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Multiscale Modeling of Woven Ablative Thermal Protection System Materials

The NASA Entry Systems Modeling project maintains a portfolio of computational model and tool development activities focused on reducing performance uncertainties in ablative Thermal Protection System (TPS) materials for NASA missions. The development activities span material scale and strive to allow microstructural characterization of material structure and properties, mesoscale analyses of damage, and macroscale evaluation of heatshield performance and recession in a given aerothermodynamic environment. This talk will detail the application of developed capabilities at all three scales to the woven TPS material that the Agency has selected as the heatshield for the Mars Sample Return Earth Entry System (MSR-EES) mission – 3D Mid-Density Carbon Phenolic (3MDCP). Each of the applications focuses on driving down uncertainties in material performance and thus risk for MSR-EES and other future missions that may leverage woven TPS. At the microscale, machine learning techniques are used to characterize images from destructive microscopy and inform structural variability. At the mesoscale, Lagrangian techniques are used to simulate ballistic impact and interpret damage modes noted in experiments. At the macroscale, coupled flow-material response techniques are validated by Arc Jet testing to enable heatshield design for missions with massive ablation.

Justin B Haskins↗

DOE OSTI2021

Deposition of integrated protective material into zirconium cladding for nuclear reactors by high-velocity thermal application

A zirconium alloy nuclear reactor cylindrical cladding has an inner Zr substrate surface, an outer volume of protective material, and an integrated middle volume of zirconium oxide, zirconium and protective material, where the protective material is applied by impaction at a velocity greater than 340 meters/second to provide the integrated middle volume resulting in structural integrity for the cladding.

Mazzoccoli, Jason P.↗

NASA NTRS2016

Analysis of Summer-Time Ozone and Precursor Species in the Southeast United States

Ozone (O3) is a greenhouse gas and toxic pollutant which plays a major role in air quality and atmospheric chemistry. The understanding and ability to model the horizontal and vertical structure of O3 mixing ratios is difficult due to the complex formation/destruction processes and transport pathways that cause large variability of O3. The Environmental Protection Agency has National Ambient Air Quality Standards for O3 set at 75 ppb with future standards proposed to be as low as 65 ppb. These lower values emphasize the need to better understand/simulate the transport processes, emission sources, and chemical processes controlling precursor species (e.g., NOx, VOCs, and CO) which influence O3 mixing ratios. The uncertainty of these controlling variables is particularly large in the southeast United States (US) which is a region impacted by multiple different emission sources of precursor species (anthropogenic and biogenic) and transport processes resulting in complex spatio-temporal O3 patterns. During this work we will evaluate O3 and precursor species in the southeast US applying models, ground-based and airborne in situ data, and lidar observations. In the summer of 2013, the UAH O3 Differential Absorption Lidar (DIAL) (part of the Tropospheric Ozone Lidar Network (TOLNet)) measured vertical O3 profiles from the surface up to approximately 12 km. During this period, the lidar observed numerous periods of dynamic temporal and vertical O3 structures. In order to determine the sources/processes impacting these O3 mixing ratios we will apply the CTM GEOS-Chem (v9-02) at a 0.25 deg x 0.3125 deg resolution. Using in situ ground-based (e.g., SEARCH Network, CASTNET), airborne (e.g., NOAA WP-3D - SENEX 2013, DC-8 - SEAC4RS), and TOLNet lidar data we will first evaluate the model to determine the capability of GEOS-Chem to simulate the spatio-temporal variability of O3 in the southeast US. Secondly, we will perform model sensitivity studies in order to quantify which emission sources (e.g., anthropogenic, biogenic, lighting, wildfire) and transport processes (e.g., stratospheric, long-range, local scale) are contributing to these TOLNet-observed dynamic O3 patterns. Results from the evaluation of the model and the study of sources/processes impacting observed O3 mixing ratios will be presented.

