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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 1,297 records · Page 72
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Thermal Modelling of the In-Situ Consolidation of Automated Fiber Placement Of Thermoplastic Composites

NASA is developing carbon fiber reinforced thermoplastic composites processing methods under the Hi-rate Composites Aircraft Manufacturing (HiCAM) project. The in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process has high potential to increase manufacturing throughput and lower costs as it combines the repeatability and fast lay down rates of AFP with the thermoformability of thermoplastic materials to achieve part consolidation out of the autoclave. Physics-based process models are employed in the ICAT process development to understand, fundamentally, the thermal response of the carbon fiber (CF)/polyaryletherketone (PAEK) material during the rapid heating and cooling associated with laser-assisted AFP. A one-dimensional (1-D) closed-form model was developed capable of predicting the temperature profile through-the-thickness of the tape material. In addition, a two-dimensional (2-D) model was developed to predict the heat transfer through-the-thickness and in the laydown x-direction of the AFP head motion. The solution of the Fourier heat-transfer equations in the 2-D model is approximated using the explicit finite difference numerical method. The temperature profile during placement of PAEK slit-tape materials at various laser target temperatures and placement speeds were measured during ICAT process development trials at Electroimpact®, Inc. †† and the resulting experimental data is compared with the predictions of the 1-D and 2-D models.

Christopher J. Stelter↗
DOE OSTI2026

Optimization of Processing, Microstructure, and Hardness of an Al–Ce–Ni–Mn–Zr Alloy With Laser Additive Manufacturing

Here, this study examines the processing behavior, microstructure, surface roughness, and hardness properties of an aluminum alloy containing 8.2 Ce, 4.5 Ni, 0.5 Mn, and 0.7 Zr (wt%) fabricated using laser powder bed fusion. Sixty samples were produced across a range of laser powers, scan speeds, and hatch spacings to evaluate their effect on porosity, hardness, and microstructural features. Porosity was measured using X-ray computed tomography, while microstructure and surface roughness were characterized by scanning electron (SEM) and laser confocal microscopy. High dense and cracking-free Al–Ni–Ce alloy was successfully manufactured. Porosity showed a U-shaped dependence on energy input, increasing under both insufficient and excessive melting conditions. Hardness increased with cooling rate due to finer cellular structures and solute redistribution. A general statistical model was developed to capture the relationships between processing parameters and material response. Results identify a narrow processing window defined by laser powers between 350 and 370 W, scan speeds from 1400 to 1800 mm/s, and hatch distances between 0.14 and 0.18 mm. Within this window, porosity is minimized (below 0.01%) and hardness is maximized (up to 160 HV), demonstrating that careful control of these parameters enables dense, high strength aluminum components suitable for demanding structural applications.

Aluminum alloys↗
NASA NTRS2019

Bimetallic Channel Wall Nozzle Development and Hot-Fire Testing Using Additively Manufactured Laser Wire Direct Closeout Technology

NASA has been developing and advancing regeneratively-cooled channel wall nozzle technology for liquid rocket engines to reduce cost and schedules associated with fabrication. One of the primary methods being advanced is Laser Wire Direct Closeout (LWDC). LWDC was developed to provide an additively manufactured laser deposited closeout of the coolant channels that also forms the structural jacket in-situ. This technique has been previously demonstrated through process development and hot-fire testing on a series of subscale nozzles at NASA Marshall Space Flight Center. The hot-fire test articles were fabricated using monolithic alloys to simplify the fabrication process. Ongoing research is being conducted to further expand use of this process for increased scale and bimetallic or multi-alloy options. The use of multi-alloys is desired to fully optimize the combination of materials in the radial and axial directions to reduce overall weight of the nozzle and allow for higher thermal and structural margins on the channel wall nozzle. NASA recently completed process development and hot-fire testing of a series of channel wall nozzles that incorporate a copper-alloy as the hotwall liner material and a superalloy and combination thereof for the structural jacket using the LWDC technique. The fabrication process was further advanced by using a multi-alloy axial joint using explosive bonding integrating a copper-alloy at the forward end of the nozzle hotwall and a stainless-alloy for the remaining length. A third alloy was then used for the channel closeout using the LWDC process. This paper will describe the process development using the LWDC process for channel closeout utilizing the multi-alloys, hardware design and results from hot-fire testing on subscale multi-alloy LWDC channel cooled nozzles.

