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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Comparison of NAE porous wall and NASA adaptive wall test results using the NAE CAST-10 airfoil model

Wind tunnels can now simulate flows over airfoils at high Reynolds numbers and high subsonic speeds. Methods to correct for (or reduce) test section wall interference at these test conditions must be validated. The National Aeronautics Establishment (NAE) of Canada and NASA have a cooperative agreement to study this area. The NAE designed, built, and tested a CAST-10 airfoil model in its conventional Two-Dimensional High Reynolds Number Facility. The results were corrected using classical correction techniques. NASA then tested the same model in its 0.3-meter Transonic Cryogenic Tunnel with the adaptive wall test section. The adaptive wall test section reduced the wall interference to what was expected to be an acceptable level. The corrected NAE results are compared with the uncorrected NASA results. The NAE results are also compared with NASA results after residual corrections for top and bottom wall interference. Finally, a comparison of both sets of results corrected for interference from all four walls is presented.

Mineck, Raymond E.↗
NASA NTRS2003

Macrovoid Defect Growth during Evaporative Casting of Polymeric Membranes

Macrovoid (MV) formation is a significant problem in evaporatively cast polymeric membranes. MVs are large, elongated or teardrop-shaped pores (~10-50 micron) that can impair membrane structural integrity. Although MVs have been extensively studied, there is no general agreement on the mechanisms governing MV growth. Recently, our research group has formulated the solutocapillary convection (SC) hypothesis, which contends that MV growth involves three principal forces: a Marangoni force generated by surface tension gradients within the MV interface, a viscous drag force, and a gravitationally induced body force. Two sets of complementary experiments were conducted to test the SC hypothesis. Ground-based videomicroscopy flow-visualization (VMFV) was utilized to measure the flow velocities at the MV-casting solution interface and deep within the casting solution. The measurements were performed with casting solutions containing 10 wt% cellulose acetate (CA), 30 wt% H2O, 60 wt% acetone, and 200- ppm TiO2 particles for flow visualization, and the surface tension was controlled by surfactant addition. Qualitatively, the experiments indicated that MV growth occurs in three distinct phases: (1) a very rapid initial growth period, (2) a much slower growth phase, and (3) absorption of selected MVs into the expanding demixed region. The presence of tracer particles inside the MVs suggests the presence of a convective flow, which transfers the particles from the bulk solution to the MV interior. Although the VMFV experiments did not establish any surfactant effect on the interfacial velocities, a statistically significant effect on the MV number density was observed. In the second set of experiments, membranes were cast aboard a KC-135 aircraft under 0-g and 2-g conditions. Despite careful attention to the design and fabrication of the membrane casting apparatus (MCA), several problems were encountered, the most significant of which was the contamination of the casting solution by the activated carbon particles used for solvent absorption.

Greenberg, A. R.↗
NASA NTRS2003

An Update on C458 AI-Li for Cryotanks

This viewgraph representation provides an overview of ongoing research being conducted on C458 Al-Li composite cryotanks. Topics covered include: structural design of C458 Al-Li cryotanks, C458 ingot casting capability, C458 plate properties, summary of attained properties, design database capabilities, fatigue tests and testing, and ongoing research projects.

Babel, Henry W.↗
DOE OSTI2018

Process Development and Optimization of a Direct Cast U-6Nb 250 mm Hemispherical Component

Direct Casting is the process of casting a near-net shape part of U-6wt%Nb in a multi-zone VIM furnace for subsequent heat treatment and machining in to a final component. This report describes work to further develop a sound technical basis and best practices for mold design and process parameters for the Direct Casting of U-6Nb components with a hemispherical geometry. Specifically, process parameters and mold design are examined in detail for producing a 250 mm diameter hemisphere component. The goal is to efficiently produce a sound casting with a minimum of microporosity and uniform niobium composition. Prior work had tried unsuccessfully to cast this shape in a large single-coil vacuum induction melting (VIM) furnace. These castings had unacceptable levels microporosity and niobium segregation. In this work, this same part was cast in a multi-zone VIM and a sound casting was obtained. Beyond simply casting a sound part, this work aimed to optimize the hot-top design, metal pouring temperature, and mold pole temperature. Sound castings where produced using both a tapered and step hot-top designs. There were slightly lower porosity levels and about 5% better metal usage with the step hot-top so that design slightly better. With the current mold design, which uses a funnel and filter arrangement, there a large amount of superheat loss in the funnel/filter during mold filling. This temperature loss, and the apparent variability in the filling behavior, lead to casting defects in the pole region of several of the castings. The variability and defects were overcome by moving to a higher mold pole temperature (850°C) and a higher metal pour temperature (1500°C). For future work it is believed that a no-funnel design, with the filter integral to the crucible, will be a better and more robust strategy.

