SEARCH · Engineering Papers

Results for “spray cooling”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 163 records · Page 9

All sources NASA NTRS DOE OSTI

NASA NTRS1977

Preliminary study of cyclic thermal shock resistance of plasma-sprayed zirconium oxide turbine outer air seal shrouds

Several experimental concepts representing potential high pressure turbine seal material systems were subjected to cyclic thermal shock exposures similar to those that might be encountered under severe engine start-up and shut-down sequences. All of the experimental concepts consisted of plasma-sprayed yttria stabilized ZrO2 on the high temperature side of the blade tip seal shroud. Between the ZrO2 and a cooled, dense metal backing, various intermediate layer concepts intended to mitigate thermal stresses were incorporated. Performance was judged on the basis of the number of thermal shock cycles required to cause loss of seal material through spallation. The most effective approach was to include a low modulus, sintered metal pad between the ZrO2 and the metallic backing. It was also found that reducing the density of the ZrO2 layer significantly improved the performance of specimens with plasma-sprayed metal/ceramic composite intermediate layers.

Bill, R. C.↗

NASA NTRS1990

Failure Morphologies of Cyclically Oxidized ZrO2-Based Thermal Barrier Coatings

Plasma-sprayed thermal barrier coatings (TBC s) were thermal cycle tested in air at 1163 C until spallation of the top coat. Each thermal cycle consisted of a 45 minute exposure at the elevated temperature followed by a 15 minute cool to ambient temperature. The TBC s consisted of a ZrO2-based top coat containing various amounts of Y2O3, and/or Yb2O3, Gd2O3, and Nd2O3 applied by air plasma spraying and an MCrAlY bond coat applied by low pressure plasma spraying. The substrate was a single-crystal, Ni-based superalloy. The time to failure of the top coat varied from tens to hundreds of thermal cycles based on composition and spray parameters. The bond coat/top coat interface morphology and sample cross sections were examined by SEM and optical microscopy. The failure morphology following the cyclic oxidation testing will be discussed in relationship to the properties of the ceramic top coats.

Nesbit, James A.↗

NASA NTRS1981

Kinematical analysis of flare spray ejecta observed in the corona

Observations in H-alpha, soft X-ray, white light and radio wavelengths are used to track cool and hot material from limb de-occultation to the extent of six solar radii. The kinematics and thermodynamics of the internal material are determined, along with the overall mass and energy budget of the event. It is found that the majority of the mass and energy is linked with the coronal material, but at least 20% of the ejected mass originated as near-surface prominence material, leading to the conclusions that the upper part of the prominence was being heated to coronal temperatures as it rose through the corona. Evidence was found that a moving type IV burst, indicative of strong magnetic fields, was associated with the upper part of the prominence, and the observations are judged to be most consistent with magnetic propulsion models of coronal transients.

Webb, D. F.↗

NASA NTRS1976

Two-layer thermal barrier coating for turbine airfoils - furnace and burner rig test results

A simple, two-layer plasma-sprayed thermal barrier coating system was developed which has the potential for protecting high temperature air-cooled gas turbine components. Of those coatings initially examined, the most promising system consisted of a Ni-16Cr-6Al-0.6Y (in wt%) thermal barrier coating (about 0.005 to 0.010 cm thick) and a ZrO2-12Y2O3 (in wt%) thermal barrier coating (about 0.025 to 0.064 cm thick). This thermal barrier substantially lowered the metal temperature of an air-cooled airfoil. The coating withstood 3,200 cycles (80 sec at 1,280 C surface temperature) and 275 cycles (1 hr at 1,490 C surface temperature) without cracking or spalling. No separation of the thermal barrier from the bond coating or the bond coating from the substrate was observed.

