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All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

High-Performance SiC/SiC Ceramic Composite Systems Developed for 1315 C (2400 F) Engine Components

As structural materials for hot-section components in advanced aerospace and land-based gas turbine engines, silicon carbide (SiC) ceramic matrix composites reinforced by high performance SiC fibers offer a variety of performance advantages over current bill-of-materials, such as nickel-based superalloys. These advantages are based on the SiC/SiC composites displaying higher temperature capability for a given structural load, lower density (approximately 30- to 50-percent metal density), and lower thermal expansion. These properties should, in turn, result in many important engine benefits, such as reduced component cooling air requirements, simpler component design, reduced support structure weight, improved fuel efficiency, reduced emissions, higher blade frequencies, reduced blade clearances, and higher thrust. Under the NASA Ultra-Efficient Engine Technology (UEET) Project, much progress has been made at the NASA Glenn Research Center in identifying and optimizing two highperformance SiC/SiC composite systems. The table compares typical properties of oxide/oxide panels and SiC/SiC panels formed by the random stacking of balanced 0 degrees/90 degrees fabric pieces reinforced by the indicated fiber types. The Glenn SiC/SiC systems A and B (shaded area of the table) were reinforced by the Sylramic-iBN SiC fiber, which was produced at Glenn by thermal treatment of the commercial Sylramic SiC fiber (Dow Corning, Midland, MI; ref. 2). The treatment process (1) removes boron from the Sylramic fiber, thereby improving fiber creep, rupture, and oxidation resistance and (2) allows the boron to react with nitrogen to form a thin in situ grown BN coating on the fiber surface, thereby providing an oxidation-resistant buffer layer between contacting fibers in the fabric and the final composite. The fabric stacks for all SiC/SiC panels were provided to GE Power Systems Composites for chemical vapor infiltration of Glenn designed BN fiber coatings and conventional SiC matrices. Composite panels with system B were heat treated at Glenn, and the pores that remained open were filled by silicon melt infiltration (MI). Panels with system A and the other SiC/SiC systems were not heat treated, and remaining open pores in these systems were filled with SiC slurry and silicon MI.

DiCarlo, James A.↗
NASA NTRS1978

Fabrication and testing of silver-hydrogen cells

The development and life testing of single electrode and multi electrode stacks to optimize the individual components and characterize the performance of a silver hydrogen battery system are described. A NASA-developed inorganic separator material was used as the main separator within the cells. Single electrode test cells were cycled at 75% of nominal capacity out through approximately 1,000 cycles in a number of cases where deterioration in performance was observed. This deterioration appears to be a decay in usable capacity of the silver electrode; but the exact mechanism is still unidentified. Twenty ampere-hour boilerplate test cells consisting of a stack of ten silver electrodes and twenty hydrogen electrodes were cycled also at 75% depth of discharge. The oldest stack achieved 522 stable cycles to the end of the program. Weight analysis of light-weight cells showed that 50 ampere-hour cells with improved components could be capable of as much as 40 watt hours per pound.

Klein, M. G.↗
NASA NTRS1999

EXPRESS Rack Technology for Space Station

The EXPRESS rack provides accommodations for standard Mid-deck Locker and ISIS drawer payloads on the International Space Station. A design overview of the basic EXPRESS rack and two derivatives, the Human Research Facility and the Habitat Holding Rack, is given in Part I. In Part II, the design of the Solid State Power Control Module (SSPCM) is reviewed. The SSPCM is a programmable and remotely controllable power switching and voltage conversion unit which distributes and protects up to 3kW of 12OVDC and 28VDC power to payloads and rack subsystem components. Part III details the development and testing of a new data storage device, the BRP EXPRESS Memory Unit (BEMU). The BEMU is a conduction-cooled device which operates on 28VDC and is based on Boeing-modified 9GB commercial disk-drive technology. In Part IV results of a preliminary design effort for a rack Passive Damping System (PDS) are reported. The PDS is intended to isolate ISPR-based experiment racks from on-orbit vibration. System performance predictions based on component developmental testing indicate that such a system can provide effective isolation at frequencies of 1 Hz and above.

