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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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Assessment of grain growth kinetics at temperatures near the melting point and investigation into the use of potential nucleating agents in combination with the naturally occurring BeO led to the definition of critical low-g experiments which would help to determine whether one or both of these possibilities are valid and whether space processing would be able to yield fine grain ingot beryllium.
This project aimed to develop scalable, cost-effective fabrication of high-performance, oxide- dispersion-strengthened (ODS) steel using advanced manufacturing methods (AMMs) for fusion blanket-breeding applications. Gas atomization reaction synthesis (GARS) enables the synthesis of precursor ODS steel powders without prolonged mechanical alloying. This process creates a chromium (Cr)-enriched surface oxide with yttrium/titanium (Y/Ti)-enriched intermetallics in powder interiors. GARS powders were consolidated to >99% of the theoretical density using a first-of-a-kind shear assisted processing and extrusion (ShAPE) and laser-based powder bed fusion (L-PBF) AM processes. These processes led to ODS steels containing a high-density of nano-oxide dispersoids that enhance high-temperature mechanical properties. Such scalable, cost-effective fabrication of ODS steels can enable efficient power conversion cycles (=40%) at operating temperatures beyond 900 K in future fusion power plants.
A wind tunnel test was conducted at the Ames Unitary Plan Wind Tunnel to characterize the transonic buffet environment of a generic launch vehicle forebody. The test examined a highly instrumented version of the Coe and Nute Model 11 test article first tested in the 1960s. One of the measurement techniques used during this test was unsteady pressure sensitive paint (uPSP) developed at the Arnold Engineering Development Complex. This optical measurement technique measured fluctuating pressures at over 300,000 locations on the surface of the model. The high spatial density of these measurements provided an opportunity to examine in depth the assumptions underpinning the development of buffet forcing functions (BFFs) used in the development of the Space Launch System vehicle. The comparison of discrete-measurement-based BFFs to BFFs developed by continuous surface pressure integration indicates that the current BFF development approach under predicts low frequency content of the BFFs while over predicting high frequency content. Coherence-based adjustments employed to reduce over prediction in the surface integration of discrete pressure measurements contribute to the inaccuracy of the BFFs and their implementation should be reevaluated.
A review of ceramic component advancements directed at developing manufacturing technologies for rotors, stators, vane-seat platforms and scrolls is presented. The first three components are being produced from HIPed Si3N4, while scrolls were prepared from a series of siliconized silicon-carbide materials. Developmental work has been conducted on all aspects of the fabrication process utilizing Taguchi experimental design methods. An assessment of material properties for various components from each process and material are made.
Thermoelectric generators have strong potential for aerospace and aircraft applications. However, traditional manufacturing methods for thermoelectric devices severely limit device adaptability and consequently marketability. Laser powder bed fusion is an additive manufacturing method which shows promising potential for producing thermoelectric devices. Thermoelectric materials pose unique challenges compared to metals because of low thermal conductivity, brittle fracture characteristics, and irregular powder particle morphologies. Herein, we communicate processing procedures to fabricate thermoelectric parts of Bi 2 Te 3 through laser powder bed fusion. In this study, we identify the successful combination of key process parameters—laser power, scan speed, hatch distance, and powder layer thickness—to achieve high-quality parts in terms of density and physical properties, and we demonstrate the impact of process parameter variation on built part quality. While it cannot exclusively determine part quality, the volumetric energy density is a useful guide in deciding process parameters for thermoelectric materials, and the optimal value is between 9 and 11 J/mm 3 for Bi 2 Te 3 . We demonstrate successful fabrication of different freeform geometries of Bi 2 Te 3 powders. The results suggest it is possible to extend this method more broadly to other semiconductor materials, including thermoelectric power generation materials applicable for space applications.
Growth configurations were developed which produced crystals having low residual stress levels. The properties of a 106 mm diameter round crucible were evaluated and it was found that this design had greatly enhanced temperature fluctuations arising from convection in the melt. Thermal modeling efforts were directed to developing finite element models of the 106 mm round crucible and an elongated susceptor/crucible configuration. Also, the thermal model for the heat loss modes from the dendritic web was examined for guidance in reducing the thermal stress in the web. An economic analysis was prepared to evaluate the silicon web process in relation to price goals.