42 ENGINEERING↗
NASA NTRS2002

Ice Accretions on a Swept GLC-305 Airfoil

An experiment was conducted in the Icing Research Tunnel (IRT) at NASA Glenn Research Center to obtain castings of ice accretions formed on a 28 deg. swept GLC-305 airfoil that is representative of a modern business aircraft wing. Because of the complexity of the casting process, the airfoil was designed with three removable leading edges covering the whole span. Ice accretions were obtained at six icing conditions. After the ice was accreted, the leading edges were detached from the airfoil and moved to a cold room. Molds of the ice accretions were obtained, and from them, urethane castings were fabricated. This experiment is the icing test of a two-part experiment to study the aerodynamic effects of ice accretions.

Vargas, Mario↗
DOE OSTI2017

Fan Fuel Casting Final Report

LANL was approached to provide material and design guidance for a fan-shaped fuel element. A total of at least three castings were planned. The first casting is a simple billet mold to be made from high carbon DU-10Mo charge material. The second and third castings are for optimization of the actual fuel plate mold. The experimental scope for optimization is only broad enough for a second iteration of the mold design. It is important to note that partway through FY17, this project was cancelled by the sponsor. This report is being written in order to capture the knowledge gained should this project resume at a later date.

42 ENGINEERING↗
DOE OSTI2015

Development of disposal container designs for disposal of high level waste and legacy spent fuel in the UK - 15471

Radioactive Waste Management Limited (RWM), a fully owned subsidiary of the Nuclear Decommissioning Authority (NDA), is responsible for the implementation of geological disposal in the UK. Three illustrative concepts of a geological disposal facility (GDF), corresponding to three generic geological environments - higher strength rock, lower strength sedimentary rock and evaporite rock - have been developed to demonstrate the viability of geological disposal of intermediate level waste, high level waste and spent fuel. It is envisaged that HLW which has been encapsulated in Waste Vitrification Plant (WVP) canisters, advanced gas-cooled reactor (AGR) SF which has been stripped of their spacers and packaged into slotted fuel cans, and PWR SF will be packaged into disposal containers for disposal. A set of schematic designs of these disposal containers was developed in the late 2000's. The design concept for the higher strength rock environment was based on the joint Posiva/SKB disposal container design, and the design concept for the lower strength sedimentary rock and evaporate rock illustrative environments was based on the disposal container concept from Switzerland's National Cooperative for the Disposal of Radioactive Waste (Nagra). The size, mass and dimensions of the disposal containers in the scheme designs vary significantly. The construction method and the lid closing method also vary between the disposal containers for the different waste contents. A design study has indicated that optimization of the number of HLW WVP canisters and the number of AGR slotted fuel cans in the disposal containers, standardizing construction method and closure arrangement across the containers for each geology type, providing handling features at both ends of the disposal container, and balancing of shielding around the containers, could bring significant advantage to the overall GDF programme by reducing the number of disposal containers, reducing GDF footprint, and reducing the extent of excavations, spoil generated and materials that are required for construction. A project to develop the scheme designs to conceptual level was carried in 2011 to 2013. In this project, the above changes were taken into account, technical underpinning of the designs was carried out and manufacturing method was considered. Two disposal container variants for different host rock environments have been developed: - Variant 1, for compatibility with the higher strength rock illustrative disposal system design. This is constructed from copper, with a cast iron insert and is based on the joint Posiva/SKB disposal container design. - Variant 2, for compatibility with the lower strength sedimentary rock and evaporite rock illustrative disposal system designs. This is a steel container based on the NAGRA disposal container design. Each variant has three internal configurations to accommodate 3 HLW vitrified canisters, 16 consolidated cans of AGR SF and 4 PWR spent fuel assemblies. These designs have been shown to bring significant benefit to the GDF designs, bringing a significant reduction to the operating programme and GDF programme cost, including reducing the number of disposal containers by 33% for HLW, 50% for AGR SF and reducing the size of the GDF footprint by 25%. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2002

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

This presentation provides an overview of the effort by Metal Matrix Cast Composites, Inc. to redesign turbopump housing joints using metal matrix composite material and a toolless net-shape pressure infiltration casting technology. Topics covered include: advantage of metal matrix composites for propulsion components, baseline pump design and analysis, advanced toolless pressure infiltration casting process, subscale pump housing, preform splicing and joining for large components, and fullscale pump housing redesign.