Davis, Ted B.↗
DOE OSTI2024

Smart manufacturing approach to manufacture bulk nanocrystalline aluminum for lightweight applications

In this research, a smart manufacturing approach was used to enhance the mechanical properties of aluminum (Al) for lightweight applications. The smart manufacturing involved cryomilling of Al powders with and without 5 wt.% magnesium (Mg) powders for varying durations followed by a high-pressure cold spray (HPCS) additive manufacturing process to prepare bulk components. The morphological changes, crystallite size, and composition of the cryomilled powders and cold sprayed (CS’ed) components were examined using scanning electron microscopy (SEM), x-ray diffraction (XRD), and transmission electron microscopy (TEM) techniques. The results showed that the crystallite size reduces with an increase in cryomilling time and the addition of Mg dopant. To test the mechanical properties of the bulk CS’ed components, microhardness tests were performed using a Vickers microhardness tester. Uniaxial tensile tests were also carried out to ascertain the material’s tensile properties. The mechanical testing results showed great improvement in the hardness and tensile strength of CS’ed Al–Mg samples as compared to pure Al samples. Subsequently, fractography analysis of the tensile failed samples was carried out to determine the nature of the failure. Here, the research article also discusses the inherent mechanisms for the improvement in mechanical properties of smart manufactured components as a result of Mg doping and cryomilling.

36 MATERIALS SCIENCE↗
NASA NTRS1996

The Effects of Promethazine on Human Performance, Mood States, and Motion Sickness Tolerance

Intramuscular (IM) injections of promethazine in 25 mg or 50 mg dosages are commonly used to treat space motion sickness in astronauts. The present study examined the effects of IM injections of promethazine on neuropsy-chological performance, mood states, and motion sickness tolerance in humans. Twelve men, mean age 36 plus or minus 3.1 participated in one training (no injections) and three treatment conditions: a 25 mg injection of promethazine, a 50 mg injection of promethazine, and a placebo injection of sterile saline. Each condition, spaced at 7 day intervals, required an 8-10 hr session in which subjects were given four repetitions of 12 performance tasks, and one rotating chair motion sickness test. On the training day subjects were trained on each task to establish stability and proficiency. On treatment days, the order in which the drug or placebo was assigned to subjects was counter-balanced and a double-blind technique was used. Statistically significant decrements in performance were observed on 10 of 12 tasks when subjects were given 25 mg or 50 mg of promethazine as compared to the placebo. Performance decrements were associated with mean blood alcohol dose equivalency levels of 0.085% for 25 mg and 0. 1 37% for 50 mg dosages. The mood scale results showed significant changes in individual subjective experiences with maximum deterioration in the arousal state and fatigue level. When compared to placebo significant increases in motion sickness tolerance were found for both dosages of promethazine. These data suggest that effective dosages of promethazine currently used to counteract motion sickness in astronauts may significantly impair task components of their operational performance.

Cowings, Patricia S.↗
NASA NTRS2003

Case Studies of Fatigue Life Improvement Using Low Plasticity Burnishing in Gas Turbine Engine Applications

Surface enhancement technologies such as shot peening, laser shock peening (LSP), and low plasticity burnishing (LPB) can provide substantial fatigue life improvement. However, to be effective, the compressive residual stresses that increase fatigue strength must be retained in service. For successful integration into turbine design, the process must be affordable and compatible with the manufacturing environment. LPB provides thermally stable compression of comparable magnitude and even greater depth than other methods, and can be performed in conventional machine shop environments on CNC machine tools. LPB provides a means to extend the fatigue lives of both new and legacy aircraft engines and ground-based turbines. Improving fatigue performance by introducing deep stable layers of compressive residual stress avoids the generally cost prohibitive alternative of modifying either material or design. The X-ray diffraction based background studies of thermal and mechanical stability of surface enhancement techniques are briefly reviewed, demonstrating the importance of minimizing cold work. The LPB process, tooling, and control systems are described. An overview of current research programs conducted for engine OEMs and the military to apply LPB to a variety of engine and aging aircraft components are presented. Fatigue performance and residual stress data developed to date for several case studies are presented including: * The effect of LPB on the fatigue performance of the nickel based super alloy IN718, showing fatigue benefit of thermal stability at engine temperatures. * An order of magnitude improvement in damage tolerance of LPB processed Ti-6-4 fan blade leading edges. * Elimination of the fretting fatigue debit for Ti-6-4 with prior LPB. * Corrosion fatigue mitigation with LPB in Carpenter 450 steel. *Damage tolerance improvement in 17-4PH steel. Where appropriate, the performance of LPB is compared to conventional shot peening after exposure to engine operating temperatures.