In this project, a genetically modified Saccharomyces cerevisiae was used to produce Histamine via fermentation of dextrose. Zymergen provided a tech transfer document based on their 1 L studies, where they observed a titer of 0.9 g/L with this strain. The ABPDU staff performed two bench scale campaigns, with four 2 L reactors in each campaign, to carry out tech transfer and process optimization studies. Optimization was pursued by varying initial glucose concentration, feed initiation conditions, feed strategies, vitamin supplementation, inoculum size, etc. We chose a 2 L process condition, with 4% inoculum volume, continuous feed initiated after complete ethanol depletion, that yielded the most promising titers (2.41 g/L) for scale up to 300 L.
Coal-based bricks and blocks (CBBs) were formulated using anthracite and thermoplastic binder. Lab scale test composites were formed by hot-press molding and commercial extrusion for test articles and for a full-scale prototype. Formulations and test matrices followed a systematic experimental design to examine the effects of and interactions among three primary independent variables: a) thermoplastic type, b) weight fractions of binder relative to the total anthracite weight, and c) relative proportions of large versus small (milled) anthracite size fractions. Technical performance metrics include compressive strength, modulus, porosity/permeability and density. These DoE studies establish composition-property relations and identify the best combination for any desired property of interest – in particular, strength. Based on CBB composition and fabrication process, validated against technical performance metrics, a techno-economic analysis was constructed which incorporated a process flow model, engineering design (with scaling), and calculated capital plus operating costs. Based on measured property metrics and estimated process economics and a projected price by TEA (techno-economic analysis), building and construction target markets were identified by a market survey assessment. With known cost, price, performance metrics and competitive advantages for CBBs matched with commercial applications/uses, a technical gap analysis was performed to identify further development required for scale-up and commercialization.
A Czochralski crystal growing furnace was converted to a continuous growth facility by installation of a premelter to provide molten silicon flow into the primary crucible. The basic furnace is operational and several trial crystals were grown in the batch mode. Numerous premelter configurations were tested both in laboratory-scale equipment as well as in the actual furnace. The best arrangement tested to date is a vertical, cylindrical graphite heater containing small fused silicon test tube liner in which the incoming silicon is melted and flows into the primary crucible. Economic modeling of the continuous Czochralski process indicates that for 10 cm diameter crystal, 100 kg furnace runs of four or five crystals each are near-optimal. Costs tend to asymptote at the 100 kg level so little additional cost improvement occurs at larger runs. For these conditions, crystal cost in equivalent wafer area of around $20/sq m exclusive of polysilicon and slicing was obtained.
This report covers the activities associated with the development and evaluation of two high-γ’ superalloys that were designed by external partners on this project, namely Carpenter Technologies Corporation and the University of California-Santa Barbra. One alloy was GammaPrint-700, a cobalt-base superalloy, and the other a nickel-base (Ni-base) superalloy GammaPrint-1100. Both were found to be printable through laser powder bed fusion (LPBF) additive manufacturing, with optimal process parameter sets being identified for each alloy. Further, high temperature mechanical testing was conducted on each alloy that showed both materials performed better than the comparative baseline (LPBF Hastelloy X), with the Ni-base superalloy being down-selected for scaling and printing of the tip shoe components.
A description is given of the hardware and software of a multiprocessor test bed - the second generation Hypercluster system. The Hypercluster architecture consists of a standard hypercube distributed-memory topology, with multiprocessor shared-memory nodes. By using standard, off-the-shelf hardware, the system can be upgraded to use rapidly improving computer technology. The Hypercluster's multiarchitecture nature makes it suitable for researching parallel algorithms in computational field simulation applications (e.g., computational fluid dynamics). The dedicated test-bed environment of the Hypercluster and its custom-built software allows experiments with various parallel-processing concepts such as message passing algorithms, debugging tools, and computational 'steering'. Such research would be difficult, if not impossible, to achieve on shared, commercial systems.