Shah, Sandeep↗
DOE OSTI2016

Predicting Stress vs. Strain Behaviors of Thin-Walled High Pressure Die Cast Magnesium Alloy with Actual Pore Distribution

In this paper, a three-dimensional (3D) microstructure-based finite element modeling method (i.e., extrinsic modeling method) is developed, which can be used in examining the effects of porosity on the ductility/fracture of Mg castings. For this purpose, AM60 Mg tensile samples were generated under high-pressure die-casting in a specially-designed mold. Before the tensile test, the samples were CT-scanned to obtain the pore distributions within the samples. 3D microstructure-based finite element models were then developed based on the obtained actual pore distributions of the gauge area. The input properties for the matrix material were determined by fitting the simulation result to the experimental result of a selected sample, and then used for all the other samples’ simulation. The results show that the ductility and fracture locations predicted from simulations agree well with the experimental results. This indicates that the developed 3D extrinsic modeling method may be used to examine the influence of various aspects of pore sizes/distributions as well as intrinsic properties (i.e., matrix properties) on the ductility/fracture of Mg castings.

Ductility↗
DOE OSTI2020

Hierarchical electrode design of highly efficient and stable unitized regenerative fuel cells (URFCs) for long-term energy storage

The unitized regenerative fuel cell (URFC) is a promising electrochemical device for intermittent renewable energy storage in chemical bonds. However, widespread application has been hindered due to low round-trip efficiencies (RTEs) and disappointing durability, in particular at high rates. In this study, we break through that barrier by demonstrating highly efficient, flexible, and stable URFCs via hierarchical design of the multiscale catalyst-layer structures. A more porous and less tortuous Pt and Ir catalyst layer is realized using a doctor blade fabrication method that significantly improves URFC performance. We demonstrate RTEs of 56% and 53% under constant-electrode and constant-gas mode, respectively, while operating at 1000 mA cm –2 , and significantly, a RTE of 45% at 2000 mA cm –2 , achievements that were previously viewed as unfeasible under the onerous demands of URFC operation. At the same time we demonstrate URFCs under both constant-electrode and constant-gas mode operated continuously for over 500 h with negligible degradation. These results demonstrate the viability of applying URFCs for long-term energy storage at previously unattainable efficiencies and cast new light on electrode design and optimization of URFCs.

25 ENERGY STORAGE↗
NASA NTRS2003

Efficient, Low-Cost Fan System Research for General Aviation and Commuter Aircraft

This document reports research investigations into efficient, low-cost fan system concepts for high bypass turbofans for future general aviation and commuter aircraft. The research specifically addressed lower pressure ratio fans for good propulsive efficiencies in the 200 to 400 knot flight speed regime. Aerodynamic design analyses yielded predicted efficiency in area of 91 to 92 percent (adiabatic). Low-cost manufacturing studies yielded an aluminum blisk rotor and investment cast stator having lowest cost. Structural design analyses yielded a design having excellent vibratory characteristics and the ability to pass One- and Four-pound bird strikes satisfactorily. The low speed and low pressure fans of the study are estimated to have 24 to 30 EPNdB lower community noise levels than larger, high pressure ratio transonic fans.

Merrill, G. L.↗
NASA NTRS2018

Qualifying Bulk Metallic Glass Gear Materials for Spacecraft Applications

NASA is evaluating bulk metallic glass (BMG) gears for extreme environment (cryogenic) applications; e.g., Europa Lander. The main purpose of this report is to recommend a quality assurance (QA) protocol for the production of consistent and reliable gear castings. Currently, there are two, separate manufacturers involved; Materion Corporation produces re-melt stock and Visser Precision Cast, Inc. produces BMG castings. Division of the existing alloy specifications document into material supplier-specific documents is proposed. Until a composition-based specification is established, processability- and performance-based methodologies may be an option during manufacturing development. It is recommended that each of the documents has a distinct focus; the processing behavior of crystalline feedstock, and the mechanical behavior of amorphous castings. The report addresses the “gray area” in QA testing between these materials suppliers by outlining an equitable division of responsibilities. The use of a number of dedicated reference dies to produce witness materials for physical and mechanical property evaluation is strongly recommended. Allocation of QA tests between screen testing of gear castings, and formal testing of witness materials, including cryogenic properties, is also proposed. The most effective suite of tests for both physical and mechanical property determination are down-selected from available national and international standards. The contents of this report create a solid basis for selection of QA tests, thereby setting the stage for negotiations between the materials suppliers and the customer.This technical paper:a) provides recommendations to advance materials specifications document JPL D-56223,Rev. A from “draft” to “preliminary” status;b) proposes division of the current document into two supplier-specific documents;c) separates testing methods by “ingots/castings” and “witness materials”;d) classifies test methodology based on “processability” and “performance”;e) assembles candidate ASTM specifications for “screen testing” and “formal testing”;f) identifies standard tests compatible with evaluation of BMG flexspline gears;g) suggests division of responsibilities for processability and performance testing; andh) addresses the QA “gray area” between production of ingots and castings.The report recommends that:a) processability- and performance-based QA methods might be used in lieu ofcompositional specifications during manufacturing development only;b) reference dies be designed for “acceptance” and “qualification” castings;c) witness materials provide physical and mechanical property data;d) formal testing be conducted at ambient and cryogenic temperatures; ande) processing/properties be correlated with compositional variations.

