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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 1,261 records · Page 70

All sources NASA NTRS DOE OSTI

DOE OSTI2020

Impact of raw material surface oxide removal on dual band infrared optical properties of As 2 Se 3 chalcogenide glass

The manufacturing of low loss chalcogenide glasses (ChGs) for optoelectronic applications is ultimately defined by the concentration of impurities present in starting materials or imparted via processing. We describe a rapid method for purifying metallic starting materials in As 2 Se 3 glass where oxide reduction is correlated to optical and physical properties. Specifically, As-O reduction enhances the glass’ dual-band optical transparency proportional to the extent (13-fold reduction) of oxide reduction, and is accompanied by a change in density and hardness associated with changes in matrix bonding. A significant modification of the glass’ index and LWIR Abbe number is reported highlighting the significant impact purification has on material dispersion control required in optical designs.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Abstract for CRADA between the National Energy Technology Laboratory and West Virginia University Research Corporation (AGMT-0819)

The U.S. Department of Energy is investigating microwave-assisted technologies for chemical conversion processes. Primarily the benefits come from the rapid and selective heating associated with MW power, which can overcome significant lag times in heating the medium over conventional, thermal heating. Beyond selective heating, a non-thermal MW effect has been proposed as a possible explanation for enhanced conversion and selectivity in reaction processes, which can produce yield beyond equilibrium values. For this project, the goal is to develop and demonstrate microwave-assisted catalytic conversion of natural gas into valueadded chemicals via direct non-oxidative natural gas conversion. NETL will collaborate with WVU to carry out microwave reactor design and test in fixed frequency (2.45 GHz) and variable frequency reactors (500W) at NETL on natural gas conversion, including microwave reactor modeling, measurement, catalyst regeneration and energy efficiency prediction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1983

Progress toward the analysis of complex propulsion installation flow phenomenon

A trend toward replacement of parametric model testing with parametric analysis for the design of aircraft is driven by the rapidly escalating cost of wind tunnel testing, the increasing availability of large fast computers, and powerful numerical flow algorithms. In connection with the complex flow phenomena characteristic of propulsion installations, it is now necessary to employ both parametric analysis and testing for design procedures. Powerful flow analysis techniques are available to predict local flow phenomena. However, the employment of these techniques is very expensive. It is, therefore, necessary to link these analyses with less powerful and less expensive procedures for an accurate analysis of propulsion installation flowfields. However, the interfacing and coupling processes needed are not available. The present investigation is concerned with progress made regarding the development of suitable linking methods. Attention is given to methods of analysis for predicting the flow around a nacelle coupled to a highly swept wing.

Kern, P. R. A.↗

NASA NTRS2003

Magnetic Flux Compression Experiments Using Plasma Armatures

Magnetic flux compression reaction chambers offer considerable promise for controlling the plasma flow associated with various micronuclear/chemical pulse propulsion and power schemes, primarily because they avoid thermalization with wall structures and permit multicycle operation modes. The major physical effects of concern are the diffusion of magnetic flux into the rapidly expanding plasma cloud and the development of Rayleigh-Taylor instabilities at the plasma surface, both of which can severely degrade reactor efficiency and lead to plasma-wall impact. A physical parameter of critical importance to these underlying magnetohydrodynamic (MHD) processes is the magnetic Reynolds number (R(sub m), the value of which depends upon the product of plasma electrical conductivity and velocity. Efficient flux compression requires R(sub m) less than 1, and a thorough understanding of MHD phenomena at high magnetic Reynolds numbers is essential to the reliable design and operation of practical reactors. As a means of improving this understanding, a simplified laboratory experiment has been constructed in which the plasma jet ejected from an ablative pulse plasma gun is used to investigate plasma armature interaction with magnetic fields. As a prelude to intensive study, exploratory experiments were carried out to quantify the magnetic Reynolds number characteristics of the plasma jet source. Jet velocity was deduced from time-of-flight measurements using optical probes, and electrical conductivity was measured using an inductive probing technique. Using air at 27-inHg vacuum, measured velocities approached 4.5 km/s and measured conductivities were in the range of 30 to 40 kS/m.