Prevey, Paul S.↗
DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗
NASA NTRS1970

Skylab Operations Handbook: Orbital Workshop (OWS), Airlock Module (AM), Multiple Docking Adapter (MDA): Systems Descriptions - Volume 1

The Skylab Program consists of three low-earth-orbit missions of the Orbital Assembly (OA) (figure 1.0-1), extending over.an a-month period. The OA consists of the CSM docked to the Saturn Workshop.(SWS). This handbook describes the systems for three of the four major components of the SWS (OWS, AM, and MDA), and also discusses significant interfaces with the Instrument Unit (IU), ATM, and CSM. The other major component of the SWS, the ATM, is treated separately in its own handbook. The OWS, AM, MDA, ATM Deployment Assembly (ATM-DA), Fixed Airlock Shroud (FAS), Payload Shroud (PS), and IU are addressed throughout this document as individual modules from a structural standpoint only. Although normally considered a part of the launch vehicle, the IU is treated in this document as part of the SWS because of its function in preparing the SWS for orbital operation. Section 1.0 describes vehicle and mission configurations of the Skylab program and provides general descriptions of the various systems. Section 2.0 provides detailed systems data covering system interfaces, functional description, subsystems and major components description, component operation, failure modes, performance and design data, operational limitations and restrictions, and instrumentation, and briefly outlines the experiments. Section 3.0 contains illustrations of all panels and identifies the controls and displays, panels, reference designators, nomenclature, functions, circuit breakers, and power sources. The Table of Contents lists in order of appearance all sections, subsections, major paragraphs, illustrations, and tables and provides their respective page locations. Appendix A defines the abbreviations and acronyms employed throughout this handbook, and Appendix B explains the symbols used. Appendix C is a locator index that references component controls contained in Section 3.0. Appendix D is an alphabetical index of paragraph headings, illustrations, and tables, according to the key word, with applicable page numbers. Additional items of significance to the user have been included in the index. The technical level to which this document is written assumes the reader to have general knowledge of engineering terms and principles.

West, W. D.↗
DOE OSTI2023

Empirical validation of building energy simulation model input parameter for multizone commercial building during the cooling season

This paper presents a critical advancement in Building Energy Modeling (BEM) through an empirical validation approach using a high-quality dataset from a multizone commercial office building in Oak Ridge, TN, USA. BEM is widely utilized in diverse construction applications, but its effectiveness relies on the accuracy of its predictions. The study focuses on empirical validation of input parameters in BEM, including building envelope data, infiltration modeling, and rooftop unit system performance curves. The validation of simulation input parameters leads to substantial improvements in the accuracy of simulation results. Notable both NMBE and cv (RMSE) values are reduced by 0.5 % for indoor air temperature and 17 % for indoor air relative humidity compared to the previous model. At the system level, both NMBE and cv (RMSE) values are reduced by 2 % for fan energy consumption and 4 % for cooling energy consumption, compared to the previous model. A literature review highlights a significant gap in empirical validation studies, which predominantly concentrate on either component-level or whole building validation. Furthermore, many studies employ simplified setups that may not faithfully represent the complexities of multizone commercial buildings. This paper distinguishes itself by emphasizing the critical importance of component-level input parameter validation. It underlines the need to validate data related to building envelope components and HVAC system performance curves, resulting in more accurate simulation outcomes. In conclusion, the utilization of actual multizone commercial building data enhances the study's practical relevance. In summary, this research underscores the pivotal role of input parameter validation in enhancing the accuracy and reliability of BEM.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1982

Advanced ceramic coating development for industrial/utility gas turbine applications

The effects of ceramic coatings on the lifetimes of metal turbine components and on the performance of a utility turbine, as well as of the turbine operational cycle on the ceramic coatings were determined. When operating the turbine under conditions of constant cooling flow, the first row blades run 55K cooler, and as a result, have 10 times the creep rupture life, 10 times the low cycle fatigue life and twice the corrosion life with only slight decreases in both specific power and efficiency. When operating the turbine at constant metal temperature and reduced cooling flow, both specific power and efficiency increases, with no change in component lifetime. The most severe thermal transient of the turbine causes the coating bond stresses to approach 60% of the bond strengths. Ceramic coating failures was studied. Analytic models based on fracture mechanics theories, combined with measured properties quantitatively assessed both single and multiple thermal cycle failures which allowed the prediction of coating lifetime. Qualitative models for corrosion failures are also presented.

Andersson, C. A.↗
NASA NTRS2000

A Comparison of Brayton and Stirling Space Nuclear Power Systems for Power Levels from 1 Kilowatt to 10 Megawatts

An analytical study was conducted to assess the performance and mass of Brayton and Stirling nuclear power systems for a wide range of future NASA space exploration missions. The power levels and design concepts were based on three different mission classes. Isotope systems, with power levels from 1 to 10 kW, were considered for planetary surface rovers and robotic science. Reactor power systems for planetary surface outposts and bases were evaluated from 10 to 500 kW. Finally, reactor power systems in the range from 100 kW to 10 mW were assessed for advanced propulsion applications. The analysis also examined the effect of advanced component technology on system performance. The advanced technologies included high temperature materials, lightweight radiators, and high voltage power management and distribution.

