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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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At least 1,675 records · Page 93
All sourcesNASA NTRSDOE OSTI
NASA NTRS1983

A basic design fault in ceramic flat packs

Recent moisture resistance tests of various multilayer top brazed ceramic flat packs and leaded and unleaded chip carriers has revealed a serious design defect. These packages, which utilize a tungsten interconnect system, in the presence of high humidity, suffer a galvanic corrosion which anodically consumes the tungsten. This process can continue until the package suffers an open circuit. The test results indicate that the lead plating system does not adequately seal off the interface area where the tungsten stripe egresses from the inside of the package. Leaded and leadless chip carrier packages were also subjected to the moisture resistance test. The familiar red and green corrosion products were visible after the test was completed. Careful sectioning of the chip carriers has revealed that the tungsten interconnect stripe instead of exiting under the castellations, exits at the top of the castellation and is thus vulnerable to the attack of moisture. These basic design faults severely impact the reliability of these packages.

Drotman, B.↗
NASA NTRS1988

Preparation for microgravity - The role of the Microgravity Material Science Laboratory

Experiments at the NASA Lewis Research Center's Microgravity Material Science Laboratory using physical and mathematical models to delineate the effects of gravity on processes of scientific and commercial interest are discussed. Where possible, transparent model systems are used to visually track convection, settling, crystal growth, phase separation, agglomeration, vapor transport, diffusive flow, and polymer reactions. Materials studied include metals, alloys, salts, glasses, ceramics, and polymers. Specific technologies discussed include the General Purpose furnace used in the study of metals and crystal growth, the isothermal dendrite growth apparatus, the electromagnetic levitator/instrumented drop tube, the high temperature directional solidification furnace, the ceramics and polymer laboratories and the center's computing facilities.

Johnston, J. Christopher↗
NASA NTRS1999

X-33/RLV Program Aerospike Engines

Substantial progress was made during the past year in support of the X-33/RLV program. X-33 activity was directed towards completing the remaining design work and building hardware to support test activities. RLV work focused on the nozzle ramp and powerpack technology tasks and on supporting vehicle configuration studies. On X-33, the design activity was completed to the detail level and the remainder of the drawings were released. Component fabrication and engine assembly activity was initiated, and the first two powerpacks and the GSE and STE needed to support powerpack testing were completed. Components fabrication is on track to support the first engine assembly schedule. Testing activity included powerpack testing and component development tests consisting of thrust cell single cell testing, CWI system spider testing, and EMA valve flow and vibration testing. Work performed for RLV was divided between engine system and technology development tasks. Engine system activity focused on developing the engine system configuration and supporting vehicle configuration studies. Also, engine requirements were developed, and engine performance analyses were conducted. In addition, processes were developed for implementing reliability, mass properties, and cost controls during design. Technology development efforts were divided between powerpack and nozzle ramp technology tasks. Powerpack technology activities were directed towards the development of a prototype powerpack and a ceramic turbine technology demonstrator (CTTD) test article which will allow testing of ceramic turbines and a close-coupled gas generator design. Nozzle technology efforts were focused on the selection of a composite nozzle supplier and on the fabrication and test of composite nozzle coupons.

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NASA NTRS2000

Development and Testing of Cooled CMCs for High Thermal Flux Applications

Ceramic Matrix Composites (CMCS) offer the potential for significant weight savings and improved performance for a range of propulsion components utilizing refractory materials. This paper describes the fabrication and testing of functionally graded CMCs produced via a low cost process that represents an order of magnitude cost savings over conventionally fabricated CMCS. Test cylinders were fabricated, characterized and evaluated during exposure to high thermal fluxes of up to 10MW/meters squared at the Laser Hardened Materials Evaluation Laboratory (LHMEL). The bulk density of the CMC tubes was approximately 2.2 grams per cubic centimeters. The performance of cryogenically cooled CMCs was compared with uncooled CMCs against similar thermal loads, and fundamental property data collected for this relatively new breed of CMC. Finally, test thrust cells were fabricated from the functionally graded composite and tested using liquid H2 and O2 propellants at NASA Glen.

Patterson , Mark↗
NASA NTRS2002

HfB2-SiC Materials for Sharp Leading Edges

Future reentry vehicles will need better maneuverability to improve safety and performance. Vehicles with sharp leading edges, as opposed to the blunt nose and leading edges on the current space shuttle, can provide improved lift-to-drag and thus improved maneuverability. Materials capable of operating at temperatures in excess of 2000 C are required. Ultrahigh temperature ceramics (UHTCs) are one class of material being investigated for this application. These materials are diborides of hafnium or zirconium with a second phase of sic. The benefits of using these materials will be discussed as developments in the processing of HfB2/SiC.

