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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 1,117 records · Page 62
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Overview of the Aerothermodynamics Analysis Conducted in Support of the STS-107 Accident Investigation

A graphic presentation of the aerothermodynamics analysis conducted in support of the STS-107 accident investigation. Investigation efforts were conducted as part of an integrated AATS team (Aero, Aerothermal, Thermal, Stress) directed by OVEWG. Graphics presented are: STS-107 Entry trajectory and timeline (1st off-nominal event to Post-LOS); Indications from OI telemetry data; Aero/aerothermo/thermal analysis process; Selected STS-107 side fuselage/OMS pod off-nominal temperatures; Leading edge structural subsystem; Relevant forensics evidence; External aerothermal environments; STS-107 Pre-entry EOM3 heating profile; Surface heating and temperatures; Orbiter wing leading edge damage survey; Internal aerothermal environments; Orbiter wing CAD model; Aerodynamic flight reconstruction; Chronology of aerodynamic/aerothermoydynamic contributions; Acreage TPS tile damage; Larger OML perturbations; Missing RCC panel(s); Localized damage to RCC panel/missing T-seal; RCC breach with flow ingestion; and Aero-aerothermal closure. NAIT served as the interface between the CAIB and NASA investigation teams; and CAIB requests for study were addressed.

Campbell, Charles H.↗
NASA NTRS2007

Powder Processing of High Temperature Cermets and Carbides at Marshall Space Flight Center

The Materials and Processing Laboratory at NASA Marshall Space Flight Center is developing Powder Metallurgy (PM) processing techniques for high temperature cermet and carbide material consolidation. These new group of materials would be utilized in the nuclear core for Nuclear Thermal Rockets (NTR). Cermet materials offer several advantages for NTR such as retention of fission products and fuels, better thermal shock resistance, hydrogen compatibility, high thermal conductivity, and high strength. Carbide materials offer the highest operating temperatures but are sensitive to thermal stresses and are difficult to process. To support the effort, a new facility has been setup to process refractory metal, ceramic, carbides and depleted uranium-based powders. The facility inciudes inert atmosphere glove boxes for the handling of reactive powders, a high temperature furnace, and powder processing equipment used for blending, milling, and sieving. The effort is focused on basic research to identify the most promising compositions and processing techniques. Several PM processing methods including Cold and Hot Isostatic Pressing are being evaluated to fabricate samples for characterization and hot hydrogen testing.

Salvail, Pat↗
NASA NTRS2006

Daytime Use of Astronomical Telescopes for Deep-Space Optical Links

Tests at the 200-inch Hale Telescope on Palomar Mountain have demonstrated this telescope's ability to withstand considerable thermal stress, and subsequently produce remarkably unaffected results. During the day of June 29,2005, the Hale telescope dome was left open, and the telescope was exposed to outside air and direct sunlight for 8 hours. During this time, portions of the telescope structure in the telescope's optical path experienced temperature elevations of 30 C, while the primary mirror experienced unprecedented heating of over 3 C. The telescope's measured blind pointing accuracy after this exposure was not noticeably degraded from the measurements taken before exposure. More remarkably, the telescope consistently produced stellar images which were significantly better after exposure of the telescope (1.2 arcsec) than before (1.6 arcsec), even though the conditions of observation were similar. This data is the first step in co-opting astronomical telescopes for daytime use as astronomical receivers, and supports the contention that deleterious effects from daytime exposure of the telescope can be held to an acceptable level for interleaved communications and astronomy.