Optical Radar↗

DOE OSTI2023

A phased workflow to define permit‐ready locations for large volume CO 2 injection and storage

Abstract To‐date, only two UIC Class VI permits have been issued by the US Environmental Protection Agency. We illustrate a four‐phase workflow to first identify regional storage resources and then down‐select sites to yield permit‐ready locations that can accept and store large volumes of CO 2 . Specific permit requirements should guide objectives and define deliverables of respective workflow phases. In the first phase we used available regional data and screened structure and injection zones to locate resources that match CO 2 volumes planned to be captured. Available data were also used to assess presence and depth of usable groundwater, the key resource being protected via permitting. We then used advanced, closed‐form, analytical solutions (EASiTool) to estimate CO 2 injectivity into each hydrologically connected injection compartment. In the second phase we acquired and conditioned additional wireline logs and leased available seismic datasets. We interpreted the depositional systems from wireline well‐log character and mapped sandbody geometry to interpolate injection and confining‐zone distribution. Using available data, we mapped faults and locations of freshwater and overpressure (or other capacity‐limiting geologic parameters) in more detail. In the third phase, we used the augmented geologic data to develop a static model for the selected area, extracted the areas of highest interest, and generated and ran dynamic (flow) models. In a fourth phase, we reduced major uncertainties identified in earlier phases. Our case study indicates that to complete preparation of a permit application requires (1) improved lithologic characterization information (thicknesses and horizontal and vertical connectivity) and (2) better definition of poorly defined local faults. © 2023 The Authors. Greenhouse Gases: Science and Technology published by Society of Chemical Industry and John Wiley & Sons Ltd.

58 GEOSCIENCES↗

DOE OSTI2021

Characterization of Materials Used as Face Coverings for Respiratory Protection

Use of masks is a primary tool to prevent the spread of the novel COVID-19 virus resulting from unintentional close contact with infected individuals. However, detailed characterization of the chemical properties and physical structure of common mask materials is lacking in the current literature. In this study, a series of commercial masks and potential mask materials, including 3M Particulate Respirator 8210 N95, a material provided by Oak Ridge National Laboratory Carbon Fiber Technology Facility (ORNL/CFTF), and a Filti Face Mask Material, were characterized by a suite of techniques, including scanning electron microscopy, X-ray diffraction, Raman spectroscopy, and X-ray photoelectron spectroscopy. Wetting properties of the mask materials were quantified by measurements of contact angle with a saliva substitute. Mask pass-through experiments were performed using a dispersed metal oxide nanoparticle suspension to model the SARS-CoV-2 virus, with quantification via spatially resolved X-ray fluorescence mapping. Notably, all mask materials tested provided a strong barrier against respiratory droplet breakthrough. The comparisons and characterizations provided in this study provide useful information when evaluating mask materials for respiratory protection.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Observation of Persistent Zero Modes and Superconducting Vortex Doublets in UTe 2

Superconducting vortices can reveal electron pairing details and nucleate topologically protected states. Yet, vortices of bulk spin-triplet superconductors have never been visualized at the atomic scale. Recently, UTe 2 has emerged as a prime spin-triplet superconductor, but its superconducting order parameter is elusive, and whether time-reversal symmetry (TRS) is broken remains unsettled. Here, in this work, we visualize vortices on the (011) surface of ultraclean UTe 2 single crystals (T c = 2.1 K) using scanning tunneling microscopy (STM). We introduce $\frac{d^{2}𝐼}{d𝑉^{2}}$ imaging as an effective technique for vortex visualization in superconductors with substantial residual zero-energy density of states (DOS), as in UTe 2 . Anisotropic single-flux-quantum vortices, with coherence lengths of ∼12 nm (4 nm) parallel (perpendicular) to the a -axis, form a triangular vortex lattice (VL) under a small out-of-plane magnetic field. The invariance of vortex structures and VL under changes of field polarity and cooling history strongly supports time-reversal invariant superconductivity under zero field. At vortex cores (VCs), nonsplit, spectrally sharp zero-bias conductance peaks (ZBPs) persist up 8 T that are consistent with symmetry-protected Majorana zero modes (MZMs) in a topological vortex line. Close examination of vortex structures reveals a mirror-asymmetric doublet─one with ZBPs and another with an enhanced apparent gap, possibly originating from a field-induced multicomponent order parameter.