Turner, M. W.↗

NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗

NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

GRX-810↗

DOE OSTI2017

Big Area Additive Manufacturing Application in Wind Turbine Molds

Tooling is a primary target for current additive manufacturing (AM), or 3D printing, technology because of its rapid prototyping capabilities. Molds of many sizes and shapes have been produced for a variety of industries. However, large tooling remained out of reach until the development of large-scale composite AM manufacturing processes like the Big Area Additive Manufacturing (BAAM) system. The Department of Energy's Oak Ridge National Laboratory (ORNL) worked with TPI Composites to use the BAAM system to fabricate a wind turbine blade mold. The fabricated wind turbine blade mold was produced in 16 additively manufactured sections, was 13 meters long, had heating channels integrated into the design, and was mounted into a steel frame post fabrication. This research effort serves as a case study to examine the technological impacts of AM on wind turbine blade tooling and evaluate the efficacy of this approach in utility scale wind turbine manufacturing.

17 WIND ENERGY↗

DOE OSTI2016

Design and Construction of the Paddys Run Streambank Stabilization Project at the Fernald Preserve, Harrison, Ohio - 16165

The Fernald Preserve is a former uranium-processing plant that underwent extensive remediation pursuant to CERCLA and is now managed by the US DOE Office of Legacy Management. While remediation of buildings and soil contamination was completed in 2006, aquifer remediation is ongoing. Paddys Run is a second-order stream that runs to the south along the western side of the Fernald Preserve. The Paddys Run watershed encompasses nearly 41 km{sup 2} (16 mi{sup 2}), including most of the Fernald site. Field personnel conducting routine site inspections in March 2014 observed that Paddys Run was migrating east via bank erosion into the 'Pit 3 Swale', an area of known surface-water contamination. The soil there was certified pursuant to site regulatory agreements and meets all final remediation levels. However, weekly surface-water monitoring is conducted from two puddles within the swale area, when water that exceeds the final remediation levels is present. Paddys Run had migrated east approximately 4 m (13 ft) in 2 years and was approximately 29 m (95 ft) from the sample location. This rapid migration threatened existing conditions that allowed for continued monitoring of the swale area and also threatened Paddys Run water quality. Therefore, DOE and regulators determined that the east bank of Paddys Run required stabilization. This was accomplished with a design that included the following components: relocation of approximately 145 m (475 ft) of streambed 9 m (30 ft) west, installation of a rock toe along the east bank, installation of two cross-vane in-stream grade-control structures, stabilization of a portion of the east bank using soil encapsulated lifts, and regrading, seeding, and planting within remaining disturbed areas. In an effort to take advantage of low-flow conditions in Paddys Run, construction was initiated in September 2014. Weather delays and subsurface flow within the Paddys Run streambed resulted in an interim shutdown of the project area in December 2014. Construction activities resumed in April 2015, with completion in November 2015. To date, this stabilization project has been successful. The regraded bank and streambed have remained stable, and no compromise to installed cross-vanes, the rock toe, or the soil encapsulated lifts has been observed. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2013

Morphological stability of Cu-Nb nanocomposites under high-energy collision cascades

We use molecular dynamics and phase field simulations to demonstrate that Cu-Nb multilayered nanocomposites with individual layer thicknesses above 2–4 nm remain morphologically stable when subjected to 100 keV collision cascades, characteristic of neutron or heavy ion irradiation. The probability of morphological instability rapidly increases as the layer thickness decreases to 1 nm, which we attribute to overlap of zones of liquid-like interdiffusion inside radiation-induced thermal spikes at neighboring interfaces in the multilayer.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Development of high-early-strength fiber-reinforced self-compacting concrete

High-early-strength fiber-reinforced self-compacting concrete (FRSCC) is a practical material for the precast concrete industry to double its production capacity. In this study, we developed high-early-strength FRSCC mixtures that achieved a compressive and flexural strength of at least 24 MPa and 3.5 MPa, respectively, at 6 h, using commercially available components, typical mixing procedures, and air curing. A mix design process was developed based on the literature and experimental results. The effect of six different fiber reinforcements on the fresh and mechanical properties of concrete was analyzed. The cost limit was set at 523 USD/m 3 to make the concrete mix cost-effective.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Rapid, efficient reduction of iron oxide with ammonia

