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All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

The effect of gravity modulation on thermosolutal convection

In a gravitational field, the opposing effects of components of different diffusivities, for example, temperature and solute, in the density profile in a fluid may produce convective instabilities that exhibit a broad range of dynamical behavior. The effect of time periodic vertical gravity modulation on the onset of these instabilities in an infinite horizontal layer with stress free boundaries is examined. This work is viewed as a first step in expanding previous results in solidification to the full problem of characterizing the effects of gravity modulation in thermosolutal convection during the directional solidification of binary alloys. Calculations carried out both with and without steady background acceleration are presented, the latter results being relevant to microgravity conditions.

Saunders, Bonita V.↗
NASA NTRS2004

Advanced Technology Development for Stirling Convertors

A high-efficiency Stirling Radioisotope Generator (SRG) for use on potential NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company, and NASA Glenn Research Center (GRC). These missions may include providing spacecraft onboard electric power for deep space missions or power for unmanned Mars rovers. GRC is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall power system. Performance and mass improvement goals have been established for second- and thirdgeneration Stirling radioisotope power systems. Multiple efforts are underway to achieve these goals, both in-house at GRC and under various grants and contracts. The status and results to date for these efforts will be discussed in this paper. Cleveland State University (CSU) is developing a multi-dimensional Stirling computational fluid dynamics code, capable of modeling complete convertors. A 2-D version of the code is now operational, and validation efforts at both CSU and the University of Minnesota are complementing the code development. A screening of advanced superalloy, refractory metal alloy, and ceramic materials has been completed, and materials have been selected for creep and joining characterization as part of developing a high-temperature heater head. A breadboard characterization is underway for an advanced controller using power electronics for active power factor control with a goal of eliminating the heavy tuning capacitors that are typically needed to achieve near unity power factors. Key Stirling developments just initiated under recent NRA (NASA Research Announcement) awards will also be discussed. These include a lightweight convertor to be developed by Sunpower Inc. and an advanced microfabricated regenerator to be done by CSU.

Thieme, Lanny G.↗
NASA NTRS2013

High-Performance, Low-Temperature-Operating, Long-Lifetime Aerospace Lubricants

The synthesis and characterization of six new ionic liquids, with fluoroether moeties on the imidazolium ring, each with vapor pressures shown to be <10(exp -7 Torr at 25 C, have been demonstrated. Thermal stability of the ionic liquids up to 250 C was demonstrated. The ionic liquids had no measurable influence upon viscosity upon addition to perfluoropolyether (PFPE) base fluids. They also had no measureable influence upon corrosion on steel substrates upon addition to base fluids. In general, 13 to 34% lower COFs (coefficients of friction), and 30 to 80% higher OK load of base fluids upon addition of the ionic liquids was shown. The compound consists of a 1,3-disubstituted imidazolium cation. The substituents comprise perfluoroether groups. A bis(trifluoromethanesulfonyl) imide anion counterbalances the charge. The fluorinated groups are intended to enhance dispersion of the ionic liquid in the PFPE base fluid. The presence of weak Van der Waals forces associated with fluorine atoms will limit interaction of the substituents on adjacent ions. The longer interionic distances will reduce the heat of melting and viscosity, and will increase dispersion capabilities.

Bergeron, Bryan↗
NASA NTRS2016

Space Launch System Booster Separation Aerodynamic Testing in the NASA Langley Unitary Plan Wind Tunnel

A wind-tunnel investigation of a 0.009 scale model of the Space Launch System (SLS) was conducted in the NASA Langley Unitary Plan Wind Tunnel to characterize the aerodynamics of the core and solid rocket boosters (SRBs) during booster separation. High-pressure air was used to simulate plumes from the booster separation motors (BSMs) located on the nose and aft skirt of the SRBs. Force and moment data were acquired on the core and SRBs. These data were used to corroborate computational fluid dynamics (CFD) calculations that were used in developing a booster separation database. The SRBs could be remotely positioned in the x-, y-, and z-direction relative to the core. Data were acquired continuously while the SRBs were moved in the axial direction. The primary parameters varied during the test were: core pitch angle; SRB pitch and yaw angles; SRB nose x-, y-, and z-position relative to the core; and BSM plenum pressure. The test was conducted at a free-stream Mach number of 4.25 and a unit Reynolds number of 1.5 million per foot.