Stecura, S.↗

NASA NTRS1977

Two-layer thermal barrier coating for high temperature components

A simple two-layer plasma-sprayed thermal barrier coating system was developed which has the potential for protecting high temperature air-cooled gas turbine components. Of the initially examined coatings, the most promising system is an Ni-16Cr-6Al-0.6Y (in wt%) bond coating (about 0.005 to 0.010 cm thick) and a ZrO2-12Y2O3 (in wt%) thermal barrier coating (about 0.025 to 0.064 cm thick). This thermal barrier substantially lowered the metal temperature of the air-cooled airfoil. The coating withstood 3200 cycles (80 s at 1280 C surface temperature) and 275 cycles (1 hr at 1490 C surface temperature) without cracking or spalling. No separation of the thermal barrier from the bond coating or the bond coating from the substrate was observed.

Stecura, S.↗

NASA NTRS1986

Effect of flame-tube head structure on combustion chamber performance

The experimental combustion performance of a premixed, pilot-type flame tube with various head structures is discussed. The test study covers an extensive area: efficiency of the combustion chamber, quality of the outlet temperature field, limit of the fuel-lean blowout, ignition performance at ground starting, and carbon deposition. As a result of these tests, a nozzle was found which fits the premixed pilot flame tube well. The use of this nozzle optimized the performance of the combustion chamber. The tested models had premixed pilot chambers with two types of air-film-cooling structures, six types of venturi-tube structures, and secondary fuel nozzles with two small spray-cone angles.

Gu, Minqqi↗

DOE OSTI2024

LES and RANS Spray Combustion Analysis of OME 3-5 and n-Dodecane

Clean-burning oxygenated and synthetic fuels derived from renewable power, so-called e-fuels, are a promising pathway to decarbonize compression–ignition engines. Polyoxymethylene dimethyl ethers (PODEs or OMEs) are one candidate of such fuels with good prospects. Their lack of carbon-to-carbon bonds and high concentration of chemically bound oxygen effectively negate the emergence of polycyclic aromatic hydrocarbons (PAHs) and even their precursors like acetylene (C 2 H 2 ), enabling soot-free combustion without the soot-NO x trade-off common for diesel engines. The differences in the spray combustion process for OMEs and diesel-like reference fuels like n-dodecane and their potential implications on engine applications include discrepancies in the observed ignition delay, the stabilized flame lift-off location, and significant deviations in high-temperature flame morphology. For CFD simulations, the accurate modeling and prediction of these differences between OMEs and n-dodecane proved challenging. This study investigates the spray combustion process of an OME 3 − 5 mixture and n-dodecane with advanced optical diagnostics, Reynolds-Averaged Navier–Stokes (RANS), and Large-Eddy Simulations (LESs) within a constant-volume vessel. Cool-flame and high-temperature combustion were measured simultaneously via high-speed (50 kHz) imaging with formaldehyde (CH 2 O) planar laser-induced fluorescence (PLIF) representing the former and line-of-sight OH* chemiluminescence the latter. Both RANS and LES simulations accurately describe the cool-flame development process with the formation of CH 2 O. However, CH 2 O consumption and the onset of high-temperature reactions, signaled by the rise of OH* levels, show significant deviations between RANS, LES, and experiments as well as between n-dodecane and OME. A focus is set on the quality of the simulated results compared to the experimentally observed spatial distribution of OH*, especially in OME fuel-rich regions. The influence of the turbulence modeling is investigated for the two distinct ambient temperatures of 900 K and 1200 K within the Engine Combustion Network Spray A setup. The capabilities and limitations of the RANS simulations are demonstrated with the initial cool-flame propagation and periodic oscillations of CH 2 O formation/consumption during the quasi-steady combustion period captured by the LES.

CFD↗

NASA NTRS1967

Metal flame spray coating protects electrical cables in extreme environment

Metal flame spray coating prevents EMF measurement error in sheathed instrumentation cables which are externally attached to cylinders which were cooled on the inside, but exposed to gamma radiation on the outside. The coating provides a thermoconductive path for radiation induced high temperatures within the cables.

Brady, R. D.↗

NASA NTRS1969

Modified cryogenic storage tank subsystem

Internal spray distribution header is put into a liquid hydrogen vaporizer. When connected to the cryogenic material, it equalizes cooling around the circumference of the inlet header.