Gradl, Paul↗
DOE OSTI2024

Ubiquitous short-range order in multi-principal element alloys

Recent research in multi-principal element alloys (MPEAs) has increasingly focused on the role of short-range order (SRO) on material performance. However, the mechanisms of SRO formation and its precise control remain elusive, limiting the progress of SRO engineering. Here, leveraging advanced additive manufacturing techniques that produce samples with a wide range of cooling rates (up to 10 7 K s –1 ) and an enhanced semi-quantitative electron microscopy method, we characterize SRO in three CoCrNi-based face-centered-cubic (FCC) MPEAs. Surprisingly, irrespective of the processing and thermal treatment history, all samples exhibit similar levels of SRO. Atomistic simulations reveal that during solidification, prevalent local chemical order arises in the liquid-solid interface (solidification front) even under the extreme cooling rate of 10 11 K s –1 . This phenomenon stems from the swift atomic diffusion in the supercooled liquid, which matches or even surpasses the rate of solidification. Therefore, SRO is an inherent characteristic of most FCC MPEAs, insensitive to variations in cooling rates and even annealing treatments typically available in experiments.

36 MATERIALS SCIENCE↗
NASA NTRS2002

Radiation Effects in a Semitransparent Gray Coating Heated by Convection and Cooled by Radiation

A parametric study using a one dimensional model of a semitransparent gray thermal barrier coating was performed to gain an understanding of the role thermal radiation can play in the heat transferred. Some ceramic materials are semitransparent in the wavelength ranges were thermal radiation is important. Therefore, absorption, emission, and scattering of thermal radiation can affect the he at transfer through the coating. In this paper, a one dimensional layer was used to model the heat transfer process occurring, in a burner test rig. The semitransparent layer is heated by a hot gas flowing over its surface. The layer and substrate at a cooled by radiation to the surroundings. The back side of the substrate is insulated. The coating is assumed to be gray (absorption and scattering coefficients are not function of wavelength). An absorption coefficient of 0.3/cm and scatter a rig coefficients of 0 (no scattering) and 100/cm (isotropic scattering) were used. The thickness and thermal conductivity of the layer are varied. The results show that the temperatures are affected by the properties of the semitransparent .ever and the emissivity of the substrate. The substrate and surface temperatures are presented. The apparent temperature an optical pyrometer would read for the emitted energy is also given. An apparent thermal conductivity was calculated for the layer.

Spuckler, Charles M.↗
DOE OSTI2024

Numerical modeling of a proof-of-principle experiment on optical stochastic cooling at an electron storage ring

Cooling of beams circulating in storage rings is critical for many applications including particle colliders and synchrotron light sources. A method enabling unprecedented beam-cooling rates, optical stochastic cooling (OSC), was recently demonstrated in the Integrable Optics Test Accelerator (IOTA) electron storage ring at Fermilab [J. Jarvis , ]. This paper describes the numerical implementation of the OSC process in the particle-tracking program and discusses the validation of the developed model with available experimental data. The model is also employed to highlight some features associated with different modes of operation of OSC. The developed simulation tool should be valuable in guiding future configurations of optical stochastic cooling and, more broadly, modeling self-field-based beam manipulations. Published by the American Physical Society 2024

43 PARTICLE ACCELERATORS↗
NASA NTRS1974

Furnace systems development

Space processing facilities, including furnace systems, will, only vaguely resemble their laboratory and industry counterparts. Within the constraints imposed by the host vehicle, flight furnaces will be more versatile. They will provide a wider range of controlled heating, cooling and sample positioning to accommodate the requirements of experiment scientists, and will be more efficiently packaged. The development of these advanced furnace systems will be an essential element in the orderly evolution of space processing technology.

Aldrich, B. R.↗
DOE OSTI2022

Dust-planetary boundary layer interactions amplified by entrainment and advections

Mineral dust contributes to more than half of the global aerosol loading. However, the radiative impacts of dust aerosols on planetary boundary layer (PBL) structure have not been explored sufficiently. During a typical dust storm event over Tarim Basin, dust aerosols exhibit a well-mixed distribution during the daytime in spite of a shallow layer of dust particles accumulated at higher altitudes. By contrast, nocturnal dust plumes are located near the surface due to stable stratification. We demonstrate that these differentiated vertical distributions determine the spatial heterogeneity of dust loading, radiative fluxes and PBL height variations. Dust aerosols cause daytime PBL suppression and nighttime PBL promotion through modulating surface and atmospheric radiative budgets. Specifically, dust-induced cooling effect within PBL directly inhibits the daytime PBL development. PBL suppression effect is then amplified by entrainment processes resulting in excessively low PBL height, especially for dust particles below but near the PBL top. Dust plumes weaken updrafts from PBL and downdrafts of the free atmosphere, which further reduce the entrainment mixing through attenuating horizontal and vertical advection, and eventually amplify PBL suppression. At night, near-surface dust aerosols stimulate a warm and unstable lower atmosphere, generate warm advection heating and promote the PBL development. Our study highlights the importance of specifying entrainment parameters and nighttime advection activities in quantifying the dust-PBL interactions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Combustion synthesis of Eu 2 O 3 nanomaterials with tunable phase composition and morphology