Johnson, Sylvia M.↗
NASA NTRS1987

Zirconia toughened SiC whisker reinforced alumina composites small business innovation research

The objective of this phase 1 project was to develop a ceramic composite with superior fracture toughness and high strength, based on combining two toughness inducing materials: zirconia for transformation toughening and SiC whiskers for reinforcement, in a controlled microstructure alumina matrix. The controlled matrix microstructure is obtained by controlling the nucleation frequency of the alumina gel with seeds (submicron alpha-alumina). The results demonstrate the technical feasibility of producing superior binary composites (Al2O3-ZrO2) and tertiary composites (Al2O3-ZrO2-SiC). Thirty-two composites were prepared, consolidated, and fracture toughness tested. Statistical analysis of the results showed that: (1) the SiC type is the key statistically significant factor for increased toughness; (2) sol-gel processing with a-alumina seed had a statistically significant effect on increasing toughness of the binary and tertiary composites compared to the corresponding mixed powder processing; and (3) ZrO2 content within the range investigated had a minor effect. Binary composites with an average critical fracture toughness of 6.6MPam sup 1/2, were obtained. Tertiary composites with critical fracture toughness in the range of 9.3 to 10.1 MPam sup 1/2 were obtained. Results indicate that these composites are superior to zirconia toughened alumina and SiC whisker reinforced alumina ceramic composites produced by conventional techniques with similar composition from published data.

Loutfy, R. O.↗
DOE OSTI2018

Crystal development during carbonation of lime-based mortars in different environmental conditions

Highlights: • High CO{sub 2} and DiloCarb® treatment favour advanced carbonation and self-healing. • In the lime mortar without ceramics, channel type pores occur in the aggregate border. • In the lime mortars with ceramics, vug type pores are produced in the binder during kneading. • The formation of tabular CaCO{sub 3} polymorphs caused an increase in stress leading to microshrinkage cracks. • The use of a ceramic provoked dissolution and then re-precipitation of more stable polymorphs. - Abstract: This study examines crystal development during the carbonation of lime mortars according to the additives used and curing conditions. Two types of samples were prepared, one with sand and the other one additionally including Roman ceramics. These mortars were cured: 1) by spraying with a carbonation accelerator product under laboratory conditions; 2) in a climate chamber under 20 °C, 60% relative humidity, and 1600 ppm CO{sub 2}; and 3) under laboratory conditions as controls. Polarized light microscopy, SEM-EDS and XRD were used at 28, 90, 120 and 180 days to monitor the carbonation process. Observations indicate the development of different CaCO{sub 3} polymorphs, which appeared as metastable phases. The early nucleation of a well-defined calcite phase as the most stable CaCO{sub 3} polymorph was only identified in the chamber-cured samples. Differences in the pore network were observed depending on the composition and morphology of the mortar components and the environmental curing conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Continuous Enzymatic Hydrolysis Development for Improved Saccharification Performance

The Continuous Enzymatic Hydrolysis Development (CEHD) project aims to reduce the cost and commercialization risks of Gen2 biorefinery sugar/lignin/ethanol production through development of a deployable continuous enzymatic hydrolysis process. Recent changes in the technical landscape of commercial enzymatic hydrolysis of Gen2 pretreated biomass dictate that the existing hybrid SSF approach be reconsidered. Most importantly, the current practice of "finishing hydrolysis" in SSF must be abandoned due to the fact that new cellulase/hemicellulose formulations from Novozymes, now the sole supplier of commercial Gen2 enzymes in North America, are now not rated for SSF (see NZ CTec3HS product bulletin). We have recently developed bench scale CEH tools to optimize saccharification of DMR pretreated biomass where, unlike SSF with yeast or Zymomonas, the pH, temperature, oxygen tension, LPMO mediator concentration, and/or removal of end-product inhibitors can be precisely controlled. In scale up, the goal is to use existing commercial cross flow ceramic membrane filtration external loops coupled to enzymatic hydrolysis (EH) reactors. Pretreated biomass solids and enzymes are retained for reaction while solubilized product sugars are removed in situ, with high extents of conversion and longer enzyme lifetimes achieved through a series of reactor-membrane unit stages. The CEHD project is focused on advancing CEH as a transformational, process-intensified, lower-cost method for producing soluble clarified biomass sugars and insoluble lignin-rich streams.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗
DOE OSTI2018

