The analysis determines the impingement depth for both the gear and the pinion. It includes the cases for speed increasers and decreasers as well as for one to one gear ratio. In some cases the jet will strike the loaded side of the teeth, and in others it will strike the unloaded side of the teeth. In nearly all cases the top land will be cooled regardless of the penetration depth, and postimpingement oil spray will usually provide adequate amounts of oil for lubrication but is marginal or inadequate for cooling.

Townsend, D. P.↗
NASA NTRS1986

Independent Orbiter Assessment (IOA): Analysis of the hydraulics/water spray boiler subsystem

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items (PCIs). To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. This report documents the independent analysis results for the Orbiter Hydraulics/Water Spray Boiler Subsystem. The hydraulic system provides hydraulic power to gimbal the main engines, actuate the main engine propellant control valves, move the aerodynamic flight control surfaces, lower the landing gear, apply wheel brakes, steer the nosewheel, and dampen the external tank (ET) separation. Each hydraulic system has an associated water spray boiler which is used to cool the hydraulic fluid and APU lubricating oil. The IOA analysis process utilized available HYD/WSB hardware drawings, schematics and documents for defining hardware assemblies, components, and hardware items. Each level of hardware was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the severity of the effect for each failure mode. Of the 430 failure modes analyzed, 166 were determined to be PCIs.

Duval, J. D.↗
NASA NTRSDate not supplied

Analysis of Supercooled Large Drop Velocity Measurement in the NASA Icing Research Tunnel

An experiment was conducted in the Icing Research Tunnel (IRT) at the NASA Glenn Research Center to measure the velocity of supercooled large drops (SLD) in the test section of the tunnel. Previous experiments in the IRT suggested that supercooled large drops passing through the test section of the tunnel do not move at the same velocity as the surrounding air flow. The difference between drop velocity and tunnel air velocity is called slip velocity. The slip velocity is important for determining the exact nature of SLD icing simulation in the IRT. It can impact the ice growth process because of its effect on drop cooling rate during transit from the spray bars to the test section. It can also affect the amount of splashing that occurs upon impact. Slip velocity is an important flow parameter to determine how far the current facility capabilities can be extended into the SLD regime. Initial measurement data analysis of the drop velocities indicates that drops with diameter larger than about 100 to 200 µm experience velocity slip.

SLD↗
NASA NTRS1976

Oil-air mist lubrication for helicopter gearing

The applicability of a once-through oil mist system to the lubrication of helicopter spur gears was investigated and compared to conventional jet spray lubrication. In the mist lubrication mode, cooling air was supplied at 366K (200 F) to the out of mesh location of the gear sets. The mist air was also supplied at 366K (200 F) to the radial position mist nozzle at a constant rate of 0.0632 mol/s (3 SCFM) per nozzle. The lubricant contained in the mist air varied between 32 - 44 cc/hour. In the recirculating jet spray mode, the flow rate was varied between 1893 - 2650 cc/hour. Visual inspection revealed the jet spray mode produced a superior surface finish on the gear teeth but a thermal energy survey showed a 15 - 20% increase in heat generated. The gear tooth condition in the mist lubrication mode system could be improved if the cooling air and lubricant/air flow ratio were increased. The test gearbox and the procedure used are described.

Mcgrogan, F.↗
DOE OSTI2024

Benchmarking MELCOR's NAC Package to ABCOVE Tests AB5 and AB6

This report presents analyses of the AB5 and AB6 ABCOVE sodium spray fire experiments with the MELCOR code. This code simulates the progression of accident events for analysis and auditing purposes of nuclear facilities during accident conditions. Historically, the ABCOVE experiments have contributed to the validation of aerosol physics and related phenomena. Given advancements in sodium-cooled reactor designs, characterization of the sodium spray combustion may further the review and validation of newly incorporated sodium properties and physics packages, namely, the sodium equations of state (EOS) and the sodium combustion (NAC) package within MELCOR. By analyzing the AB5 and AB6 experiments with and without the NAC package, sodium specificity for spray combustion and aerosol formation as well as speciation of the combustion products are reviewed with the new packages. This effort provides code users with a demonstration of the current code capabilities. This report provides the current best practices for the NAC package as well as a discussion of any issues observed while performing the presented analyses.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Benchmarking MELCOR's NAC Package to ABCOVE Test AB7

This report presents analyses of the AB7 ABCOVE sodium spray fire experiment with the MELCOR code. This code simulates the progression of accident events for analysis and auditing purposes of nuclear facilities during accident conditions. Historically, the ABCOVE experiments have contributed to the validation of aerosol physics and related phenomena. Given advancements in sodium-cooled reactor designs, characterization of the sodium spray combustion may further the review and validation of newly incorporated sodium properties and physics packages, namely, the sodium equations of state (EOS) and the sodium combustion (NAC) package within MELCOR. Previously, the AB5 and AB6 experiments were analyzed with and without the NAC package. This work builds on the previous analyses with a demonstration of the current code capabilities of MELCOR with a more mild Na spray and pool fire scenario.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1985