Combustion reactions in europium nitrate – acetylacetone – 2-methoxyethanol solutions and gels were investigated to produce europium (III) oxide (Eu 2 O 3 ) nanocrystalline materials and thin films. Thermal analyses of solutions indicated that the 2-methoxyethanol solvent also acts as a fuel in the absence of acetylacetone. Adding acetylacetone increases the overall heat of the reaction. Thermal analysis results revealed that the slow oxidation of unburned hydrocarbon residues follows the primary combustion reaction. Time-temperature profile measurements of the bulk combustion synthesis process in air and nitrogen atmospheres enabled the extraction of the maximum reaction temperature and the heating and cooling rates in the combustion zone. Several direct correlations exist between measured combustion parameters and the phase composition of the products. Combustion in air results in mixed-phase cubic and monoclinic nanocrystalline Eu 2 O 3 . Increasing the acetylacetone concentration in solutions increases the synthesis temperature and decreases the quantity of cubic Eu 2 O 3 . Here, the reaction of solutions in a nitrogen atmosphere or diluted with Eu 2 O 3 provides control of the product phase composition and reduces the quantity of the monoclinic phase. Transmission electron microscopy imaging shows that the Eu 2 O 3 end products are highly porous aggregates of nanocrystalline particles. Electrospraying of reactive solutions onto different substrates followed by short annealing makes the preparation of Eu 2 O 3 materials with diverse morphologies possible.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Equilibration of the planar modes of ultracold two-dimensional ion crystals in a Penning trap

In this work, planar thermal equilibration is studied using direct numerical simulations of ultracold two-dimensional ion crystals in a Penning trap with a rotating wall. The large magnetic field of the trap splits the modes that describe in-plane motion of the ions into two branches: high-frequency cyclotron modes dominated by kinetic energy and low-frequency E × B modes dominated by potential energy associated with thermal position displacements. Using an eigenmode analysis we extract the equilibration rate between these two branches as a function of the ratio of the frequencies that characterize the two branches and observe this equilibration rate to be exponentially suppressed as the ratio increases. Under experimental conditions relevant for current work at NIST, the predicted equilibration time is orders of magnitude longer than any relevant experimental timescales. We also study the coupling rate dependence on the initial energy of the planar modes and the number of ions. In addition, we show how increasing the rotating wall strength improves crystal stability. These details of in-plane mode dynamics help set the stage for developing strategies to efficiently cool the in-plane modes and improve the performance of single plane ion crystals for quantum information processing.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Ytterbium ion trap quantum computing: The current state-of-the-art

In this work, we present an overview of contemporary quantum computing with ytterbium ion traps, placing the emphasis on industry implementations. We provide brief, concrete descriptions of various key features, such as trap loading, electronic structure, qubit function, gates, error analysis, and benchmarking. We focus on the underlying science and current technologies to provide readers with a holistic picture of available techniques for using ytterbium in contemporary ion trap designs.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Volcanic forcing degrades multiyear-to-decadal prediction skill in the tropical Pacific

Volcanic aerosol forcing can affect global climate, but its role in climate prediction remains poorly understood. We isolate the impact of volcanic eruptions on multiyear-to-decadal climate prediction skill by comparing two suites of initialized decadal hindcasts conducted with and without historical volcanic forcing. Unexpectedly, the inclusion of volcanic forcing in the prediction system significantly degrades the forecast skill of detrended multiyear-to-decadal sea surface temperature (SST) variability in the central-eastern tropical Pacific. The ensemble mean hindcasts produce multiyear-to-decadal tropical Pacific SST cooling in response to large tropical volcanic eruptions through thermodynamic and El Niño–Southern Oscillation (ENSO)–like dynamic processes. However, in observations, these eruptions coincided with tropical Pacific warming, which is well predicted by the no-volcano hindcasts and, hence, is likely related to internal climate variability. Improved model representation of volcanic response and its interaction with internal climate variability is required to advance prediction of tropical Pacific decadal variability and associated global impacts.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