Wilcox, Floyd J., Jr.↗
NASA NTRSDate not supplied

Mechanisms of Interfacial Mixing in the Blown Powder Deposition of Inconel 625 to Copper Alloy for Liquid Rocket Engine Applications

There is an increasing need for functional materials to support high heat flux applications and optimize weight by using bimetallic additive manufacturing (AM). While one promising fabrication technology is the use of blown powder directed energy deposition (DED) AM, challenges remain with bi-metallic combinations. Prominent among these challenges is the need to understand mixing of materials at the bimetallic interface for forming stronger, more durable and reliable joints to extend the versatility of AM into critical applications. One application is the manufacturing of combustion chambers with copper-alloy liners and Superalloy structural jackets. In this application, material combinations are selected for effective heat dissipation, using copper, and retention of strength at high temperatures using Inconel 625. Currently, the dominant problem with this configuration is the highly variable strength of the interface and its correlation with deposition parameters. In this study, samples were fabricated at several vendors with Inconel 625 deposited onto wrought C-18150 (Cu-Cr-Zr) to form a bimetallic interface. Characterization of the interfaces were achieved through optical and electron microscopy, mechanical testing of mini tensile specimens, and electron dispersion spectroscopy to understand diffusion and bulk mixing behaviors at the joint. A theoretical framework was constructed in the context of solidification and mixing mechanisms to explain the resulting differences in the interface. This qualitative approach utilized a fluid dynamics perspective to sum the order of magnitudes of the various acting forces on the weld pool during deposition to predict convection trends based off known parameters. The predicted trends for each vendor are compared to obtain a better understanding of how mixing in the molten pool varied based on deposition parameters.

Additive Manufacturing↗
NASA NTRSDate not supplied

Investigation of Liquid Fuel Injection Processes in a Rotating Detonation Combustor using Megahertz Planar Laser-Induced Fluorescence Imaging

Direct imaging of liquid fuel injection is performed within an optically accessible rotating detonation combustor (RDC) using planar laser-induced fluorescence (PLIF) to spatio-temporally resolve the highly dynamic spray characteristics at rates up to 1 MHz. The RDC is operated on air and hydrogen to sustain a stable, cyclically propagating detonation wave with cycle periods of up to ∼250 μs. One of the hydrogen fuel injection sites is replaced with a liquid jet to introduce a diesel spray as a fuel surrogate to enable tracer-free fluorescence excitation using the 355 nm third-harmonic output of a burst-mode Nd:YAG laser. The time-resolved PLIF measurements reveal the evolution of the highly unsteady spray, including the dwell period after the arrival of the detonation wave, the jet recovery, breakup and entrainment into the supersonic crossflow of air, propagation into the detonation chamber, and interaction with the detonation wave. Following passage of the detonation wave, the spray characteristics reveal significant changes in the momentum flux ratio between the liquid and air streams, altering the jet trajectory and temporarily halting fuel delivery to the detonation channel. This temporary cessation of fuel spray injection into the combustor is quantified, along with the fill rate as a function of time. As the injection system recovers, the fuel spray eventually returns to a quasi-steady position prior to the arrival of the detonation wave, allowing qualitative comparisons with theoretical jet trajectories for a range of air mass-flux conditions. These data, enabled by ultra-high-speed PLIF imaging, represent some of the first detailed measurements for characterizing and quantifying the interactions of liquid jets and detonations in an operating RDC.