Hales, Stephen J.↗
DOE OSTI2015

CASTING DEFECT MODELING IN AN INTEGRATED COMPUTATIONAL MATERIALS ENGINEERING APPROACH

To accelerate the introduction of new cast alloys, the simultaneous modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components. The required models related to casting defects, such as microporosity and hot tears, are reviewed. Three aluminum alloys are considered A356, 356 and 319. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Examples are given for predicting microporosity defects and microstructure distribution for a plate casting. Models to predict fatigue life and yield stress are briefly highlighted here for the sake of completion and to illustrate how the length scales of the microstructure features as well as porosity defects are taken into account for modeling the mechanical properties. Thus, the data on casting defects, including microstructure features, is crucial for evaluating the final performance-related properties of the component. ACKNOWLEDGEMENTS This work was performed under a Cooperative Research and Development Agreement (CRADA) with the Nemak Inc., and Chrysler Co. for the project "High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines. The author would also like to thank Amit Shyam for reviewing the paper and Andres Rodriguez of Nemak Inc. Research sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Office, as part of the Propulsion Materials Program under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Part of this research was conducted through the Oak Ridge National Laboratory's High Temperature Materials Laboratory User Program, which is sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Program.

Sabau, Adrian S↗
DOE OSTI2023

Strontium Effects on the Formation of Iron-Intermetallic Phases in Secondary Al–9Si–0.6Fe Alloys

The presence and morphology of Fe-containing intermetallic phases affect the mechanical properties of aluminum alloys, especially in secondary Al–Si-based cast alloys. Although strontium (Sr) addition of 50 to 500 ppm is known to refine the needle-type eutectic silicon structure, the influence of Sr on the formation of Fe-intermetallic phases remains unclear. The present work investigates the combined additions of Sr and Mn to Al–9Si–0.6Fe–0.35Mg (All compositions are in wt pct except otherwise stated.) alloys on the formation of Fe-intermetallic phases at different solidification rates from ~ 1.5 to ~ 60 °C/s. Long and branched-type AlFeSi phase with size ranging from 50 to 120 µm are more common when solidified at the rate of 1.5 °C/s regardless of Sr and Mn additions. However, at the fast solidification rate of 60 °C/s, a 60 ppm Sr addition significantly reduced the average length of needle-shaped AlFeSi phase to less than 3 to 5 µm. Thermodynamic simulations have been performed using CALculation of PHAse Diagrams (CALPHAD) models to predict the formation of various phases and their possible interactions during solidification. The results indicated that the combination of a high solidification rate and about 60 ppm of Sr is beneficial to refining the δ-Al 3 FeSi 2 phase in Al–Si–Mg alloys containing 0.6 pctFe. As a result, this unexpected finding of Fe-intermetallic refinement by low Sr addition (~60 ppm) provides an important guide in designing secondary alloys for sustainable casting applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Prototyping and Manufacturing of Magnetic Gearbox Components using Innovations in Castings

This project combines additive manufacturing with the broadly deployed practice of metal casting. Combining these methods will unlock new design possibilities while reducing the economic burden of early stage prototyping while leveraging well established high throughput sand casting. Two main approaches are evaluated: direct printing of single use sand molds and printing of reusable impression patterns used to create sand molds. Reusable impression molds typically can be used to produce hundreds to several thousands of casting thereby amplifying the function of the 3D printed replica mold. Emrgy’s newly developed and tested proprietary magnetic gearbox system for low head hydroelectricity generation was the subject part of this study. Leveraging ORNL’s additive manufacturing capability and expertise, a pattern impression was produced and used to create multiple sand molds of the gearbox during phase 1. Even before considering the cost savings possible once rigging and pattern mounting is optimized through repetition and improved design, final part costs using this combined method resulted in an 80% cost reduction over EMRGY’s previous method of subtractive manufacturing for gearbox production.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Manipulating the diffusion energy barrier at the lithium metal electrolyte interface for dendrite-free long-life batteries

