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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 1,135 records · Page 63
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

The LiAl/FeS2 battery power source for the future

Advanced high power density rechargeable batteries are currently under development. These batteries have the potential of greatly increasing the power and energy densities available for space applications. Depending on whether the system is optimized for high power or high energy, values up to 150 Wh/kg and 2100 W/kg (including hardware) are projected. This is due to the fact that the system uses a high conductivity molten salt electrolyte. The electrolyte also serves as a separator layer with unlimited freeze thaw capabilities. Life of 1000 cycles and ten calendar years is projected. The electrochemistry consists of a lithium aluminum alloy negative electrode, iron disulfide positive electrode, and magnesium oxide powder immobilized molten salt electrolyte. Processed powders are cold compacted into circular discs which are assembled into bipolar cell hardware with peripheral ceramic salts. The culmination of the work will be a high energy battery of 40 kWh and a high power battery of 28 kWh.

Briscoe, J. Douglass↗
NASA NTRS1991

Ceramic superconducting components

An approach to the application of high-Tc ceramic superconductors to practical circuit elements was developed and demonstrated. This method, known as the rigid conductor process (RCP), involves the mounting of a preformed, sintered, and tested superconductor material onto an appropriate, rigid substrate with an epoxy adhesive which also serves to encapsulate the element from the ambient environment. Circuit elements such as straight conductors, coils and connectors were fabricated from YBa2Cu3O(7-x) superconducting material. Performance results are included for a low-noise low-thermal-conductivity superconducting grounding link for NASA.

Haertling, G. H.↗
NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt.% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF/HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damages at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, were observed especially for the combined LCF/HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗
NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF-HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damage at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, was observed especially for the combined LCF-HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗
NASA NTRS1998

Technical Challenges for Next Generation Liquid Rocket Engine Nozzles

Next generation launch and propulsion systems face significant challenges of providing increased performance at lower cost with shorter development cycles. The use of existing materials in new application areas and the development and application of "advanced" material systems are enabling for the achievement of these aggressive goals. An area which offers substantial opportunity to decrease liquid rocket engine systems weight, and thus provide a measure of increased performance, is the nozzle. This presentation will examine the technical issues and showstoppers limiting the application of alternate materials to liquid rocket engine nozzles and identify the key material systems which have the potential for high payoff relative to the forcing functions of cost and performance (weight). Existing nozzle material development projects will be cited and opportunities for future joint partnerships to address these materials and processes challenges will be addressed. The presentation will include overviews of activities in low cost ablative nozzles, ceramic matrix composite cooled and uncooled nozzles, and advanced metallics.

Clinton, R. G., Jr.↗
NASA NTRS2004

Ultra-High Temperature Ceramic Composites for Leading Edges

Issues associated with the development and use of Ultra-High Temperature Ceramic Composites (UHTCC) for leading edges of hypersonic vehicles will be discussed. These include attachments, constituent selection, processing, oxidation, physical and mechanical properties, and attachments.

Levine, Stanley R.↗
NASA NTRS2016

Radio Frequency Plasma Synthesis of Boron Nitride Nanotubes (BNNTs) for Structural Applications: Part I

It is evident that nanotubes, such as carbon, boron nitride and even silicon, offer great potential for many aerospace applications. The opportunity exists to harness the extremely high strength and stiffness exhibited by high-purity, low-defect nanotubes in structural materials. Even though the technology associated with carbon nanotube (CNT) development is mature, the mechanical property benefits have yet to be fully realized. Boron nitride nanotubes (BNNTs) offer similar structural benefits, but exhibit superior chemical and thermal stability. A broader range of potential structural applications results, particularly as reinforcing agents for metal- and ceramic- based composites. However, synthesis of BNNTs is more challenging than CNTs mainly because of the higher processing temperatures required, and mass production techniques have yet to emerge. A promising technique is radio frequency plasma spray (RFPS), which is an inductively coupled, very high temperature process. The lack of electrodes and the self- contained, inert gas environment lend themselves to an ultraclean product. It is the aim of this White Paper to survey the state of the art with regard to nano-material production by analyzing the pros and cons of existing methods. The intention is to combine the best concepts and apply the NASA Langley Research Center (LaRC) RFPS facility to reliably synthesize large quantities of consistent, high-purity BNNTs.