Long flexible boom models were required to develop ground vibration test methods for very low frequency space structures with applications to the proposed MAST program and Space Station. Pultruded quasi-isotropic composite beams were selected as an option over extruded aluminum alloy structures because of the lower cost potential, higher specific strength, flexural properties, and dynamic similarity considerations. A comparison is made of four different pultrusions having varied matrices and fiber orientations. Test results indicate that the pultrusion process can be used to produce quasi-isotropic composite structures by selective fiber orientation using the knit-lock fabric concept.
Real clouds and clouds systems are inherently three dimensional (3D). Because of the limitations in computer resources, however, most cloud-resolving models (CRMs) today are still two-dimensional (2D). A few 3D CRMs have been used to study the response of clouds to large-scale forcing. In these 3D simulations, the model domain was small, and the integration time was 6 hours. Only recently have 3D experiments been performed for multi-day periods for tropical cloud system with large horizontal domains at the National Center for Atmospheric Research. The results indicate that surface precipitation and latent heating profiles are very similar between the 2D and 3D simulations of these same cases. The reason for the strong similarity between the 2D and 3D CRM simulations is that the observed large-scale advective tendencies of potential temperature, water vapor mixing ratio, and horizontal momentum were used as the main forcing in both the 2D and 3D models. Interestingly, the 2D and 3D versions of the CRM used in CSU and U.K. Met Office showed significant differences in the rainfall and cloud statistics for three ARM cases. The major objectives of this project are to calculate and axamine: (1)the surface energy and water budgets, (2) the precipitation processes in the convective and stratiform regions, (3) the cloud upward and downward mass fluxes in the convective and stratiform regions; (4) cloud characteristics such as size, updraft intensity and lifetime, and (5) the entrainment and detrainment rates associated with clouds and cloud systems that developed in TOGA COARE, GATE, SCSMEX, ARM and KWAJEX. Of special note is that the analyzed (model generated) data sets are all produced by the same current version of the GCE model, i.e. consistent model physics and configurations. Trajectory analyse and inert tracer calculation will be conducted to identify the differences and similarities in the organization of convection between simulated 2D and 3D cloud systems.
The National Aeronautics and Space Administration (NASA) is supporting research to transition from a legacy, air traffic management (ATM) system to Trajectory-Based Operations (TBO) environment targeting the 2035-2045 timeframe by creating simulation scenarios for current and future studies. TBO in the National Airspace System (NAS) focuses on modernizing the current operating paradigm to increase efficiency, predictability, resilience, and flexibility while migrating toward greater operational autonomy across the airspace. These simulation scenarios offer a wide dissemination and use of system-level constraints and aircraft state/intent data, routine use of data communications to request complex trajectory modifications and to receive clearances, and aircraft that are flying on 4-D trajectories with flexibility when desired, but structure where required. This report describes the end-to-end development of scenarios for the NASA Langley Research Center simulation environment to represent a 2040 Trajectory-Based Operations airspace for air transport operations research.
The development of high temperature fuel cladding materials to withstand a variety of extreme environments have received much attention. Several potential materials systems that have been identified for the fuel systems and core structural materials application in advanced reactor systems are ferritic/martensitic steel (e.g., HT9), austenitic stainless steels (e.g., 316 LN), oxide-dispersion strengthened steels (e.g., 12 YWT), Ni-based alloys and ceramic-based composites depending on the type of the reactors. Though these material systems have promising properties conducive for radiation-resistant performance, they suffer beyond the design-limit from one or more damage processes such as void swelling, radiation embrittlement, phase instability, corrosion, and limited creep life.
A barrier crucible design which consistently maintains melt stability over long periods of time was successfully tested and used in long growth runs. The pellet feeder for melt replenishment was operated continuously for growth runs of up to 17 hours. The liquid level sensor comprising a laser/sensor system was operated, performed well, and meets the requirements for maintaining liquid level height during growth and melt replenishment. An automated feedback loop connecting the feed mechanism and the liquid level sensing system was designed and constructed and operated successfully for 3.5 hours demonstrating the feasibility of semi-automated dendritic web growth. The sensitivity of the cost of sheet, to variations in capital equipment cost and recycling dendrites was calculated and it was shown that these factors have relatively little impact on sheet cost. Dendrites from web which had gone all the way through the solar cell fabrication process, when melted and grown into web, produce crystals which show no degradation in cell efficiency. Material quality remains high and cells made from web grown at the start, during, and the end of a run from a replenished melt show comparable efficiencies.