UTe2↗

NASA NTRS2011

Mars Exploration Rover Heatshield Observation Campaign

For the first time ever, engineers were able to observe a heatshield on the surface of another planet after a successful entry through the atmosphere. A three-week heatshield observation campaign was conducted in December 2004 after the Mars Exploration Rover Opportunity exited "Endurance Crater." By utilizing the rover's scientific instruments, data was collected to make a qualitative assessment of the performance of the heatshield. This data was gathered to gain a better understanding of how the heatshield performed during entry through the Martian atmosphere. In addition, this unprecedented look at the heatshield offered engineers the opportunity to assess if any unexpected anomalies occurred. Once a survey of the heatshield debris was completed, multiple targets of interest were chosen for the collection of imaging data. This data was then used to assess the char depth of the thermal protection material, which compared well with design and post-flight computational predictions. Extensive imaging data was collected and showed the main seal in pristine conditions, and no observable indications of structure overheating. Additionally, unexpected vehicle dynamics during the atmospheric entry were explained by the observation of thermal blanket remnants attached to the heatshield.

Thermal Protection System (TPS)↗

DOE OSTI2021

Conceptual design of HFIR irradiation experiment for material compatibility study on liquid Sn divertor

Liquid Sn is one of the promising coolants for liquid surface divertor concept of fusion reactors. However, the compatibility between liquid Sn and structural materials is an important issue that has to be addressed, because liquid Sn is extremely corrosive to steels at high temperatures. The corrosion may be mitigated when a protective Al2O 3 layer is formed on the surface of alumina forming steels. However, the effect of neutron irradiation on the integrity of protective layer is not made clear so far. Japan and US joint research project “FRONTIER” started in 2019 to investigate the material compatibility under neutron irradiation. The purpose of the present study is to develop the conceptual design of the irradiation test capsule which enables material compatibility tests for the alumina forming steels - liquid metal systems under neutron irradiation in the High Flux Isotope Reactor at Oak Ridge National Laboratory, TN, USA. The three dimensional drawing of capsule structure was then developed. The validity of the material selections for the capsule design was investigated by means of corrosion tests of SiC, Si3N4, Ti, and Mo in liquid Sn at 773 K for 262 hr.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2020

Plant unusual fatty acids: learning from the less common

The plant kingdom contains an abundance of structurally diverse fatty acids referred to as unusual fatty acids. Unusual fatty acids on plant surfaces can form polyesters that contribute to the function of cutin as a barrier for water loss and pathogen protection. Unusual fatty acids are also found as abundant components of seed oils of selected species and often confer desirable properties for industrial and nutritional applications. Here in this paper, we review recent findings on the biosynthesis and metabolism of unusual fatty acids in cutin and seed oils and use of this information for enzyme structure-function studies and seed oil metabolic engineering. We also highlight the recent discovery of unusual fatty acids that are formed from a previously undescribed variation of fatty acid elongation.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Solvation-protection-enabled high-voltage electrolyte for lithium metal batteries

To facilitate the practical application of lithium metal batteries (LMBs), stable interfaces between the electrolyte and the lithium metal must be achieved. Herein, we introduce a solvation protection strategy for designing a functional electrolyte for high-voltage LMBs. Fluoroethylene carbonate (FEC) was introduced as a solvation protection solvent for the difluoroethylene carbonate (DFEC)/trifluoroethyl methyl carbonate (FEMC) electrolyte system to enable the cycling of lithium metal anode. The addition of FEC alters the structures of lithium complexes in solution because of its relatively high solvating power. Through the precise control of the solvation number (> 1) of fluorinated cyclic carbonate (i.e., FEC:DFEC > critical ratio), lithium complexes with Li + solvated solely by FEMC, which decompose on the lithium surface to form detrimental by-products, can be effectively eliminated. Here, the new ternary FEC/DFEC/FEMC system not only maintains the beneficial effect of DFEC in forming a robust solid-electrolyte interphase on the lithium anode, but also confers outstanding anodic stability provided by FEMC, while eliminating detrimental FEMC decomposition through the solvation protection effect of FEC. Clearly, this ternary system outperforms the FEC/FEMC and DFEC/FEMC binary systems in facilitating the stable cycling of LMBs.