Hales, Stephen J.↗
NASA NTRS2009

Reliability of recolumned area array packages

This report presents qualification guidelines developed for recolumned, high I/O ceramic column grid array (CCGA) packages assembled onto printed wiring/circuit boards (PWBs/PCBs). It includes recolumn and assembly process development for two types of CCGA packages: those with and those without interposer. Thermal cycle test results and photomicrographs showing damage progress for recolumned CCGA assemblies are documented and presented.

Ghaffarian, Reza↗
DOE OSTI2017

Using Conductive Firebrick Resistance Heating to Enable Very High-Temperature Heat Storage in Nuclear Gas Turbine Systems

In order to economically deploy renewable energy on large scales, affordable energy storage is a must. While the cost of current work storage technologies are too high to deploy in quantities that satisfy renewable energy deployment, heat storage options hold promise for dramatically cheaper storage, which can be used to (1) couple with industrial furnaces or refineries to provide high temperature heat to industry, or (2) couple with air-Brayton cycles to add heat for electricity production. The design space and preliminary performance evaluation for an affordable heat storage concept, called Firebrick Resistance-heated Energy Storage (FIRES), has shown promise for near-term deployment in industrial processes by using readily available materials: metallic resistance heaters for converting electricity to stored heat, and common ceramic firebricks used in furnaces for storing heat at temperatures as high as 1200 deg. C. There however remains serious interest in replacing traditional resistance heaters with electrically conductive firebricks that may serve as both the heating element and the storage medium. The work underway is the experimental development of a high-temperature low-cost electric resistance heater system using conductive firebrick, with the aims of (1) proving that conductive firebrick can be used to replace separate electrical heating system to reduce costs, increase operating temperatures, and increase reliability, and (2) developing methodology to enable design and prediction of performance of such systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Reflow-oven-processing of pressureless sintered-silver interconnects

Here, a method was developed to pressurelessly fabricate strong and consistent sinterable-silver joints or interconnects using reflow oven heating. Circular sinterable-silver interconnects, having nominal diameter of 5 mm and 0.1 mm thickness were stencil printed, contact-dried, and then pressurelessly sinter-bonded to Au-plated direct copper bonded ceramic substrates at 250 °C in ambient air. That sintering was done in either a reflow oven or a convective oven (latter being a conventional heating source for processing sinterable-silver). Consistently strong (>40 MPa) interconnects were produced with reflow oven heating and were as strong as those produced with convective oven heating. This is significant because reflow oven technology affords better potential for continuous mass production and it was shown that strong sintered-silver bonds can indeed be achieved with its use.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Additive Manufacturing for Cost Efficient Production of Compact Ceramic Heat Exchangers and Recuperators

An additive manufacture technique known as laminated object manufacturing (LOM) was used to fabricate compact ceramic heat exchanger prototypes. LOM uses precision CO2 laser cutting of ceramic green tapes, which are then precision stacked to build a 3D object with fine internal features. Modeling was used to develop prototype designs and predict the thermal response, stress, and efficiency in the ceramic heat exchangers. Build testing and materials analyses were used to provide feedback for the design selection. During this development process, laminated object manufacturing protocols were established. This included laser optimization, strategies for fine feature integrity, lamination fluid control, green handling, and firing profile. Three full size prototypes were fabricated using two different designs. One prototype was selected for performance testing. During testing, cross talk leakage prevented the application of a high pressure differential, however, the prototype was successful at withstanding the high temperature operating conditions (1300 °F). In addition, analysis showed that the bulk of the part did not have cracks or leakage issues. This led to the development of a module method for next generation LOM heat exchangers. A scale-up cost analysis showed that given a purpose built LOM system, these ceramic heat exchangers would be affordable for the applications.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Scalable Bottom-Up Synthesis of Nanoporous Hexagonal Boron Nitride ( h -BN) for Large-Area Atomically Thin Ceramic Membranes