Burns, W. J.↗

NASA NTRS1981

Progress in Protective Coatings for Aircraft Gas Turbines: A Review of NASA Sponsored Research

Problems associated with protective coatings for advanced aircraft gas turbines are reviewed. Metallic coatings for preventing titanium fires in compressors are identified. Coatings for turbine section are also considered, Ductile aluminide coatings for protecting internal turbine-blade cooling passage surface are also identified. Composite modified external overlay MCrAlY coatings deposited by low-pressure plasma spraying are found to be better in surface protection capability than vapor deposited MCrAlY coatings. Thermal barrier coating (TBC), studies are presented. The design of a turbine airfoil is integrated with a TBC, and computer-aided manufacturing technology is applied.

Merutka, J. P.↗

NASA NTRS2003

Cryogenic Temperature-Gradient Foam/Substrate Tensile Tester

The figure shows a fixture for measuring the tensile strength of the bond between an aluminum substrate and a thermally insulating polymeric foam. The specimen is meant to be representative of insulating foam on an aluminum tank that holds a cryogenic liquid. Prior to the development of this fixture, tensile tests of this type were performed on foam/substrate specimens immersed in cryogenic fluids. Because the specimens were cooled to cryogenic temperatures throughout their thicknesses, they tended to become brittle and to fracture at loads below true bond tensile strengths. The present fixture is equipped to provide a thermal gradient from cryogenic temperature at the foam/substrate interface to room temperature on the opposite foam surface. The fixture includes an upper aluminum block at room temperature and a lower aluminum block cooled to -423 F (approx. -253 C) by use of liquid helium. In preparation for a test, the metal outer surface (the lower surface) of a foam/substrate specimen is bonded to the lower block and the foam outer surface (the upper surface) of the specimen is bonded to the upper block. In comparison with the through-the-thickness cooling of immersion testing, the cryogenic-to-room-temperature thermal gradient that exists during testing on this fixture is a more realistic approximation of the operational thermal condition of sprayed insulating foam on a tank of cryogenic liquid. Hence, tensile tests performed on this fixture provide more accurate indications of operational bond tensile strengths. In addition, the introduction of the present fixture reduces the cost of testing by reducing the amount of cryogenic liquid consumed and the time needed to cool a specimen.

Vailhe, Christophe↗

NASA NTRS2005

Multicomponent, Rare-Earth-Doped Thermal-Barrier Coatings

Multicomponent, rare-earth-doped, perovskite-type thermal-barrier coating materials have been developed in an effort to obtain lower thermal conductivity, greater phase stability, and greater high-temperature capability, relative to those of the prior thermal-barrier coating material of choice, which is yttria-partially stabilized zirconia. As used here, "thermal-barrier coatings" (TBCs) denotes thin ceramic layers used to insulate air-cooled metallic components of heat engines (e.g., gas turbines) from hot gases. These layers are generally fabricated by plasma spraying or physical vapor deposition of the TBC materials onto the metal components. A TBC as deposited has some porosity, which is desirable in that it reduces the thermal conductivity below the intrinsic thermal conductivity of the fully dense form of the material. Undesirably, the thermal conductivity gradually increases because the porosity gradually decreases as a consequence of sintering during high-temperature service. Because of these and other considerations such as phase transformations, the maximum allowable service temperature for yttria-partially stabilized zirconia TBCs lies in the range of about 1,200 to 1,300 C. In contrast, the present multicomponent, rare-earth-doped, perovskite-type TBCs can withstand higher temperatures.