Strain isolated ceramic coatings

Plasma sprayed ceramic coatings are used in gas turbine engines to improve component temperature capability and cooling air efficiency. A compliant metal fiber strain isolator between a plasma sprayed ceramic coating and a metal substrate improves ceramic durability while allowing thicker coatings for better insulation. Development of strain isolated coatings has concentrated on design and fabrication of coatings and coating evaluation via thermal shock testing. In thermal shock testing, five types of failure are possible: buckling failure im compression on heat up, bimetal type failure, isothermal expansion mismatch failure, mudflat cracking during cool down, and long term fatigue. A primary failure mode for thermally cycled coatings is designated bimetal type failure. Bimetal failure is tensile failure in the ceramic near the ceramic-metal interface. One of the significant benefits of the strain isolator is an insulating layer protecting the metal substrate from heat deformation and thereby preventing bimetal type failure.

Tolokan, R. P.↗
NASA NTRS1986

Plasma-Sprayed Coatings on Porous Surfaces

Need for combining benefits of duplex thermal-barrier coatings with film cooling on gas-turbine vanes and blades stimulated development of improved method for plasma spraying these coatings. Method reduces blocking of holes by plasma-sprayed material and at same time reduces base-metal oxidation during coating operation. Features provide potential for increased engine efficiency and power, reduced fuel consumption, use of less costly materials or construction procedures, and extended life and durability.

Leibert, C. H.↗
DOE OSTI2025

Free-spray characteristics and spray-wall interactions of methanol on a gasoline direct injector under flash-boiling and non-flash-boiling conditions

Methanol is considered a promising alternative fuel for internal combustion engines (ICEs) due to its high-octane number, fast laminar flame speed, and elevated latent heat of vaporization, all of which support higher compression ratios and improved thermal efficiency. However, its substantial latent heat of vaporization also poses cold-start challenges, such as misfire and fuel film deposition. This study aims to investigate methanol spray morphology and spray-wall interaction using the Spray M injector from the Engine Combustion Network within a constant-pressure flow vessel. A recently developed unified numerical framework capable of modeling both flash and non-flash boiling sprays is validated against experimental liquid volume fraction data acquired via 3-D computed tomography. Here, the results reveal that flash boiling significantly alters the spray morphology, leading to smaller droplets and spray collapse due to enhanced air-entrainment-induced turbulence. Quantitative agreement between experiments and simulations confirms this behavior. Coupled 0-D equilibrium and 3-D computational fluid dynamics analyses show that flash boiling accelerates evaporation and reduces fuel residence time, while non-flash conditions maintain a persistent liquid core more susceptible to wall wetting. Wall temperature diagnostics reveal that spray collapse alters heat transfer patterns by shifting cooling effects. Mixture fraction analysis indicates that evaporation is primarily governed by shear-layer turbulence, though deviations from adiabatic equilibrium mixing emerge under low-turbulence conditions. Finally, increasing fuel, ambient, and wall temperatures reduces wall wetting and film thickness, mitigating cold-start risks. These findings enhance the understanding of methanol sprays’ behavior and support its adoption as a viable, alternative fuel for ICEs.

Engine Combustion Network↗
NASA NTRS2004

Composite-Material Tanks with Chemically Resistant Liners

Lightweight composite-material tanks with chemically resistant liners have been developed for storage of chemically reactive and/or unstable fluids . especially hydrogen peroxide. These tanks are similar, in some respects, to the ones described in gLightweight Composite-Material Tanks for Cryogenic Liquids h (MFS-31379), NASA Tech Briefs, Vol. 25, No. 1 (January, 2001), page 58; however, the present tanks are fabricated by a different procedure and they do not incorporate insulation that would be needed to prevent boil-off of cryogenic fluids. The manufacture of a tank of this type begins with the fabrication of a reusable multisegmented aluminum mandrel in the shape and size of the desired interior volume. One or more segments of the mandrel can be aluminum bosses that will be incorporated into the tank as end fittings. The mandrel is coated with a mold-release material. The mandrel is then heated to a temperature of about 400 F (approximately equal to 200 C) and coated with a thermoplastic liner material to the desired thickness [typically approxiamtely equal to 15 mils (approximately equal to 0.38 mm)] by thermal spraying. In the thermal-spraying process, the liner material in powder form is sprayed and heated to the melting temperature by a propane torch and the molten particles land on the mandrel. The sprayed liner and mandrel are allowed to cool, then the outer surface of the liner is chemically and/or mechanically etched to enhance bonding of a composite overwrap. The etched liner is wrapped with multiple layers of an epoxy resin reinforced with graphite fibers; the wrapping can be done either by manual application of epoxy-impregnated graphite cloth or by winding of epoxy-impregnated filaments. The entire assembly is heated in an autoclave to cure the epoxy. After the curing process, the multisegmented mandrel is disassembled and removed from inside, leaving the finished tank. If the tank is to be used for storing hydrogen peroxide, then the liner material should be fluorinated ethylene/propylene (FEP), and one or more FEP O ring(s) should be used in the aluminum end fitting(s). This choice of materials is dictated by experimental observations that pure aluminum and FEP are the only materials suitable for long-term storage of hydrogen peroxide and that other materials tend to catalyze the decomposition of hydrogen peroxide to oxygen and water. Other thermoplastic liner materials that are suitable for some applications include nylon 6 and polyethylene. The processing temperatures for nylon 6 are lower than those for FEP. Nylon 6 is compatible with propane, natural gas, and other petroleum-based fuels. Polyethylene is compatible with petroleum- based products and can be used for short-term storage of hydrogen peroxide.