Nanopores embedded within monolayer hexagonal boron nitride (h-BN) offer possibilities of creating atomically thin ceramic membranes with unique combinations of high permeance (atomic thinness), high selectivity (via molecular sieving), increased thermal stability, and superior chemical resistance. However, fabricating size-selective nanopores in monolayer h-BN via scalable top-down processes remains nontrivial due to its chemical inertness, and characterizing nanopore size distribution over a large area remains extremely challenging. Here, we demonstrate a facile and scalable approach of exploiting the chemical vapor deposition (CVD) process temperature to enable direct incorporation of subnanometer/nanoscale pores into the monolayer h-BN lattice, in combination with manufacturing compatible polymer casting to fabricate centimeter-scale nanoporous atomically thin ceramic membranes. We leverage diffusive transport of analytes including size-selective Ficoll sieving to characterize subnanometer-scale and nanoscale defects that manifest as pores in centimeter-scale h-BN membranes, overcoming previous limitations in large-area characterization of nanoscale defects in h-BN. Our approach opens a new frontier to advance atomically thin membranes to 2D ceramic materials, such as h-BN via facile and direct formation of nanopores, for size-selective separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Magnesia tuned multi-walled carbon nanotubes–reinforced alumina nanocomposites

Magnesia tuned alumina ceramic nanocomposites, reinforced with multi-walled carbon nanotubes, were condensed using pressureless and hot-press sintering processes. Densification, microstructure and mechanical properties of the produced nanocomposites were meticulously investigated. Electron microscopy studies revealed the homogenous carbon nanotube dispersion within the alumina matrix and confirmed the retention of carbon nanotubes' distinctive tubular morphology and nanoscale features during the extreme mixing/sintering processes. Pressureless sintered nanocomposites showed meagre mechanical responses due to the poorly-integrated microstructures with a slight improvement upon magnesia addition. Conversely, both the magnesia addition and application of hot-press sintering technique resulted in the nanocomposite formation with near-theoretical densities (~ 99%), well-integrated microstructures and superior mechanical properties. Hot-press sintered nanocomposites incorporating 300 and 600 ppm magnesia exhibited an increase in hardness (10 and 11%), flexural strength (5 and 10%) and fracture toughness (15 and 20%) with respect to similar magnesia-free samples. Compared to monolithic alumina, a decent rise in fracture toughness (37%), flexural strength (22%) and hardness (20%) was observed in the hot-press sintered nanocomposites tuned with merely 600 ppm magnesia. Mechanically superior hot-press sintered magnesia tailored nanocomposites are attractive for several load-bearing structural applications. - Highlights: • MgO tailored Al{sub 2}O{sub 3}–2 wt.% CNT nanocomposites are presented. • The role of MgO and sintering on nanocomposite structures and properties was studied. • Well-dispersed CNTs maintained their morphology/structure after harsh sintering. • Hot-pressing and MgO led nanocomposites to higher properties/unified structures. • MgO tuned composites showed higher toughness (37%) and strength (22%) than Al{sub 2}O{sub 3}.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
NASA NTRS1995

(abstract) Microwave Induced Combustion Synthesis of Ceramic and Ceramic-Metal Composites