Propulsion↗
NASA NTRSDate not supplied

Recent Langley Aerothermodynamic Laboratory Testing (2019-2022)

In support of flight programs, multiple wind tunnel entries were conducted on reentry vehicle configurations to investigate blunt body aeroheating environments. Blunt body block thermal protection system (TPS) roughness, the Low-Earth Orbit Flight Test of an Inflatable Decelerator aeroshell scalloping, and a woven TPS all were tested to determine the effects of those parameters on increased surface heating to the vehicle. Commercial Crew Program studies also utilized the speed and ease of testing in the LAL to analyze parametric databases of low-earth reentry configurations, like the Boeing CST-100, and vehicles designed to travel to the moon or Mars, such as the SpaceX Starship. LAL wind tunnel investigations also supported several DoD and AFRL flight projects, such as HIFiRE 6 and BOLT. External customers leveraged the LAL testing capability to advance their research programs, including UPSTAR, RocketLab, and Lawrence Livermore National Laboratory. Academia groups benefitted from the inexpensive cost to test in the tunnels for many university collaborations, such as studies conducted in partnership with the University of Maryland on a flat plate, using a pressure rake and investigating fluid structure interactions. Multiple studies in collaboration with Purdue considered boundary layer transition on various cone configurations. Another study was conducted using a cone with shaped roughness elements borrowed from the Arnold Engineering Development Complex. Internal testing included studies using a phosphor thermography system that can measure higher temperatures than the current LAL phosphor capability and a characterization study of the noise in the wind tunnel flow. The breadth of testing across research and commercial paradigms, both internal and external to NASA, different configurations, a variety of test techniques and aerodynamic and aerothermal environments will be discussed in this overview presentation of the recent work conducted in the LAL.

wind tunnel test↗
DOE OSTI2020

Continued Validation Studies using the MOOSE Framework for Plasma Simulation with Electromagnetics

Resources and tools for the modeling and simulation of low-temperature plasma (LTP) discharges are increasingly vital to progress in the field in order to properly characterize and study complex source designs and plasma chemistries beyond the scope of traditional diagnostics. Open-source software provides powerful platforms for this work and can enable community-driven LTP R&D. Within the Multiphysics Object-Oriented Simulation Environment (MOOSE) open-source framework [1], capabilities have been demonstrated in the areas of plasma fluids (Zapdos [2]), plasma chemistry (CRANE [3]), and general electromagnetic wave theory (Electromagnetic Library for Kinetics & fluids [ELK] [4]). ELK has since been coupled to Zapdos/CRANE to enable fully coupled electromagnetic plasma simulations. This talk will detail the continued validation efforts and discuss Zapdos-ELK-CRANE code coupling with various-low temperature plasma sources. The impact of fully coupled electromagnetics on process parameters (e.g., temperature and electron/ion energy) versus an electrostatic description will also be discussed. [1] Permann et al., SoftwareX, 11 (2020) 100430. [2] Lindsay et al., J. Phys. D: Appl. Phys. 49 (2016) 235204. [3] Keniley et al., Talk, GEC Session DT3.00002 (2019). [4] Icenhour et al., Talk, GEC Session RR1.00006 (2019). Acknowledgements: INL Graduate Fellowship Program, NSF SI2 Grant 1740300, U.S. Dept. of Energy Office of Science Graduate Student Research Program

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Characterization of surface–solute interactions by diffusioosmosis

The accurate measurement of wall zeta potentials and solute–surface interaction length scales for electrolyte and non-electrolyte solutes, respectively, is critical to the design of many biomedical and microfluidic applications. We present a novel microfluidic approach using diffusioosmosis for measuring either the zeta potentials or the characteristic interaction length scales for surfaces exposed to, respectively, electrolyte or non-electrolyte solutes. When flows containing different solute concentrations merge in a junction, local solute concentration gradients can drive diffusioosmotic flow due to electrokinetic, steric, and other interactions between the solute molecules and solid surfaces. We demonstrate a microfluidic system consisting of a long, narrow pore connecting two large side channels in which solute concentration gradients drive diffusioosmosis within the pore, resulting in predictable fluid velocity/pressure and solute profiles. Furthermore, we present analytical results and a methodology to determine the zeta potential or interaction length scale for the pore surfaces based on the solute concentrations in the main side channels, the flow rate in the pore, and the pressure drop across the pore. We apply this method to the experimental data of Lee et al. to predict the zeta potentials of their system, and we use 3D numerical simulations to validate the theory and show that end effects caused by the junctions are negligible for a wide range of parameters. Because the dynamics in the proposed system are driven by diffusioosmosis, this technique does not suffer from certain disadvantages associated with the use of sensitive electronics in traditional zeta potential measurement approaches such as streaming potential, streaming current, or electroosmosis. As a result, to the best of our knowledge this is the first flow-based approach to characterize surface/solute interactions with non-electrolyte solutes.