25 ENERGY STORAGE↗

NASA NTRS1994

The use of silica aerogel to collect interplanetary dust in space

We report on impact experiments to evaluate the suitability of silica aerogel as a capture medium for interplanetary dust particles in space. The structure of silica aerogel is such that even micrometer-sized hypervelocity particles may sense it as a target of very low density; consequently shock stresses and temperatures due to impact should be minimized. We performed impact experiments in a light gas gun that employed projectiles manufactured from forsterite, pyrrhotite, and calcite. From these experiments we have developed techniques that will permit the successful extrication of interplanetary dust particles from aerogel. We note a rough correlation between increasing particle penetration lengths and decreasing aerogel density, and there is a poor correlation of track lengths with impact velocity at laboratory-attainable velocities of 5-7 km/s. We conclude that aerogel track length should not be used even as (crude) velocity indicators. Transmission electron microscope studies show the re covered particulate residues are encased in melted silica aerogel, which possibly protects the residue from some impact damage. Individual minerals within interplanetary dust are expected to exhibit differential survival, and may be vaporized, melted, dehydrated, or structurally reordered. However, some mineral grains should successfully be captured in an unmelted state at encounter velocities less than 8 km/s.

Zolensky, Michael E.↗

DOE OSTI2024

Prefusion-stabilized SARS-CoV-2 S2-only antigen provides protection against SARS-CoV-2 challenge

Ever-evolving SARS-CoV-2 variants of concern (VOCs) have diminished the effectiveness of therapeutic antibodies and vaccines. Developing a coronavirus vaccine that offers a greater breadth of protection against current and future VOCs would eliminate the need to reformulate COVID-19 vaccines. Here, we rationally engineer the sequence-conserved S2 subunit of the SARS-CoV-2 spike protein and characterize the resulting S2-only antigens. Structural studies demonstrate that the introduction of interprotomer disulfide bonds can lock S2 in prefusion trimers, although the apex samples a continuum of conformations between open and closed states. Immunization with prefusion-stabilized S2 constructs elicits broadly neutralizing responses against several sarbecoviruses and protects female BALB/c mice from mouse-adapted SARS-CoV-2 lethal challenge and partially protects female BALB/c mice from mouse-adapted SARS-CoV lethal challenge. These engineering and immunogenicity results should inform the development of next-generation pan-coronavirus therapeutics and vaccines.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1979

Thermal-structural Design Study of an Airframe-integrated Scramjet

Design concepts for the cooled structures assembly for the Langley Scramjet engine, for engine subsystems, and for the aircraft/engine interface were developed and evaluated. Results show that the objectives for the Scramjet engine can be met. A thermal protection system was defined that makes it possible to attain a life of 100 hours and 1000 cycles, which is the specified goal. With stoichiometric combustion, the fuel provides an adequate heat sink for cooling the engine at Mach numbers up to 9 at the minimum fuel flow condition. The mechanical design is feasible for manufacture using conventional materials. For the cooled structures in a six-module engine, the mass per unit capture area is 1328 kg/sq m (259 lb/sq ft). The total mass of a six-module engine assembly including the fuel system is 1577 kg (3477 lb).

Buchmann, O. A.↗

DOE OSTI2022

Additively Manufactured Tamper Evident Container

Los Alamos National Laboratory has developed a revolutionary and reliable new tamper evident container (TEC) to monitor and protect the health, security, and distribution of high-value assets, technological advancements, products, materials and more that are critical to the operations of businesses and government organizations. Unlike traditional tamper evident seals, the entire TEC serves as a seal, with encrypted on-board electronics able to continuously monitor and log structural health data including but not limited to force, temperature, pressure, humidity, orientation, radiation, acceleration, or vibration as needed. Analog and encrypted digital boards safely stored inside the TEC permanently record the complete integrity history of the protected items and have the ability to alert the TEC owners or take immediate defensive actions should a disruptive or tamper event take place.