telescope heat↗
NASA NTRS2007

Fabrication and Characterization of Diffusion Bonds for Silicon Carbide

Diffusion bonds of silicon carbide (SiC) were fabricated using several different types of titanium (Ti) based interlayers between the SiC substrates. The interlayers were an alloyed Ti foil, a pure Ti foil, and a physically vapor deposited (PVD) Ti coating. Microscopy was conducted to evaluate the cross-sections of the resulting bonds. Microprobe analysis identified reaction formed phases in the diffusion bonded region. Uniform and well adhered bonds were formed between the SiC substrates. In the case where the alloyed Ti foil or a thick Ti coating (i.e. 20 micron) was used as the interlayer, microcracks and several phases were present in the diffusion bonds. When a thinner interlayer was used (i.e. 10 micron PVD Ti), no microcracks were observed and only two reaction formed phases were present. The two phases were preferred and fully reacted phases that did not introduce thermal stresses or microcracks during the cool-down stage after processing. Diffusion bonded samples were evaluated with the non-destructive evaluation (NDE) methods of pulsed thermography and immersion ultrasonic testing. Joined SiC substrates that were fully bonded and that had simulated bond flaws in the interlayer were also evaluated using immersion ultrasound. Pull testing was conducted on the bonds to determine the tensile strength. To demonstrate the joining approach for a complex multilayered component for a low NOx injector application, the diffusion bonding approach was used to join three 4" diameter SiC discs that contained complex fuel and air flow channels.

Halbig, Michael↗
NASA NTRS2008

Development and Characterization of the Bonding and Integration Technologies Needed for Fabricating Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding technology, titanium interlayers (coatings and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness, and processing time were investigated. Electron microprobe analysis was used to identify the reaction formed phases. In the diffusion bonds, an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner interlayers of pure titanium and/or longer processing times resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Nondestructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig,Michael C.↗
NASA NTRS2008

Bonding and Integration Technologies for Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding, titanium interlayers (PVD and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness (10, 20, and 50 microns), processing time and temperature, and cooling rates were investigated. Microprobe analysis was used to identify the phases in the bonded region. For bonds that were not fully reacted an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner titanium interlayers and/or longer processing times resulted in stable and compatible phases that did not contribute to microcracking and resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Non-destructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig, Michael C.↗
NASA NTRS2008

Opto-Mechanics of the Constellation-X SXT Mirrors: Challenges in Mounting and Assembling the Mirror Segments

The Constellation-X Spectroscopy X-Ray Telescopes consists of segmented glass mirrors with an axial length of 200 mm, a width of up to 400 mm, and a thickness of 0.4 mm. To meet the requirement of less than 15 arc-second half-power diameter with the small thickness and relatively large size is a tremendous challenge in opto-mechanics. How shall we limit distortion of the mirrors due to gravity in ground tests, that arises from thermal stress, and that occurs in the process of mounting, affixing and assembling of these mirrors? In this paper, we will describe our current opto-mechanical approach to these problems. We will discuss, in particular, the approach and experiment where the mirrors are mounted vertically by first suspending it at two points.

Chan, Kai-Wing↗
NASA NTRS2008

Photochemically Synthesized Polyimides

An alternative to the conventional approach to synthesis of polyimides involves the use of single monomers that are amenable to photopolymerization. Heretofore, the synthesis of polyimides has involved multiple-monomer formulations and heating to temperatures that often exceed 250 C. The present alternative approach enables synthesis under relatively mild conditions that can include room temperature. The main disadvantages of the conventional approach are the following: Elevated production temperatures can lead to high production costs and can impart thermal stresses to the final products. If the proportions of the multiple monomeric ingredients in a given batch are not exactly correct, the molecular weight and other physical properties of the final material could be reduced from their optimum or desired values. To be useful in the alternative approach, a monomer must have a molecular structure tailored to exploit Diels-Alder trapping of a photochemically generated ortho-quinodimethane. (In a Diels-Alder reaction, a diene combines with a dienophile to form molecules that contain six-membered rings.) In particular, a suitable monomer (see figure) contains ortho-methylbenzophenone connected to a dienophile (in this case, a maleimide) through a generic spacer group. Irradiation with ultraviolet light gives rise to a photochemical intermediate the aforementioned ortho-quinodimethane from the ortho-methylbenzophenone. This group may react with the dienophile on another such monomer molecule to produce an oligomer that, in turn may react in a stepgrowth manner to produce a polyimide. This approach offers several advantages in addition to those mentioned above: The monomer can be stored for a long time because it remains unreactive until exposed to light. Because the monomer is the only active starting ingredient, there is no need for mixing, no concern for ensuring correct proportions of monomers, and the purity of the final product material is inherently high. The use of solvents is optional: The synthesis can be performed using the neat monomer or the monomer mixed with one or more solvent(s) in dilute or concentrated solution. The solubility of the monomer and the physical and chemical properties of the final polymer can be tailored through selection of the spacer group.