Interfacial Characteristics Investigation for One-Step EDM Drilling of Cooling Holes in TBCs

In this study, the one-step electrical discharge machining of inclined cooling holes is performed in thermal-barrier-coated nickel-based superalloys via the assisting electrode method. The effects of the process parameters, including the inclination angle, peak current, pulse duration, and duty cycle, on interfacial characteristics of cooling holes were investigated. The research results are as follows: After machining, the hardness of TBCs increases slightly and the adhesion strength of ceramic coating has a slight reduction. Delamination prevailingly appears at the ceramic coating/bonding coating interface, and its length at the trailing edge is greater than that at the leading edge. Increasing either the discharge energy or the duty cycle also aggravates the severity of the delamination. Under an excessive peak current of 22.5 A, the complete spalling of the ceramic coating occurs in the vicinity of the holes. Additionally, a reduction in the inclination angle results in a significant increase in delamination cracking and poorer interface integrity. The interfacial microstructure features of the holes vary with the inclination angle. The large-scale spalling of ceramic coating is prone to occur at the trailing edge when using an inclination angle of 30°. The spattering is susceptible to appear at the entrance of the holes under inclination angles of 60° and 75°, and its composition is primarily Ni, C, Zr, Cr, Nb, Fe, and Cu.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Oxygen redox and instability in energy ceramics

Energy ceramics, including solid electrolytes and catalysts for high-temperature fuel/electrolysis cells and oxide cathodes for batteries, often experience harsh chemical and electrochemical conditions. Practical and new applications require that these devices are operated under ever more extreme redox conditions for higher energy density and power density. This challenges the stability of the energy ceramic materials and calls for a better understanding of the degradation mechanisms and innovative strategies for degradation mitigation. Here we present our analysis and perspectives on degradation phenomena in three categories of electrochemical devices of practical interest, including solid oxide fuel/electrolysis cells, protonic ceramic fuel/electrolysis cells, and lithium-ion batteries. We also discuss the stability/degradation of the key ceramic components from the view of oxygen redox and instability arising from anodic bias, transport limitation, and coupled electro-chemo-mechanics at the virtual and physical interfaces. We hope these perspectives provide design principles for electroceramic chemistry, microstructure, and processing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Enhance D. C. resistivity of Ba{sub 0.7}Sr{sub 0.3}TiO{sub 3} ceramic by acceptor (Mn) doping

In the present work, we prepared Ba{sub 0.7}Sr{sub 0.3}TiO{sub 3} and Mn (2 and 3 at % on Ti site) doped Ba{sub 0.7}Sr{sub 0.3}TiO{sub 3} ceramic by sol- gel method. The samples were characterized by X-ray diffraction (XRD). The XRD patterns reveled that Mn ions did not change the perovskite structure of BST (70/30). The dielectric measurements proved that dielectric constant decreased with Mn doping. The dc resistivity was studied by using I-V measurements. The dc resistivity of the BST increased with Mn doping, which suppressed the leakage current.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Structural and electrical properties of ferroelectric Na{sub 0.5} (Bi{sub 1-x}Pr{sub x} ){sub 0.5}TiO{sub 3} (x=0.00 and 0.10) ceramics synthesized by Sol-Gel method

Ferroelectric Na{sub 0.5}(Bi{sub 1-x}Pr{sub x}){sub 0.5}TiO{sub 3} (x=0.00, 0.10) ceramics have been synthesized through sol-gel method. The phase formation has been confirmed by X-ray diffraction analysis of ceramics annealed at 800°C. The relaxation mechanism is observed from variation of dielectric constant with respect to temperature and frequency. Substitution of Pr reduces vacancies and defects identified from leakage current measurements. Further, the polarization Vs electric field (P-E) measurements have been performed at room temperature.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Raman effect, structural and dielectric properties of sol-gel synthesized polycrystalline GaFe{sub 1-x}Zr{sub x}O{sub 3} (0≤x≤0.15)