DeLay, Thomas K.↗
NASA NTRS1988

Methods for heat transfer and temperature field analysis of the insulated diesel, phase 3

Work during Phase 3 of a program aimed at developing a comprehensive heat transfer and thermal analysis methodology for design analysis of insulated diesel engines is described. The overall program addresses all the key heat transfer issues: (1) spatially and time-resolved convective and radiative in-cylinder heat transfer, (2) steady-state conduction in the overall structure, and (3) cyclical and load/speed temperature transients in the engine structure. These are all accounted for in a coupled way together with cycle thermodynamics. This methodology was developed during Phases 1 and 2. During Phase 3, an experimental program was carried out to obtain data on heat transfer under cooled and insulated engine conditions and also to generate a database to validate the developed methodology. A single cylinder Cummins diesel engine was instrumented for instantaneous total heat flux and heat radiation measurements. Data were acquired over a wide range of operating conditions in two engine configurations. One was a cooled baseline. The other included ceramic coated components (0.050 inches plasma sprayed zirconia)-piston, head and valves. The experiments showed that the insulated engine has a smaller heat flux than the cooled one. The model predictions were found to be in very good agreement with the data.

Morel, Thomas↗
NASA NTRS2005

Testing of a Spray-bar Thermodynamic Vent System in Liquid Nitrogen

To support development of a microgravity pressure control capability for liquid oxygen, thermodynamic vent system (TVS) testing was conducted at Marshall Space Flight Center (MSFC) using liquid nitrogen (LN2) as a LOX simulant. The spray bar TVS hardware used was originally designed by the Boeing Company for testing in liquid hydrogen (LH2). With this concept, a small portion of the tank fluid is passed through a Joule-Thomson (J-T) device, and then through a longitudinal spray bar mixed-heat exchanger in order to cool the bulk fluid. To accommodate the larger mass flow rates associated with LN2, the TVS hardware was modified by replacing the recirculation pump with an LN2 compatible pump and replacing the J-T valve. The primary advantage of the spray-bar configuration is that tank pressure control can be achieved independent of liquid and vapor location, enhancing the applicability of ground test data to microgravity conditions. Performance testing revealed that the spray-bar TVS was effective in controlling tank pressure within a 6.89 kPa band for fill levels of 90%, 50%, and 25%. Tests were also conducted with gaseous helium (GHe) in the ullage. The TVS operated nominally with GHe in the ullage, with performance similar to the tests with gaseous nitrogen (GN2). Testing demonstrated that the spray-bar TVS design was flexible enough for use in two different propellants with minimal hardware modifications.

Flachbart, R. H.↗
NASA NTRS1982

The cryogenic wind tunnel for high Reynolds number testing

An improved way to increase the Reynolds numbers capability of wind tunnels has been developed at the Langley Research Center. Cooling the test gas to cryogenic temperatures by spraying liquid nitrogen into the tunnel circuit increases Reynolds number with no increase in dynamic pressure and a reduction in drive power. In addition, the ability to vary the temperature of the test gas independently of pressure and Mach number allows for the first time the independent determination of Reynolds number, Mach number, and aeroelastic effects. A new fan-driven transonic cryogenic tunnel being built at the Langley Research Center will provide an order of magnitude increase in Reynolds number capability over existing transonic tunnels in the United States when it is completed later this year.