Mason, Lee S.↗
NASA NTRS2006

Intracavity Rayleigh/Mie Scattering for Multipoint, Two-Component Velocity Measurement

A simultaneous multi-point two-component Doppler velocimeter is described. The system uses two optical cavities: a Fabry-Perot etalon and an optical cavity for collecting and re-circulating the Rayleigh/Mie scattered light that is collected from the measurement volume in two parallel, but opposite directions. Single-pulse measurements of two orthogonal components of the velocity vector in a supersonic free jet were performed to demonstrate the technique. The re-circulation of the light rejected by the interferometer input mirror also increased the signal intensity by a factor of 3.5. 2005 Optical Society of America Interferometric Rayleigh scattering has previously been used for single-point velocity measurements in unseeded gas flow. However, this past work has generally been limited to probing with continuous-wave lasers resulting in time-averaged measurements of velocity. Multiple velocity components have been measured simultaneously by separate instruments.1,2 It has also been demonstrated that two orthogonal velocity components can be measured simultaneously at one point using one interferometer by reflecting back the probing laser beam, although this approach results in directional ambiguity of the flow velocity vector.3 This measurement ambiguity was removed by prior knowledge of the approximate magnitude and sign of the velocity components. Furthermore, it was shown that multiple points could be measured simultaneously with a Rayleigh scattering interferometric approach, but only one component of velocity was measured.4 Another method of performing multiple component velocity measurements with Rayleigh scattering uses a pair of cameras to image the flow, one of which views the flow through an iodine gas filter. This iodine-filter technique has the advantage of allowing high-resolution velocity imaging, but it generally has a lower dynamic range.

Bivolaru, Daniel↗
NASA NTRS2014

Extending Our Understanding of Compliant Thermal Barrier Performance

Thermal barriers and seals are integral components in the thermal protection systems (TPS) of nearly all aerospace vehicles. They are used to minimize the flow of hot gases through interfaces and protect underlying temperature-sensitive components and systems. Although thermal barriers have been used extensively on many aerospace vehicles, the factors affecting their thermal and mechanical performance are not well-understood. Because of this, vehicle TPS designers are often left with little guidance on how to properly design and optimize these barriers. An ongoing effort to better understand thermal barrier performance and develop models and design tools is in progress at the NASA Glenn Research Center. Testing has been conducted to understand the degree to which insulation density influences structural performance and permeability. In addition, the development of both thermal and mechanical models is ongoing with the goal of providing an improved ability to design and implement these critical TPS components.

high temperature↗
NASA NTRS1999

Human Engineering Operations and Habitability Assessment: A Process for Advanced Life Support Ground Facility Testbeds

Design and Human Engineering (HE) processes strive to ensure that the human-machine interface is designed for optimal performance throughout the system life cycle. Each component can be tested and assessed independently to assure optimal performance, but it is not until full integration that the system and the inherent interactions between the system components can be assessed as a whole. HE processes (which are defining/app lying requirements for human interaction with missions/systems) are included in space flight activities, but also need to be included in ground activities and specifically, ground facility testbeds such as Bio-Plex. A unique aspect of the Bio-Plex Facility is the integral issue of Habitability which includes qualities of the environment that allow humans to work and live. HE is a process by which Habitability and system performance can be assessed.

Connolly, Janis H.↗
NASA NTRS2020

Development of High-Performance Graphene-HgCdTe Detector Technology for Mid-Wave Infrared Applications

A high-performance graphene-based HgCdTe detector technology is being developed for sensing over the mid-wave infrared (MWIR) band for NASA Earth Science, defense, and commercial applications. This technology involves the integration of graphene into HgCdTe photodetectors that combines the best of both materials and allows for higher MWIR(2-5 m) detection performance compared to photodetectors using only HgCdTe material. The interfacial barrier between the HgCdTe-based absorber and the graphene layer reduces recombination of photogenerated carriers in the detector. The graphene layer also acts as high mobility channel that whisks away carriers before they recombine, further enhancing the detector performance. Likewise, HgCdTe has shown promise for the development of MWIR detectors with improvements in carrier mobility and lifetime. The room temperature operational capability of HgCdTe-based detectors and arrays can help minimize size, weight, power and cost for MWIR sensing applications such as remote sensing and earth observation, e.g., in smaller satellite platforms. The objective of this work is to demonstrate graphene-based HgCdTe room temperature MWIR detectors and arrays through modeling, material development, and device optimization. The primary driver for this technology development is the enablement of a scalable, low cost, low power, and small footprint infrared technology component that offers high performance, while opening doors for new earth observation measurement capabilities.

Sood, Ashok K.↗