42 ENGINEERING↗
NASA NTRS1987

Spacelab Life Sciences flight experiments: an integrated approach to the study of cardiovascular deconditioning and orthostatic hypotension

The microgravity environment of spaceflight produces rapid cardiovascular changes which are adaptive and appropriate in that setting, but are associated with significant deconditioning and orthostatic hypotension on return to Earth's gravity. The rapidity with which these space flight induced changes appear and disappear provides an ideal model for studying the underlying pathophysiological mechanisms of deconditioning and orthostatic hypotension, regardless of etiology. Since significant deconditioning is seen after flights of very short duration, muscle atrophy due to inactivity plays, at most, a small role. These changes in circulatory control associated with cephalad fluid shifts, rather than inactivity per se, are probably more important factors. In order to test this hypothesis in a systematic way, a multidisciplinary approach which defines and integrates inputs and responses from a wide variety of circulatory sub-systems is required. The cardiovascular experiments selected for Spacelab Life Sciences flights 1 and 2 provide such an approach. Both human and animal models will be utilized. Pre- and post-flight characterization of the payload crew includes determination of maximal exercise capacity (bicycle ergometry), orthostatic tolerance (lower body negative pressure), alpha and beta adrenergic sensitivity (isoproterenol and phenylephrine infusions), baroreflex sensitivity (ECG-gated, stepwise changes in carotid artery transmural pressure with a pneumatic neck collar), and responses to a 24 h period of 5 deg head-down tilt. Measurements of cardiac output (CO2 and C2H2 rebreathing), cardiac chamber dimensions (phased-array 2-dimensional echocardiography), direct central venous pressure, leg volume (Thornton sock), limb blood flow and venous compliance (occlusion plethysmography), blood and plasma volumes, renal plasma flow and glomerular filtration rates, and various hormonal levels including catecholamines and atrial natriuretic factor will also be obtained. The central venous catheter will be inserted immediately pre-launch and monitored with heart rate and blood pressure in-flight until cardiac output, respiratory gas exchange and quantitative 2D echocardiography measurements can be performed. In-flight hemodynamic measurements will be repeated at rest and during submaximal exercise daily and also during maximal exercise midway through the flight to document the timecourse and extent of cardiovascular changes in the payload crew. Parallel studies are planned for the animals. In addition to measurements of right atrial and aortic pressures and cardiac output, a dorsal micro-circulatory chamber will allow determinations of changes in capillary and venular architecture and function in six of the rats. The techniques and findings from many of the SLS-1 and 2 supporting studies have already yielded significant information about circulatory regulation in patients with both hypo- and hypertension. The flight experiments themselves will provide new data to test the validity of both animal and human models currently used for simulating the fluid shifts of a micro-gravity environment. The development of effective countermeasures, not only for short and long duration space travellers, but also for Earth-bound medical patients can then be physiologically based on experimental data rather than anecdote.

Non-NASA Center↗
DOE OSTI2017

High-Resolution X-Ray and Neutron Computed Tomography of an Engine Combustion Network Spray G Gasoline Injector