Reducing iron oxide to iron metal with fossil fuels produces circa 4% of annual anthropogenic CO 2 , ca. 2 Gt/a, as direct chemical emissions from the process. Using ammonia instead of coke—releasing only water and nitrogen as byproducts—could be a widely deployable method of decarbonizing industrial ironmaking, because ammonia carries hydrogen and can be transported easily worldwide. However, initial reports suggest that the reaction of ammonia with iron oxide is slow and inefficient, completed only in hours and using only a few percent of the ammonia supplied. Drawing on thermodynamic and kinetic analysis of the reaction, we explored high-temperature, high-flow reaction conditions designed to increase the reaction rate and the ammonia utilization. We report the reduction of iron oxide in 1 min while using 64% of the ammonia supplied. We show that these insights translate to the gram scale and the reduction of pelletized ore, a common form used industrially.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Three-dimensional Zn-based alloys for dendrite-free aqueous Zn battery in dual-cation electrolytes

Aqueous zinc-ion batteries, in terms of integration with high safety, environmental benignity, and low cost, have attracted much attention for powering electronic devices and storage systems. However, the interface instability issues at the Zn anode caused by detrimental side reactions such as dendrite growth, hydrogen evolution, and metal corrosion at the solid (anode)/liquid (electrolyte) interface impede their practical applications in the fields requiring long-term performance persistence. Despite the rapid progress in suppressing the side reactions at the materials interface, the mechanism of ion storage and dendrite formation in practical aqueous zinc-ion batteries with dual-cation aqueous electrolytes is still unclear. Herein, we design an interface material consisting of forest-like three-dimensional zinc-copper alloy with engineered surfaces to explore the Zn plating/stripping mode in dual-cation electrolytes. The three-dimensional nanostructured surface of zinc-copper alloy is demonstrated to be in favor of effectively regulating the reaction kinetics of Zn plating/stripping processes. The developed interface materials suppress the dendrite growth on the anode surface towards high-performance persistent aqueous zinc-ion batteries in the aqueous electrolytes containing single and dual cations. This work remarkably enhances the fundamental understanding of dual-cation intercalation chemistry in aqueous electrochemical systems and provides a guide for exploring high-performance aqueous zinc-ion batteries and beyond.

25 ENERGY STORAGE↗

DOE OSTI2013

Modelica buildings library

This paper describes the Buildings library, a free open-source library that is implemented in Modelica, an equation-based object-oriented modeling language. The library supports rapid prototyping, as well as design and operation of building energy and control systems. First, we describe the scope of the library, which covers HVAC systems, multi-zone heat transfer and multi-zone airflow and contaminant transport. Next, we describe differentiability requirements and address how we implemented them. We describe the class hierarchy that allows implementing component models by extending partial implementations of base models of heat and mass exchangers, and by instantiating basic models for conservation equations and flow resistances. We also describe associated tools for pre- and post-processing, regression tests, co-simulation and real-time data exchange with building automation systems. Furthermore, the paper closes with an example of a chilled water plant, with and without water-side economizer, in which we analyzed the system-level efficiency for different control setpoints.

42 ENGINEERING↗

DOE OSTI2022

Transformational challenge reactor design characteristics

The Transformational Challenge Reactor (TCR) program was conceived with the goal to reduce costs and time frames associated with advanced reactor deployment by leveraging developments in advanced manufacturing, advanced materials, data science, and rapid prototyping and testing. The final deliverable of the TCR program was to be an operational test of a novel reactor design. The TCR core design incorporates a dense tri-structural-isotropic/SiC fuel form and volumetrically efficient yttrium hydride moderator, both of which were manufactured and characterized under the TCR program. The TCR is a 3 MW{sub th} He-cooled experimental nuclear reactor designed to reach a total integrated burnup of less than 24 effective full-power hours to keep the radioactive source term to a very low level. TCR design process revealed a positive moderator coefficient; however, the negative doppler coefficients for the fuel and thermal expansion of fuel, moderator, and core support plate yield an overall negative reactivity coefficient. Calculated fuel element temperatures and stresses are well within safety margins. The maximum hypothetical accident (i.e., de-pressurized loss of forced cooling) yields only a modest increase in reactor temperatures that are all within safety margins. This paper summarizes the high-level TCR design characteristics, which were derived from neutronics, thermohydraulics, thermomechanics, and safety analyses.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2011