Meador, Michael A.↗
NASA NTRS2009

Lightning Pin Injection Testing on MOSFETS

Lightning transients were pin-injected into metal-oxide-semiconductor field-effect transistors (MOSFETs) to induce fault modes. This report documents the test process and results, and provides a basis for subsequent lightning tests. MOSFETs may be present in DC-DC power supplies and electromechanical actuator circuits that may be used on board aircraft. Results show that unprotected MOSFET Gates are susceptible to failure, even when installed in systems in well-shielded and partial-shielded locations. MOSFET Drains and Sources are significantly less susceptible. Device impedance decreased (current increased) after every failure. Such a failure mode may lead to cascading failures, as the damaged MOSFET may allow excessive current to flow through other circuitry. Preliminary assessments on a MOSFET subjected to 20-stroke pin-injection testing demonstrate that Breakdown Voltage, Leakage Current and Threshold Voltage characteristics show damage, while the device continues to meet manufacturer performance specifications. The purpose of this research is to develop validated tools, technologies, and techniques for automated detection, diagnosis and prognosis that enable mitigation of adverse events during flight, such as from lightning transients; and to understand the interplay between lightning-induced surges and aging (i.e. humidity, vibration thermal stress, etc.) on component degradation.

Ely, Jay J.↗
NASA NTRS2010

Coatings Extend Life of Engines and Infrastructure

MesoCoat Inc., of Euclid, Ohio, collaborated with Glenn Research Center to provide thermal barrier coating (TBC) technology, developed by Glenn researcher Dongming Zhu, to enhance the lifespan and performance of engines in U.S. Air Force legacy aircraft. The TBC reduces thermal stresses on engine parts, increasing component life by 50 percent. MesoCoat is also producing metal cladding technology that may soon provide similar life-lengthening benefits for the Nation's infrastructure. Through a Space Act Agreement with Glenn, the company employs the Center's high-density infrared arc lamp system to bond its cladding materials for demonstration prototypes; the coating technology can prevent corrosion on metal beams, pipes, and rebar for up to 100 years.

Source record↗
NASA NTRS2011

Finite Element Model Characterization Of Nano-Composite Thermal And Environmental Barrier Coatings

Thermal and environmental barrier coatings have been applied for protecting Si based ceramic matrix composite components from high temperature environment in advanced gas turbine engines. It has been found that the delamination and lifetime of T/EBC systems generally depend on the initiation and propagation of surface cracks induced by the axial mechanical load in addition to severe thermal loads. In order to prevent T/EBC systems from surface cracking and subsequent delamination due to mechanical and thermal stresses, T/EBC systems reinforced with nano-composite architectures have showed promise to improve mechanical properties and provide a potential crack shielding mechanism such as crack bridging. In this study, a finite element model (FEM) was established to understand the potential beneficial effects of nano-composites systems such as SiC nanotube-reinforced oxide T/EBC systems.

Yamada, Yoshiki↗
NASA NTRS2012

Restoration and Reexamination of Data from the Apollo 11, 12, 14, and 15 Dust, Thermal and Radiation Engineering Measurements Experiments

As part of an effort by the Lunar Data Node (LDN) we are restoring data returned by the Apollo Dust, Thermal, and Radiation Engineering Measurements (DTREM) packages emplaced on the lunar surface by the crews of Apollo 11, 12, 14, and 15. Also commonly known as the Dust Detector experiments, the DTREM packages measured the outputs of exposed solar cells and thermistors over time. They operated on the surface for up to nearly 8 years, returning data every 54 seconds. The Apollo 11 DTREM was part of the Early Apollo Surface Experiments Package (EASEP), and operated for a few months as planned following emplacement in July 1969. The Apollo 12, 14, and 15 DTREMs were mounted on the central station as part of the Apollo Lunar Surface Experiments Package (ALSEP) and operated from deployment until ALSEP shutdown in September 1977. The objective of the DTREM experiments was to determine the effects of lunar and meteoric dust, thermal stresses, and radiation exposure on solar cells. The LDN, part of the Geosciences Node of the Planetary Data System (PDS), operates out of the National Space Science Data Center (NSSDC) at Goddard Space Flight Center. The goal of the LDN is to extract lunar data stored on older media and/or in obsolete formats, restore the data into a usable digital format, and archive the data with PDS and NSSDC. For the DTREM data we plan to recover the raw telemetry, translate the raw counts into appropriate output units, and then apply calibrations. The final archived data will include the raw, translated, and calibrated data and the associated conversion tables produced from the microfilm, as well as ancillary supporting data (metadata) packaged in PDS format.