Given the importance of the fuel-injection process on the combustion and emissions performance of gasoline direct injected engines, there has been significant recent interest in understanding the fluid dynamics within the injector, particularly around the needle and through the nozzles. Furthermore, the pressure losses and transients that occur in the flow passages above the needle are also of interest. Simulations of these injectors typically use the nominal design geometry, which does not always match the production geometry. Computed tomography (CT) using x-ray and neutron sources can be used to obtain the real geometry from production injectors, but there are trade-offs in using these techniques. X-ray CT provides high resolution, but cannot penetrate through the thicker parts of the injector. Neutron CT has excellent penetrating power but lower resolution. Here, we present results from a joint effort to characterize a gasoline direct injector representative of the Spray G injector as defined by the Engine Combustion Network. High-resolution (1.2 to 3 µm) x-ray CT measurements from the Advanced Photon Source at Argonne National Laboratory were combined with moderate-resolution (40 µm) neutron CT measurements from the High Flux Isotope Reactor at Oak Ridge National Laboratory to generate a complete internal geometry for the injector. This effort combined the strengths of both facilities’ capabilities, with extremely fine spatially resolved features in the nozzles and injector tips and fine resolution of internal features of the needle along the length of injector. Analysis of the resulting surface model of the internal fluid flow volumes of the injector reveals how the internal cross-sectional area and nozzle hole geometry differs slightly from the design dimensions. A simplified numerical simulation of the internal flow shows how deviations from the design geometry can alter the flow inside the sac and holes. Our results of this study will provide computational modelers with very accurate solid and surface models for use in computational fluid dynamics studies and experimentalists with increased insight into the operating characteristics of their injectors.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

Liouvillian integrability of gravitating static isothermal fluid spheres

We examine the integrability properties of the Einstein field equations for static, spherically symmetric fluid spheres, complemented with an isothermal equation of state, ρ = np. In this case, Einstein's equations can be reduced to a nonlinear, autonomous second order ordinary differential equation (ODE) for m/R (m is the mass inside the radius R) that has been solved analytically only for n = -1 and n = -3, yielding the cosmological solutions by De Sitter and Einstein, respectively, and for n = -5, case for which the solution can be derived from the De Sitter's one using a symmetry of Einstein's equations. The solutions for these three cases are of Liouvillian type, since they can be expressed in terms of elementary functions. Here, we address the question of whether Liouvillian solutions can be obtained for other values of n. To do so, we transform the second order equation into an equivalent autonomous Lotka–Volterra quadratic polynomial differential system in R² and characterize the Liouvillian integrability of this system using Darboux theory. We find that the Lotka–Volterra system possesses Liouvillian first integrals for n = -1, -3, -5, which descend from the existence of invariant algebraic curves of degree one, and for n = -6, a new solvable case, associated to an invariant algebraic curve of higher degree (second). For any other value of n, eventual first integrals of the Lotka–Volterra system, and consequently of the second order ODE for the mass function must be non-Liouvillian. This makes the existence of other solutions of the isothermal fluid sphere problem with a Liouvillian metric quite unlikely.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Influence of Longer Range Transfer of Vapor Interface Modified Caging Constraints on the Spatially Heterogeneous Dynamics of Glass-Forming Liquids

Based on the elastically collective nonlinear Langevin equation (ECNLE) theory of bulk relaxation in glass-forming liquids, and our recent ideas of how interface-nucleated modification of caging constraints are spatially transferred into the interior of a thick film, we present a force-based theory for dynamical gradients in thick films with one vapor interface that includes collective elasticity effects. Quantitative applications to the foundational hard sphere fluid and polymer melts of diverse fragilities are presented. In this work, we predict a roughly exponential spatial variation of the total activation barrier which is nonperturbatively modified to similar to 10 particle diameters into the film. This leads, to leading order, to the prediction of a reduced alpha relaxation time gradient of a double-exponential form characterized by a nearly constant spatial decay length, in qualitative accord with simulations. The relaxation acceleration at the surface grows exponentially with increasing packing fraction or decreasing temperature. The rate of increase with cooling of the alpha time strongly weakens upon approaching the vapor interface, with the top two layers remaining liquid-like down to similar to ~80-85% of the bulk glass transition temperature. These spatially heterogeneous changes of the temperature variation of the alpha time result in a large and long-range gradient of the local glass transition temperature. An average interfacial layer thickness relevant to ensemble-averaged dielectric and other experiments is also computed. It is predicted to be rather large at the bulk glass transition temperature, decreasing roughly linearly with heating. Remarkably, to leading order the ratio of this layer-averaged interfacial relaxation time to its bulk analogue is invariant to chemistry, volume fraction, and temperature and of modest absolute magnitude. Spatially inhomogeneous power law decoupling of the alpha relaxation time from its bulk value is predicted, with an effective exponent that decays to zero with distance from the free surface in a nearly exponential manner, trends which are in qualitative accord with recent simulations. Finally, this behavior and the double-exponential alpha time gradient are related and can be viewed as consequences of an effective quasi-universal factorization of the total barrier in films into the product of its bulk-temperature-dependent value times a function solely of location in the film.