Abstract Constructing an artificial solid electrolyte interphase (SEI) on lithium metal electrodes is a promising approach to address the rampant growth of dangerous lithium morphologies (dendritic and dead Li 0 ) and low Coulombic efficiency that plague development of lithium metal batteries, but how Li + transport behavior in the SEI is coupled with mechanical properties remains unknown. We demonstrate here a facile and scalable solution-processed approach to form a Li 3 N-rich SEI with a phase-pure crystalline structure that minimizes the diffusion energy barrier of Li + across the SEI. Compared with a polycrystalline Li 3 N SEI obtained from conventional practice, the phase-pure/single crystalline Li 3 N-rich SEI constitutes an interphase of high mechanical strength and low Li + diffusion barrier. We elucidate the correlation among Li + transference number, diffusion behavior, concentration gradient, and the stability of the lithium metal electrode by integrating phase field simulations with experiments. We demonstrate improved reversibility and charge/discharge cycling behaviors for both symmetric cells and full lithium-metal batteries constructed with this Li 3 N-rich SEI. These studies may cast new insight into the design and engineering of an ideal artificial SEI for stable and high-performance lithium metal batteries.

25 ENERGY STORAGE↗
DOE OSTI2020

(Invited) All-Solid-State Batteries Using Li 7 La 3 Zr 2 O 12 Garnet Electrolyte Framework

All-solid-state batteries (ASSB) using LLZO (variants of Li 7 La 3 Zr 2 O 12 ) garnet solid electrolyte with lithium metal anode potentially offer higher energy density and improved safety. Rational design of cell architecture as well as manufacturing scalability are key aspects to consider as the technology readiness level advances. A thick composite cathode layer attached to a thin solid electrolyte layer is desirable to obtain superior energy densities. Furthermore, the architecture within the composite cathode may be engineered to contain directional conduction paths of lithium ions or electrons for enhanced rate capabilities. Here, we demonstrate a functioning bulk-type LLZO based all-solid-state battery with a practical form factor incorporating the above described design concepts. Freeze-tape-casting (FTC), a scalable and environmentally friendly ceramic processing method, is used to construct 3D porous LLZO scaffolds composed of vertical arrays of LLZO walls. The thin solid-electrolyte layer is fabricated by tape-casting (TC). By sintering the stacks of FTC and TC green tapes, porous/dense bilayers and porous/dense/porous trilayers of LLZO frameworks are obtained. An ASSB was constructed using a porous/dense bilayer by infiltrating LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathode powder and carbon black into the porous layer and adhering lithium metal foil to the dense side. We find it crucial to introduce a plastic crystal based soft solid electrolyte to the porous layer to electrochemically connect all cathode components, obviating the need for co-sintering to establish contact. The soft nature of the plastic crystal based solid-electrolyte may be able to accommodate the volume change of the cathode material as it cycles. In this device, which contained no liquid component, the initial discharge capacities were similar to those observed in a lithium ion battery configuration using the same cathode powder at C/10 rates.

25 ENERGY STORAGE↗
DOE OSTI2017

Soft Ionic Electroactive Polymer Actuators with Tunable Non-Linear Angular Deformation

The most rational approach to fabricate soft robotics is the implementation of soft actuators. Conventional soft electromechanical actuators exhibit linear or circular deformation, based on their design. This study presents the use of conjugated polymers, Poly(3,4- ethylenedioxythiophene)-poly(styrenesulfonate) (PEDOT:PSS) to locally vary ion permeability of the ionic electroactive polymer actuators and manipulate ion motion through means of structural design to realize intrinsic angular deformation. Such angular deformations are closer to biomimetic systems and have potential applications in bio-robotics. Electrochemical studies reveal that the mechanism of actuation is mainly associated with the charging of electric double layer (EDL) capacitors by ion accumulation and the PEDOT:PSS layer’s expansion by ion interchange and penetration. Dependence of actuator deformation on structural design is studied experimentally and conclusions are verified by analytical and finite element method modeling. The results suggest that the ion-material interactions are considerably dominated by the design of the drop-cast PEDOT:PSS on Nafion.

36 MATERIALS SCIENCE↗