McBride, Marie J.↗
NASA NTRS2014

A Morphing Radiator for High-Turndown Thermal Control of Crewed Space Exploration Vehicles

Spacecraft designed for missions beyond low earth orbit (LEO) face a difficult thermal control challenge, particularly in the case of crewed vehicles where the thermal control system (TCS) must maintain a relatively constant internal environment temperature despite a vastly varying external thermal environment and despite heat rejection needs that are contrary to the potential of the environment. A thermal control system may be required to reject a higher heat load to warm environments and a lower heat load to cold environments, necessitating a relatively high turndown ratio. A modern thermal control system is capable of a turndown ratio of on the order of 12:1, but crew safety and environment compatibility have constrained these solutions to massive multi-loop fluid systems. This paper discusses the analysis of a unique radiator design that employs the behavior of shape memory alloys (SMAs) to vary the turndown of, and thus enable, a single-loop vehicle thermal control system for space exploration vehicles. This design, a morphing radiator, varies its shape in response to facesheet temperature to control view of space and primary surface emissivity. Because temperature dependence is inherent to SMA behavior, the design requires no accommodation for control, instrumentation, or power supply in order to operate. Thermal and radiation modeling of the morphing radiator predict a turndown ranging from 11.9:1 to 35:1 independent of TCS configuration. Coupled thermal-stress analyses predict that the desired morphing behavior of the concept is attainable. A system level mass analysis shows that by enabling a single loop architecture this design could reduce the TCS mass by between 139 kg and 225 kg. The concept has been demonstrated in proof-of-concept benchtop tests.

Cognata, Thomas J.↗
NASA NTRS2013

Development of a Multi-Disciplinary Aerothermostructural Model Applicable to Hypersonic Flight

The harsh and complex hypersonic flight environment has driven design and analysis improvements for many years. One of the defining characteristics of hypersonic flight is the coupled, multi-disciplinary nature of the dominant physics. In an effect to examine some of the multi-disciplinary problems associated with hypersonic flight engineers at the NASA Dryden Flight Research Center developed a non-linear 6 degrees-of-freedom, full vehicle simulation that includes the necessary model capabilities: aerothermal heating, ablation, and thermal stress solutions. Development of the tool and results for some investigations will be presented. Requirements and improvements for future work will also be reviewed. The results of the work emphasize the need for a coupled, multi-disciplinary analysis to provide accurate

hypersonics↗
NASA NTRS2014

Development Status of a CVD System to Deposit Tungsten onto UO2 Powder via the WCI6 Process

Nuclear Thermal Propulsion (NTP) is under development for deep space exploration. NTP's high specific impulse (> 850 second) enables a large range of destinations, shorter trip durations, and improved reliability. W-60vol%UO2 CERMET fuel development efforts emphasize fabrication, performance testing and process optimization to meet service life requirements. Fuel elements must be able to survive operation in excess of 2850 K, exposure to flowing hydrogen (H2), vibration, acoustic, and radiation conditions. CTE mismatch between W and UO2 result in high thermal stresses and lead to mechanical failure as a result UO2 reduction by hot hydrogen (H2) [1]. Improved powder metallurgy fabrication process control and mitigated fuel loss can be attained by coating UO2 starting powders within a layer of high density tungsten [2]. This paper discusses the advances of a fluidized bed chemical vapor deposition (CVD) system that utilizes the H2-WCl6 reduction process.