36 MATERIALS SCIENCE↗
DOE OSTI2016

The effect of oxygen vacancies on water wettability of transition metal based SrTiO 3 and rare-earth based Lu 2 O 3

Understanding the structural, physical and chemical properties of the surface and interfaces of different metal-oxides and their possible applications in photo-catalysis and biology is a very important emerging research field. Motivated in this direction, this article would enable understanding of how different fluids, particularly water, interact with oxide surfaces. We have studied the water contact angle of 3d transition metal oxide thin films of SrTiO 3 , and of 4f rare-earth oxide thin films of Lu 2 O 3 . These metal oxides were grown using pulsed laser deposition and they are atomically flat and with known orientation and explicitly characterized for their structure and composition. Further study was done on the effects of oxygen vacancies on the water contact angle of the 3d and 4f oxides. For 3d SrTiO 3 oxide with oxygen vacancies, we have observed an increase in hydroxylation with consequent increase of wettability which is in line with the previous reports whereas an interesting opposite trend was seen in the case of rare-earth Lu 2 O 3 oxide. Density functional theory simulations of water interaction on the above mentioned systems have also been presented to further substantiate our experimental findings.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Identified corrosion and erosion mechanisms in SCO2 Brayton Cycles.

Supercritical Carbon Dioxide (S-CO2) is an efficient and flexible working fluid for power production. Research to interface S-CO2 systems with nuclear, thermal solar, and fossil energy sources is currently underway. To proceed, we must address concerns regarding compatibility of materials, at high temperature, and compatibility between significantly different heat transfer fluids. Dry, pure S-CO2 is thought to be relatively inert [1], while the addition of ppm levels of water and oxygen result in formation of a protective chromia layer and iron oxide [2]. Thin oxides are favorable as diffusion barriers, and for their minimal impact on heat transfer. While S-CO2 is typically understood to be the secondary fluid, many varieties of primary fluids exist for nuclear applications. Molten salts, for use in the Molten Salt Reactor concept, are given as an example to contrast the materials requirements of primary and secondary fluids. Thin chromia layers are soluble in molten salt systems (nitrate, chloride, and fluoride based salts) [3-8], making materials selection for heat exchangers a precarious balancing act between high temperature oxidation (S-CO2) and metal dissolution (salt side of heat exchanger). Because concerns have been raised regarding component lifetimes, S-CO2 work has begun to characterize starting materials and to establish a baseline by analysis of 1) as-received stainless steel piping, and 2) piping exposed to S-CO2 under typical operating conditions with Sandia National Laboratories Brayton systems. A second issue discovered by SNL involves substantial erosion in the turbine blade and inlet nozzle. It is believed that this is caused by small particulates that originate from different materials around the loop that are entrained by the S-CO2 to the nozzle, where they impact the inlet nozzle vanes, causing erosion. We believe that, in some way, this is linked to the purity of the S-CO2, the corrosion contaminants, and the metal particulates that are present in the loop and its components.

Fleming, Darryn D.↗
DOE OSTI2017

Triple Plate Mold Final Report: Optimization of the Mold Design and Casting Parameters for a Thin U-10mo Fuel Casting