Kilgore, R. A.↗
NASA NTRS2009

System Modeling of Metabolic Heat Regenerated Temperature Swing Adsorption (MTSA) Subassembly for Prototype Design

This paper describes modeling methods for the three core components of a Metabolic heat regenerated Temperature Swing Adsorption (MTSA) subassembly: the sorbent bed, a sublimation (cooling) heat exchanger (SHX), and a condensing icing (warming) heat exchanger (CIHX). The primary function of the MTSA, removing carbon dioxide from a ventilation loop, is performed via the sorbent bed. The CIHX is used to heat the sorbent bed for desorption and to remove moisture from the ventilation loop while the SHX is alternately employed to cool the sorbent bed via sublimation of a spray of water at low pressure to prepare the reconditioned bed for the next cycle. This paper describes a system level model of the MTSA as developed in Thermal Desktop and SINDA/FLUINT including assumptions on geometry and physical phenomena, modeling methodology and relevant pa ra mete rizatio ns. Several areas of particular modeling interest are discussed. In the sorbent bed, capture of the translating CO2 saturation front and associated local energy and mass balance in both adsorbing and desorbing modes is covered. The CIHX poses particular challenges for modeling in SINDA/FLUINT as accounting for solids states in fluid submodels are not a native capability. Methods for capturing phase change and latent heat of ice as well as the transport properties across a layer of low density accreted frost are developed. This extended modeling capacity is applicable to temperatures greater than 258 K. To extend applicability to the minimum device temperature of 235 K, a method for a mapped transformation of temperatures from below the limit temperatures to some value above is given along with descriptions for associated material property transformations and the resulting impacts to total heat and mass transfer. Similar considerations are shown for the SHX along with assumptions for flow mechanics and resulting model methods for sublimation in a flow.

Bower, Chad↗
NASA NTRS2010

Modeling Of Metabolic Heat Regenerated Temperature Swing Adsorption (MTSA) Subassembly For Prototype Design

This paper describes modeling methods for the three core components of a Metabolic heat regenerated Temperature Swing Adsorption (MTSA) subassembly: a sorbent bed, a sublimation (cooling) heat exchanger (SHX), and a condensing icing (warming) heat exchanger (CIHX). The primary function of the MTSA, removing carbon dioxide from a space suit Portable Life Support System (PLSS) ventilation loop, is performed via the sorbent bed. The CIHX is used to heat the sorbent bed for desorption and to remove moisture from the ventilation loop while the SHX is alternately employed to cool the sorbent bed via sublimation of a spray of water at low pressure to prepare the reconditioned bed for the next cycle. This paper describes subsystem heat a mass transfer modeling methodologies relevant to the description of the MTSA subassembly in Thermal Desktop and SINDA/FLUINT. Several areas of particular modeling interest are discussed. In the sorbent bed, capture of the translating carbon dioxide (CO2) front and associated local energy and mass balance in both adsorbing and desorbing modes is covered. The CIHX poses particular challenges for modeling in SINDA/FLUINT as accounting for solids states in fluid submodels are not a native capability. Methods for capturing phase change and latent heat of ice as well as the transport properties across a layer of low density accreted frost are developed. This extended modeling capacity is applicable to temperatures greater than 258 K. To extend applicability to the minimum device temperature of 235 K, a method for a mapped transformation of temperatures from below the limit temperatures to some value above is given along with descriptions for associated material property transformations and the resulting impacts to total heat and mass transfer. Similar considerations are given for the SHX along with functional relationships for areal sublimation rates as limited by flow mechanics in t1he outlet duct.

Bower, Chad E.↗
DOE OSTI2024

Characterization of compositional variation and solidification condition on rapid solidification behavior of beta stabilized titanium

Rapid solidification (RS) is a field of study that has increased in importance due to the rise of additive manufacturing (AM) techniques. The breakdown of equilibrium at the solid-liquid interface results in an inability to use traditional solidification models that have been applied to great success in casting. As such, there is a current need for a high-throughput testing method to screen alloys at rapid solidification conditions without the significant cost for powder atomization. In this work, twin hammer splat quenching (SQ) is utilized and theoretically developed as a technique uniquely placed to test alloy systems for AM applications. Using analytical thermal spray models and numerical heat transfer simulations, the cooling rate and solidification conditions of splat quenching are compared across several parameters to evaluate the key parameters for generating cooling rates relevant to AM process. Once a framework for the cooling rates and relevancy of SQ are developed, SQ was used to process alloy compositions in the Ti5553 alloy space (AMS 7026) to study the formation of detrimental secondary phases occurring upon rapid quenching from the melt. A martensitic phase is found to occur at the lower end of the standard, but the composition listed in the standard were found to be safe. Finally, the rapid solidification behavior of Ti-5553 is evaluated by comparing splat quenching, laser welding, and plasma atomization that offer a wide window of solidification conditions. The segregation and solidification structure are analyzed and compared to models to provide a deeper understanding of the solidification behavior of beta stabilized titanium alloys.

Williamson, Christopher J.↗