36 MATERIALS SCIENCE↗

NASA NTRS2011

Mars Exploration Rover Heatshield Observation Campaign

Mars Exploration Rovers↗

DOE OSTI2023

Mitigating Corrosion in Mg Sheet in Conjunction with a Sheet-Joining Method that Satisfies Structural Requirements within Sub-assemblies

This work was undertaken as a LightMAT project funded by the DOE-Vehicles Technology Office. The goal of this work was to develop corrosion protection strategies that simultaneously mitigate corrosion and achieve Class-A surface finish for Mg components in automotive applications. While automotive metals such as steel and aluminum are protected against corrosion through a variety of coating schemes/packages, the efficacy of these existing coating schemes for Mg and Mg- joints is not clear and needs to be determined. Therefore, five commercially available coating schemes and two joining techniques (riveting and Arplas resistance spot welding) were evaluated. The corresponding individual Mg sheet coupons or Mg/Mg joint test coupons were provided by Magna that were then corrosion tested at PNNL using ASTM B117 procedure. The microstructures and mechanical properties of the coupons were analyzed to determine the effectiveness of the joining and corrosion mitigation strategies. Of the coating schemes evaluated, Henkel Bonderite MgC 2.0 pre-treatment + E-coat showed the best corrosion protection and surface finish for individual Mg coupons and Arplas resistance spot welded coupons. However, the strength of Mg/Mg welded joint was reduced after corrosion testing due to some corrosion at the weld nugget. Mg/Mg rivet joints in conjunction with Chemetall oxisilan pre-treatment + polyurethane coating showed good corrosion resistance and some discoloration on the surface finish. Coating schemes comprising pre-treatment with Alodine 5200 + E-coat or Bonderite 1455 + polyurethane coating, in conjunction with Al rivet joints, showed significant corrosion and extensive discoloration of the surface. We anticipate that the results from this work will provide useful guidance to the automotive industry in selecting the appropriate combinations of corrosion protection coatings and joining techniques to fabricate light-weight Mg-based automotive components.

36 MATERIALS SCIENCE↗

NASA NTRS1973

Apollo experience report: Spacecraft heating environment and thermal protection for launch through the atmosphere of the earth

The techniques that were used to define the aerothermodynamic environment of the Apollo spacecraft during the boost phase and to predict the structural temperatures of the spacecraft are discussed. The wind-tunnel and radiant-heating tests that were used to support the analytical predictions are discussed. The analytical predictions are discussed. The accuracy of the boost-phase heating-analysis techniques is shown by comparing the techniques with flight data. The analytical techniques for predicting heating characteristics and structural temperatures of the spacecraft were adequate for predicting the temperatures of the Apollo spacecraft during the boost phase.

Dotts, R. L.↗

DOE OSTI2022

Anticorrosive epoxy coatings from direct epoxidation of bioethanol fractionated lignin

The development of lignin-based anticorrosive epoxy coatings for steel protection is beneficial for both alleviating the fossil resource depletion and value-added utilization of lignin but remains a challenge due to the inherent heterogeneous structure of lignin. Here, in this study, we selectively extract the low molecular weight (MW) fraction of a crop residue-derived enzymatic hydrolysis lignin (EHL) through a bioethanol fractionation process and prepare epoxy resin by direct epoxidation of the bioethanol fractionated lignin (BFL). The coatings are then fabricated using 20–100 wt% of BFL-based epoxy resin (LEp) as the commercial epoxy resin substitute. The low MW and high p-hydroxyphenyl content of the BFL offer high solubility and good workability for BFL and LEp during epoxidation and coating production, respectively. Lignin-based coatings with 20–40 wt% LEp exhibit good adhesion property (5B) and superior corrosion resistance, compared to the commercial epoxy coating. Although coating with high LEp concentrations (i.e., 60–100 wt%) resulted in decreased adhesion strength, the coating with 100 wt% LEp still displayed corrosion protection performance comparable to that of the commercial epoxy coating. Overall, this study provides a simple and effective approach to converting lignin to epoxy resins for a wide variety of surface coating applications.

09 BIOMASS FUELS↗