Miller, Robert A.↗

DOE OSTI2022

Thermo-Mechanical Distortion of Tungsten-Coated Steel During High Heat Flux Testing Using Plasma Arc Lamps

An experimental setup and a test section were designed and fabricated for high heat flux testing (HHFT) of neutron-irradiated specimens using water-wall plasma arc lamps. Because of the radiological considerations and limitations of reactor irradiation, the size of the test articles was limited to disks less than 10 mm in diameter. The specimen was clamped onto an actively cooled block, and clamping allowed the insertion of several thermocouples on the back surface of the specimen through a copper (Cu) block. Five vacuum plasma sprayed tungsten (W)–coated F82H steel specimens were subjected to HHFT. Surface profilometry measurements, which were conducted after HHFT, revealed central bowing of the top W surface. This type of residual distortion occurred for all of the specimens, and the larger the specimens were, the larger was the distortion.In an attempt to understand specimen distortion and address the science questions related to the testing of subsize specimens during HHFT, a simplified thermo-mechanical model was developed. By using a measured temperature in the Cu as an isothermal boundary condition, the model eliminated the need for coupling cooling fluid flow models with stress models, greatly simplifying the analysis. The main variable in the proposed model is hC, i.e., the thermal contact conductance between the F82H and the Cu washer. Inelastic properties, including hardening properties, were considered for F82H steel and Cu. Numerical simulation results demonstrated a buildup of residual deformation during HHFT and a very complex state of stress and deformation during typical heat flux (HF) cycling. Additionally, hoop stress evolution during a high heat flux cycle reveals that F82H at an interface with W would be mainly in compression during HF application and experienced a transition to a tension state during cooldown. Also, specimen distortion evolves during each HF cycle, as the specimen bows downward during HF application and upward during the cooldown period between HF cycles. The final specimen distortion, i.e., upward bowing of the specimen center, was qualitatively predicted for hC values of 4000 to 5000 W/(m 2 ·K). This hC range of values, for which bulging is obtained, is at the lower spectrum of the range of values for hC, consistent with the low thermal contact conductance expected from the unpolished F82H surface.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1974

Development of sputtered techniques for thrust chambers, task 1

Filler materials proposed for use in the sputter fabrication regeneratively cooled thrust chambers were evaluated. Low melting castable alloys, CERROBEND. CERROCAST, and CERROTRU, slurry applied SERMETEL 481 and flame-sprayed aluminum were investigated as filler materials. Sputter deposition from a cylindrical cathode inverted magnestron was used to apply an OFHC copper closeout layer to filled OFHC copper ribbed-wall cylindrical substrates. The sputtered closeout layer structure was evaluated with respect to filler material contamination, predeposition machining and finishing operations, and deposition parameters. The application of aluminum by flame-spraying resulted in excessiver filler porosity. Though the outgassing from this porosity was found to be detrimental to the closeout layer structure, bond strengths in excess of 10,500 psi were achieved. Removal of the aluminum from the grooves was readily accomplished by leaching in a 7.0 molar solution of sodium hydroxide at 353 K. Of the other filler materials evaluated, CERROTRU was found to be the most suitable material with respect to completely filling the ribbed-wall cylinders and vacuum system compatibility. However, bond contamination resulted in low closeout layer bond strength with the CERROTRU filler. CERROBEND, CERROCAST, and SERMETEL 481 were found to be unacceptable as filler materials.