This work describes the experiments and modeling that have been performed to improve and try to optimize the simultaneous casting of three plates of U-10wt%Mo in a single coil vacuum induction melting (VIM) furnace. The plates of interest are 280 mm wide by 203 mm tall by 5 mm thick (11" x 8" x 0.2"). The initial mold design and processing parameters were supplied by Y-12. The mold and casting cavity were instrumented with a number of thermocouples, and the casting performed to determine the thermal history of the mold and casting. The resulting cast plates were radiographed and numerous defects identified. Metallography was performed to help identify the nature of the radiographically observed defects. This information was then used to validate a mold filling and solidification model of that casting. Based on the initial casting, good casting design practice, and process simulation of several design alternatives, a revised design was developed with the goal of minimizing casting defects such as porosity. The redesigned mold had a larger hot-top and had its long axis along the horizontal direction. These changes were to try to develop a strong thermal gradient conducive to good feeding and minimization of micro- and macroporosity in the cast plates. An instrumented casting was then performed with the revised mold design and a linear distributor. This design yielded cast plates with significantly less radiographically identified defects. Unfortunately, there was significant variation in plate weight and metal content in their hot-tops. Fluid flow simulations were then performed on this mold/distributor design. This helped identify the issue with this linear distributor design. Additional simulations were then performed on candidate distributor redesigns and a preferred distributor annular design was identified. This improved annular design was used to produce a third instrumented casting with favorable results. These refined designs and their radiographic characterization are compared to the initial design.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Creep and Fatigue Characterization of High Strength Alloy Thin Sections in Advanced CO2 Heat Exchangers

The objective of this work was to characterize and model elevated temperature creep and fatigue behavior for thin sheet and foil forms of gamma-prime strengthened alloys in wrought form and as-processed folded and brazed constructions. This work was motivated by the demanding temperature and pressure service conditions of the GEN3 Concentrated Solar Power (CSP) and supercritical CO2 (sCO2) power cycle working fluid. More specifically, the possibility of leveraging the superior creep strength of gamma-prime alloys in folded-fin and brazed-plate heat exchanger constructions. Gamma-prime alloys represent a step-change in raw-material strength over solid-solution strengthened alloys. And the folded-fin and brazed-plate heat exchanger architecture is lightweight and leverages cost-effective material stock forms. The investigation contained two parallel paths. (1) The first is referred to as a fundamental investigation where Oak Ridge National Laboratory conducts uniaxial creep testing on thin sheet and foil in wrought form. This effort aimed to serve as a benchmark against a relatively sparse existing database and a baseline comparison for path number 2. (2) The second path is referred to as the practical investigation where Brayton Energy manufactures plate-fin heat exchangers and performs pressurized creep and fatigue testing. This effort aimed to de-risk heat exchanger manufacturing process for service under sCO2 CSP conditions. A total of 14 uniaxial creep tests were completed using Haynes 282 thin sheet and foil. A variety of heat treatments were specified to coincide with path number 2. Baseline metallography of test samples and creep strength performance are contained. Benchmarks relatively to existing thick-form Haynes 282 are made, as well as to other thin-form Nickel-based superalloys. Description of a wrought-form modeling approach for thin gamma-prime alloys is also discussed. A total of 11 pressurized creep and fatigue tests were completed successfully with Haynes 282 heat exchanger prototypes. Manufacturing processing details, testing details, testing results, and failure analysis are discussed. Additionally, creep modeling techniques to predict failure are discussed, and modeling to support technological-to-market. In conclusion, Haynes 282 foils were demonstrated to yield rupture two-to-three orders of magnitude higher than Haynes 230 foils under similar conditions. And the manufactured heat exchanger prototypes demonstrated strength similar to the wrought constituents. Both of which contribute to elevated performance potential or cost savings in practice. Discussion is included.

14 SOLAR ENERGY↗
NASA NTRS1986

Improved silicon carbide for advanced heat engines

The development of silicon carbide materials of high strength was initiated and components of complex shape and high reliability were formed. The approach was to adapt a beta-SiC powder and binder system to the injection molding process and to develop procedures and process parameters capable of providing a sintered silicon carbide material with improved properties. The initial effort was to characterize the baseline precursor materials, develop mixing and injection molding procedures for fabricating test bars, and characterize the properties of the sintered materials. Parallel studies of various mixing, dewaxing, and sintering procedures were performed in order to distinguish process routes for improving material properties. A total of 276 modulus-of-rupture (MOR) bars of the baseline material was molded, and 122 bars were fully processed to a sinter density of approximately 95 percent. Fluid mixing techniques were developed which significantly reduced flaw size and improved the strength of the material. Initial MOR tests indicated that strength of the fluid-mixed material exceeds the baseline property by more than 33 percent. the baseline property by more than 33 percent.

Whalen, Thomas J.↗