High Critical Current Coated Conductors

One of the important critical needs that came out of the DOE’s coated conductor workshop was to develop a high throughput and economic deposition process for YBCO. Metal-organic chemical vapor deposition (MOCVD) technique, the most critical steps in high technical micro fabrications, has been widely employed in semiconductor industry for various thin film growth. SuperPower has demonstrated that (Y,Gd)BCO films can be deposited rapid with world record performance. In addition to high critical current density with increased film thickness, flux pinning properties of REBCO films needs to be improved to meet the DOE requirements for various electric-power equipments. We have shown that doping with Zr can result in BZO nanocolumns, but at substantially reduced deposition rate. The primary purpose of this subtask is to develop high current density MOCVD-REBCO coated conductors based on the ion-beam assisted (IBAD)-MgO deposition process. Another purpose of this subtask is to investigate HTS conductor design optimization (maximize Je) with emphasis on stability and protection issues, and ac loss for REBCO coated conductors.

36 MATERIALS SCIENCE↗

NASA NTRS1990

Knowledge structure representation and automated updates in intelligent information management systems

A continuing effort to apply rapid prototyping and Artificial Intelligence techniques to problems associated with projected Space Station-era information management systems is examined. In particular, timely updating of the various databases and knowledge structures within the proposed intelligent information management system (IIMS) is critical to support decision making processes. Because of the significantly large amounts of data entering the IIMS on a daily basis, information updates will need to be automatically performed with some systems requiring that data be incorporated and made available to users within a few hours. Meeting these demands depends first, on the design and implementation of information structures that are easily modified and expanded, and second, on the incorporation of intelligent automated update techniques that will allow meaningful information relationships to be established. Potential techniques are studied for developing such an automated update capability and IIMS update requirements are examined in light of results obtained from the IIMS prototyping effort.

Corey, Stephen↗

NASA NTRS2004

Advanced Manufacturing Techniques Demonstrated for Fabricating Developmental Hardware

NASA Glenn Research Center's Engineering Development Division has been working in support of innovative gas turbine engine systems under development by Glenn's Combustion Branch. These one-of-a-kind components require operation under extreme conditions. High-temperature ceramics were chosen for fabrication was because of the hostile operating environment. During the designing process, it became apparent that traditional machining techniques would not be adequate to produce the small, intricate features for the conceptual design, which was to be produced by stacking over a dozen thin layers with many small features that would then be aligned and bonded together into a one-piece unit. Instead of using traditional machining, we produced computer models in Pro/ENGINEER (Parametric Technology Corporation (PTC), Needham, MA) to the specifications of the research engineer. The computer models were exported in stereolithography standard (STL) format and used to produce full-size rapid prototype polymer models. These semi-opaque plastic models were used for visualization and design verification. The computer models also were exported in International Graphics Exchange Specification (IGES) format and sent to Glenn's Thermal/Fluids Design & Analysis Branch and Applied Structural Mechanics Branch for profiling heat transfer and mechanical strength analysis.

Redding, Chip↗

NASA NTRSDate not supplied

Lightweight Thrust Chamber Composite Overwrap Lessons Learned

The manufacturing, design, and analysis of filament wound carbon fiber/polymer composite overwraps for additively manufactured, copper combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. Ideally, the composite overwrap acts as a light-weight structural jacket and allows significant weight reduction of the high pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication schedules. Chamber assemblies for 2000 lb. (2k) and 7000 lb. (7k) of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware, such as the 2k and 7k chambers, will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide (BMI) materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. Recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.

Allison Clark↗