We have used microwaves to induce self-propagating high temperature synthesis (SHS) in the reaction 3TiO(sub 2)+3C+(4+x)Al ---> 3TiC+2Al(sub 2)O(sub 3)+xAl. The SHS process was studied for x = 0 and 4, with and without the application of uniaxial pressure. A TE102 microwave cavity mode internally ignited the samples using less than 50 watts. The resultant microstructure of the microwave processed samples were compared to SHS products obtained using a conventional hot wire ignition technique. Uniaxial stresses along the vertical axis of approximately 1400 and 200 psi were applied simultaneously as the SHS reactions were initiated in some of the conventional and microwave processed samples, respectively. SEM photomicrographs will be presented that show the different microstructural features of the products using the microwave and hot wire techniques.

ceramic microwave ceramic-metal composites microwa↗
DOE OSTI2016

A high performance neutron powder diffractometer at 3 MW Triga Mark-II research reactor in Bangladesh

A high performance neutron diffractometer called Savar Neutron Diffractometer (SAND) was built and installed at radial beam port-2 of TRIGA Mark II research reactor at AERE, Savar, Dhaka, Bangladesh. Structural studies of materials are being done by this technique to characterize materials crystallograpohically and magnetically. The micro-structural information obtainable by neutron scattering method is very essential for determining its technological applications. This technique is unique for understanding the magnetic behavior in magnetic materials. Ceramic, steel, electronic and electric industries can be benefited from this facility for improving their products and fabrication process. This instrument consists of a Popovicimonochromator with a large linear position sensitive detector array. The monochromator consists of nine blades of perfect single crystal of silicon with 6 mm thickness each. The monochromator design was optimized to provide maximum flux on 3 mm diameter cylindrical sample with a relatively flat angular dependence of resolution. Five different wave lengths can be selected by orienting the crystal at various angles. A sapphire filter was used before the primary collimator to minimize the first neutron. The detector assembly is composed of 15 linear position sensitive proportional counters placed at either 1.1 m or 1.6 m from the sample position and enclosed in a air pad supported high density polythene shield. Position sensing is obtained by charge division using 1-wide NIM position encoding modules (PEM). The PEMs communicate with the host computer via USB. The detector when placed at 1.1 m, subtends 30° (2θ) at each step and covers 120° in 4 steps. When the detector is placed at 1.6 m it subtends 20° at each step and covers 120° in 6 steps. The instrument supports both low and high temperature sample environment. The instrument supports both low and high temperature sample environment. The diffractometer is a state-of-the art technology for diffraction study in our country.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2013

Temperature modeling for analysis and design of the sintering furnance in HTR fuel type of ball

One of the factors that determine the safety of the operation of the sintering furnace fuel HTR ball is the temperature distribution in the ceramic tube furnace. The temperature distribution must be determined at design stage. The tube has a temperature of 1600 °C at one end and about 40 °C at the other end. The outside of the tube was cooled by air through natural convection. The tube is a furnace ceramic tube which its geometry are 0.08, 0.09 and 0.5 m correspondingly for the inner tube diameter, outer tube diameter and tube length. The temperature distribution of the tube is determined by the natural convection coefficient (NCF), which is difficult to be calculated manually. The determination of NCF includes the Grasshoff, Prandtl, and Nusselt numbers which is a function of the temperature difference between the surrounding air with the ceramic tube. If the temperature vary along the tube, the complexity of the calculations increases. Thus the proposed modeling was performed to determine the temperature distribution along the tube and heat transfer coefficient using a self-developed software which permit the design process easier.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRSDate not supplied

CMC Research at NASA Glenn in 2021: Recent Progress and Plans

As part of NASA’s Aeronautics research, Glenn Research Center has developed SiC/SiC Ceramic Matrix Composites for 2700°F turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development and characterization of constituents and fabrication processes that enabled this advancement will be reviewed, and the resulting improvements in CMC mechanical properties and durability will be summarized. Progress toward the development and experimental validation of analytical models predicting the effects of engine operating conditions on the durability of Ceramic Matrix Composites with Environmental Barrier Coatings will be summarized. Results from current collaborative research with industry, universities and other government agencies will be reviewed. Research plans for 2021 and opportunities for future collaborations with NASA will also be summarized.

Ceramic Matrix Composites↗