Mireles, O. R.↗
NASA NTRS2012

Accelerated Aging Experiments for Capacitor Health Monitoring and Prognostics

This paper discusses experimental setups for health monitoring and prognostics of electrolytic capacitors under nominal operation and accelerated aging conditions. Electrolytic capacitors have higher failure rates than other components in electronic systems like power drives, power converters etc. Our current work focuses on developing first-principles-based degradation models for electrolytic capacitors under varying electrical and thermal stress conditions. Prognostics and health management for electronic systems aims to predict the onset of faults, study causes for system degradation, and accurately compute remaining useful life. Accelerated life test methods are often used in prognostics research as a way to model multiple causes and assess the effects of the degradation process through time. It also allows for the identification and study of different failure mechanisms and their relationships under different operating conditions. Experiments are designed for aging of the capacitors such that the degradation pattern induced by the aging can be monitored and analyzed. Experimental setups and data collection methods are presented to demonstrate this approach.

Prognostics of Electronics↗
NASA NTRS2014

Hot Hydrogen Testing of Tungsten-Uranium Dioxide (W-UO2) CERMET Fuel Materials for Nuclear Thermal Propulsion

CERMET fuel materials are being developed at the NASA Marshall Space Flight Center for a Nuclear Cryogenic Propulsion Stage. Recent work has resulted in the development and demonstration of a Compact Fuel Element Environmental Test (CFEET) System that is capable of subjecting depleted uranium fuel material samples to hot hydrogen. A critical obstacle to the development of an NCPS engine is the high-cost and safety concerns associated with developmental testing in nuclear environments. The purpose of this testing capability is to enable low-cost screening of candidate materials, fabrication processes, and further validation of concepts. The CERMET samples consist of depleted uranium dioxide (UO2) fuel particles in a tungsten metal matrix, which has been demonstrated on previous programs to provide improved performance and retention of fission products1. Numerous past programs have utilized hot hydrogen furnace testing to develop and evaluate fuel materials. The testing provides a reasonable simulation of temperature and thermal stress effects in a flowing hydrogen environment. Though no information is gained about radiation damage, the furnace testing is extremely valuable for development and verification of fuel element materials and processes. The current work includes testing of subscale W-UO2 slugs to evaluate fuel loss and stability. The materials are then fabricated into samples with seven cooling channels to test a more representative section of a fuel element. Several iterations of testing are being performed to evaluate fuel mass loss impacts from density, microstructure, fuel particle size and shape, chemistry, claddings, particle coatings, and stabilizers. The fuel materials and forms being evaluated on this effort have all been demonstrated to control fuel migration and loss. The objective is to verify performance improvements of the various materials and process options prior to expensive full scale fabrication and testing. Post test analysis will include weight percent fuel loss, microscopy, dimensional tolerance, and fuel stability.

Hickman, Robert↗
NASA NTRS2014

Structure and Evolution of the Lunar Procellarum Region as Revealed by GRAIL Gravity Data

The Procellarum region is a broad area on the nearside of the Moon that is characterized by low elevations, thin crust, and high surface concentrations of the heat-producing elements uranium, thorium, and potassium. The Procellarum region has been interpreted as an ancient impact basin approximately 3200 km in diameter, though supporting evidence at the surface would have been largely obscured as a result of the great antiquity and poor preservation of any diagnostic features. Here we use data from the Gravity Recovery and Interior Laboratory (GRAIL) mission to examine the subsurface structure of Procellarum. The Bouguer gravity anomalies and gravity gradients reveal a pattern of narrow linear anomalies that border the Procellarum region and are interpreted to be the frozen remnants of lava-filled rifts and the underlying feeder dikes that served as the magma plumbing system for much of the nearside mare volcanism. The discontinuous surface structures that were earlier interpreted as remnants of an impact basin rim are shown in GRAIL data to be a part of this continuous set of quasi-rectangular border structures with angular intersections, contrary to the expected circular or elliptical shape of an impact basin. The spatial pattern of magmatic-tectonic structures bounding Procellarum is consistent with their formation in response to thermal stresses produced by the differential cooling of the province relative to its surroundings, coupled with magmatic activity driven by the elevated heat flux in the region.

Procellarum↗