Space biology BLEO research is inherently driven by the differences between the LEO and BLEO environments, which can be broadly characterized by the five-hazard “RIDGE” paradigm (Radiation, Isolation, Distance, Gravity, Environment, e.g., similar to Figure 2 in (1)). Thus, the envisioned goals over the next decade will include using the cislunar and lunar surface environments to (A) characterize deep-space environments including biological effects of radiation and other stressors, (B) gain experience from isolation of very small groups in very small enclosures, (C) learn to compensate for distance from Earth via in situ resource utilization (ISRU) and bioregenerative life support, (D) gain assurance that all aspects of deep-space exploration can proceed in altered or artificial gravity environments, (E) develop essential adaptation scenarios for the built (e.g., low pressure) and external (e.g., temperature extremes, dust) environments.
The decline of coal use for energy production provides an abundance of local feedstock for new innovative uses and value-added products. Expanding the U.S. coal-value chain to manufacture high-value carbon products can strengthen the nation’s energy and mineral security, enhance the U.S. national defense security, increase the United States’ economic prosperity, while achieving U.S. environmental objectives. The primary project goal is a relatively light-weight composite product with superior (or comparable) compressive strength. Both virgin and, where available, post-consumer recycled thermoplastic versions are tested for each thermoplastic species. A useful attribute of thermoplastics as binders is that they can be heated to their melting point, cooled, and reheated again without significant degradation. A key advantage of thermoset CBBs is that they require only mixing and molding. CBB advantages include low cost, availability, binding ability and processability. Coal-based bricks and blocks (CBBs) weigh about 50% less than clay bricks and can be manufactured with an interlocking design to promote ease of use for the novice builder. CBB formulation is evaluated according to a design-of-experiments (DoE) approach. DoE variables are a) relative weight fractions of binder, b) relative proportions of large versus small (milled) anthracite size fractions, and c) additive percentage. Fabrication methods include hot-press molding and extrusion, the later being the most commercially viable. CBBs are tested for compressive strength, modulus of rupture (by flexure test) and water absorption per ASTM C67, with density determined by the Archimedes drainage method. Fractured interfaces are examined by SEM (Scanning Electron Microscopy) to resolve fracture dynamics and interior microstructure uniformity. Differential scanning calorimetry (DSC) is used to compare plastic transition temperatures i.e., glass and melting temperatures to contrast virgin with post-consumer recycled thermoplastics and optimize their usage. These results are used in the DoE analysis to identify the binder and relative weight percentages for optimum strength, density, and porosity. Overall, CBBs possess strength comparable to clay-based bricks but are non-permeable and hydrophobic, and hence resistant to degradation by freeze-fracturing, corrosion, and efflorescence. The strongest composites have been made with the following thermoplastic binders (in order of strength): thermoset, high-density polyethylene crosslink resin, high-density polyethylene, nylon 6/6, and polypropylene. Results from a techno-economic analysis TEA show economy of scale for CBBs by modularization and reveal the binder as the cost driver for material costs. Ideally, the incorporation of post-consumer recycled thermoplastic will decrease material acquisition costs and increase product sustainability. Notably, CBBs do not require the high temperature calcination needed to produce cement, nor do they require firing in the 1600-2400 °F range for three days using natural gas, as do clay brick equivalents. Instead, CBBs are heated to a modest <600 °F according to the melt flow index of the thermoplastic binder. Existing anthracite mines can be expanded to produce CBBs to reduce aggregate transportation costs and emissions that exist for clay bricks. TEA reflects this reduced energy cost while a comparative CO2 emission analysis quantifies the reduced environmental footprint. The market survey identifies several commercialization opportunities, dependent upon the brick classification.