SR19036 - Improve TRP Cutter Head Performance

The current Target Rod Preparation (TRP) Cutter Head suffers from overheating problems during TPBAR breaching operations. The overheating leads to work stoppage due to the periodic need to allow the TRP Cutter Head motor to cool. This work stoppage and allowance for cooldown of the motor leads to a very inefficient TPBAR breaching process. Due to the increased need for Tritium gas, the system must be improved to increase the efficiency of the TPBAR breaching process.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Nanostructured Alumina Forming Austenitic Alloy (NAFA) Production using Advanced Manufacturing

Alumina-forming austenitic (AFA) alloys are well known for their exceptional corrosion-resistant properties due to the formation of a dense oxide scale beneficial in their application as a nuclear material. However, use of the alloys in core material applications is limited due to the high nickel-transmutation and helium generation rate in service, leading to swelling and reduced lifetimes. Enhancing the sink strength to pin gas bubbles and increasing gas management of the material may mitigate many of the degradation phenomena expected during alloy deployment (such as high-temperature helium embrittlement and cavity swelling for lead-cooled fast-reactor applications). Nanostructured materials are usually produced using a time-consuming and expensive batch process like mechanical alloying to achieve the fine homogenous distribution of nanoprecipitates throughout the matrix material. Integrating the nanoprecipitates in modern additive manufacturing processes has proven difficult, as the required nano-sizes or number densities cannot be achieved simultaneously. Efforts to increase the number density of precipitates by adding more precipitate-forming rare-earth elements led to agglomeration of such elements, while the nano-sized precipitates did not form in sufficient quantity when not enough rare-earth element was use. In this work a novel approach to advanced manufacturing and the fabrication of Nanostructured AFA (NAFA) materials was chosen. A dual precipitate-forming NAFA steel with a chemistry more suitable for advanced reactor applications was produced to create an environmentally resistant, high-sink-strength austenitic alloy for advanced reactor cladding applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Nanostructured Alumina-Forming Austenitic Alloy (NAFA) Production Using Advanced Manufacturing

Alumina-forming austenitic (AFA) alloys are well known for their exceptional corrosion-resistant properties due to the formation of a dense oxide scale beneficial in their application as a nuclear material. However, use of the alloys in core material applications is limited due to the high nickel-transmutation and helium generation rate in service, leading to swelling and reduced lifetimes. Enhancing the sink strength to pin gas bubbles and increasing gas management of the material may mitigate many of the degradation phenomena expected during alloy deployment (such as high-temperature helium embrittlement and cavity swelling for lead-cooled fast-reactor applications). Nanostructured materials are usually produced using a time-consuming and expensive batch process like mechanical alloying to achieve the fine homogenous distribution of nanoprecipitates throughout the matrix material. Integrating the nanoprecipitates in modern additive manufacturing processes has proven difficult, as the required nano-sizes or number densities cannot be achieved simultaneously. Efforts to increase the number density of precipitates by adding more precipitate-forming rare-earth elements led to agglomeration of such elements, while the nano-sized precipitates did not form in sufficient quantity when not enough rare-earth element was use. In this work a novel approach to advanced manufacturing and the fabrication of Nanostructured AFA (NAFA) materials was chosen. A dual precipitate-forming NAFA steel with a chemistry more suitable for advanced reactor applications was produced to create an environmentally resistant, high-sink-strength austenitic alloy for advanced reactor cladding applications.

36 MATERIALS SCIENCE↗
NASA NTRS1968

Rocket engine nozzle photographic system

Protective enclosure for a camera, located on the exhaust stream of a rocket engine, permits continuous recording of erosion processes of materials used in nozzle throat structures. The system uses a standard camera in a water-cooled, pressurized enclosure having a unique, inert gas-swept viewing duct.

Bailey, R. L.↗
NASA NTRS1969

SPAN C - Terminal sterilization process analysis program

Computer program, SPAN-C, measures the dry heat thermal sterilization process applied to a planetary capsule and calculates the time required for heat application, steady state conditions, and cooling. The program is based on the logarithmic survival of micro-organisms. Temperature profiles must be input on cards.

Source record↗
NASA NTRS1969

SPAN - Terminal sterilization process analysis program

Computer program, SPAN, measures the dry heat thermal sterilization process applied to a planetary capsule and calculates the time required for heat application, steady state conditions, and cooling. The program is based on the logarithmic survival of micro-organisms. Temperature profiles must be input on tape.

Source record↗