Mullaly, J. R.↗

NASA NTRS1999

Optical Imaging of Flow Pattern and Phantom

Time-resolved optical imaging technique has been used to image the spatial distribution of small droplets and jet sprays in a highly scattering environment. The snake and ballistic components of the transmitted pulse are less scattered, and contain direct information about the sample to facilitate image formation as opposed to the diffusive components which are due to multiple collisions as a light pulse propagates through a scattering medium. In a time-gated imaging scheme, these early-arriving, image-bearing components of the incident pulse are selected by opening a gate for an ultrashort period of time and a shadowgram image is detected. Using a single shot cooled CCD camera system, the formation of water droplets is monitored as a function of time. Picosecond time-gated image of drop in scattering cells, spray droplets as a function of let speed and gas pressure, and model calcification samples consisted of calcium carbonate particles of irregular shapes ranging in size from 0. 1 to 1.5 mm affixed to a microscope slide have been measured. Formation produced by an impinging jet will be further monitored using a CCD with 1 kHz framing illuminated with pulsed light. The desired image resolution of the fuel droplets is on the 20 pm scale using early light through a highly scattering medium. A 10(exp -6)m displacement from a jet spray with a flow speed of 100 m/sec introduced by the ns grating pulse used in the imaging is negligible. Early ballistic/snake light imaging offers nondestructive and noninvasive method to observe the spatial distribution of hidden objects inside a highly scattering environment for space, biomedical, and materials applications. In this paper, the techniques we will present are time-resolved K-F transillumination imaging and time-gated scattered light imaging. With a large dynamic range and high resolution, time-gated early light imaging has the potential for improving rocket/aircraft design by determining jets shape and particle sizes. Refinements to these techniques may enable drop size measurements in the highly scattering, optically dense region of multi-element rocket injectors. These types of measurements should greatly enhance the design of stable, and higher performing rocket engines.

Galland, Pierre A.↗

NASA NTRS1938

Heat Transfer to Fuel Sprays Injected into Heated Gases

This report presents the results of a study made of the influence of several variables on the pressure decrease accompanying injection of a relatively cool liquid into a heated compressed gas. Indirectly, this pressure decrease and the time rate of change of it are indicative of the total heat transferred as well as the rate of heat transfer between the gas and the injected liquid. Air, nitrogen, and carbon dioxide were used as ambient gases; diesel fuel and benzene were the injected liquids. The gas densities and gas-fuel ratios covered approximately the range used in compression-ignition engines. The gas temperatures ranged from 150 degrees c. to 350 degrees c.

Selden, Robert F↗

NASA NTRS2010

Advanced Vacuum Plasma Spray (VPS) for a Robust, Longlife and Safe Space Shuttle Main Engine (SSME)

In 1984, the Vacuum Plasma Spray Lab was built at NASA/Marshall Space Flight Center for applying durable, protective coatings to turbine blades for the space shuttle main engine (SSME) high pressure fuel turbopump. Existing turbine blades were cracking and breaking off after five hot fire tests while VPS coated turbine blades showed no wear or cracking after 40 hot fire tests. Following that, a major manufacturing problem of copper coatings peeling off the SSME Titanium Main Fuel Valve Housing was corrected with a tenacious VPS copper coating. A patented VPS process utilizing Functional Gradient Material (FGM) application was developed to build ceramic lined metallic cartridges for space furnace experiments, safely containing gallium arsenide at 1260 degrees centigrade. The VPS/FGM process was then translated to build robust, long life, liquid rocket combustion chambers for the space shuttle main engine. A 5K (5,000 Lb. thrust) thruster with the VPS/FGM protective coating experienced 220 hot firing tests in pristine condition with no wear compared to the SSME which showed blanching (surface pulverization) and cooling channel cracks in less than 30 of the same hot firing tests. After 35 of the hot firing tests, the injector face plates disintegrated. The VPS/FGM process was then applied to spraying protective thermal barrier coatings on the face plates which showed 50% cooler operating temperature, with no wear after 50 hot fire tests. Cooling channels were closed out in two weeks, compared to one year for the SSME. Working up the TRL (Technology Readiness Level) to establish the VPS/FGM process as viable technology, a 40K thruster was built and is currently being tested. Proposed is to build a J-2X size liquid rocket engine as the final step in establishing the VPS/FGM process TRL for space flight.

Holmes, Richard R.↗

NASA NTRS1983

New black paint for cryogenic infrared applications

A black paint has been developed and tested for cryogenic applications involving wavelengths beyond 10 microns. The paint has been used extensively for liquid helium cooled applications in a variety of instruments operating between 10 and 120 microns. The material is applied by brush over a spray or brush applied primer coat. A final covering is applied by either brush or spray. The composition and preparation of the paint are described, as are data about its outgassing properties. Infrared reflection and scattering data obtained by other groups which compare this material to other commercially available surface preparations are presented.

Houck, J. R.↗