Polycrystalline ceramic samples of Zirconium (Zr)-doped GaFeO{sub 3} (GaFe{sub 1-x}Zr{sub x}O{sub 3}) were studied using powder X-ray diffraction, complex impedance spectroscopy and Raman spectroscopic measurements to understand the effect of Zr doping on the structural and dielectric properties. The samples with varying Zr content were prepared by Sol-Gel method. X-ray data analysis confirmed the formation of single phase material without formation of any secondary phases and all are crystallized in Pc2{sub 1}n orthorhombic symmetry. Rietveld refinement of the X-ray data suggested an increase in the lattice constants due to size effect and decreases on x = 0.15 due to the effect of change in interplanner spacing. Impedance studies on the samples showed that the dielectric constant increases while loss tangent decrease as the Zr content increases. Raman scattering on GaFe{sub 1-x}Zr{sub x}O{sub 3} (x = 0, 0.05, 0.10, & 0.15) used to understand the composition dependence on phonon modes at room temperature. On Zr doping, Raman modes frequencies shifts to lower energies consistent with the X-ray data.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Tuning Surface Stoichiometry of SOFC Electrodes at the Molecular and Nano-scale for Enhanced Performance and Durability

This project achieved the following objectives. Different cation segregation behaviors of different common SOFC cathodes, including La 0.6 Sr 0.4 Co0.2Fe 0.8 O 3-δ (LSCF), Sr 0.5 Sm 0.5 O 3-δ (SSC), and PrBa 0.5 Sr 0.5 Co 1.5 Fe 0.5 O5 +δ (PBSCF), were determined. We showed how oxygen partial pressure and gas impurities impact the stability of SOFC cathodes. We developed atomic layer deposition (ALD) coating techniques for electrodes and showed that by introducing different elements and different ALD oxidizers, electrode surface chemistry can be altered, resulting in enhanced oxygen reduction kinetics. In addition, we developed solution infiltration technique to enhance performance and durability of electrodes. Different infiltrates as well as different thermal treatment processes were screened to identify the optimal surface modification process that yields both low impedance and high durability. The modified cathode shows excellent stability and has a low area specific resistance (ASR) of only 0.2 Ωcm 2 at 600 °C after over 2000 hours of operation. Further, we developed ceramic anodes, SrFe(Co,Mo)O 3 (SFCM) and SrFe(Ni,Mo)O 3 (SFNM), and enhanced anode oxidation kinetics by solution infiltration or in situ catalyst exsolution from the ceramic anode surface. The modified anodes showed improved performance in full SOFCs, and the optimized anode modification shows high stability for over 400 hours at 550 °C. Moreover, the modified anode also demonstrates high durability in methane. This work provides fundamental understanding of electrode surface chemistry and demonstrates a simple, facile, cost-effective approach to enhance catalytic activity and durability of SOFC electrodes.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1988

Composites That Exceed Superalloys In Rupture Strength

Ceramic-fiber-reinforced iron alloys show promise as turbine parts for intermediate-temperature service. Intermediate-temperature composites reduce weights of turbine blades by 40 percent and increase life expectancies of blades. In study, relatively-low-temperature fabrication process, hollow-cathode sputtering developed.

Petrasek, Donald W.↗
NASA NTRS1988

Proposal for a lunar tunnel-boring machine

A need exists for obtaining a safe and habitable lunar base that is free from the hazards of radiation, temperature gradient, and micrometeorites. A device for excavating lunar material and simultaneously generating living space in the subselenian environment was studied at the conceptual level. Preliminary examinations indicate that a device using a mechanical head to shear its way through the lunar material while creating a rigid ceramic-like lining meets design constraints using existing technology. The Lunar Tunneler is totally automated and guided by a laser communication system. There exists the potential for the excavated lunar material to be used in conjunction with a surface mining process for the purpose of the extraction of oxygen and other elements. Experiments into lunar material excavation and further research into the concept of a mechanical Lunar Tunneler are suggested.

Allen, Christopher S.↗
NASA NTRS1999

Method for Forming Fiber Reinforced Composite Bodies with Graded Composition and Stress Zones

A near-net, complex shaped ceramic fiber reinforced silicon carbide based composite bodies with graded compositions and stress zones is disclosed. To provide the composite a fiber preform is first fabricated and an interphase is applied by chemical vapor infiltration, sol-gel or polymer processes. This first body is further infiltrated with a polymer mixture containing carbon, and/or silicon carbide, and additional oxide, carbide, or nitride phases forming a second body. One side of the second body is spray coated or infiltrated with slurries containing high thermal expansion and oxidation resistant. crack sealant phases and the other side of this second body is coated with low expansion phase materials to form a third body. This third body consisting of porous carbonaceous matrix surrounding the previously applied interphase materials, is then infiltrated with molten silicon or molten silicon-refractory metal alloys to form a fourth body. The resulting fourth body comprises dense composites consisting of fibers with the desired interphase which are surrounded by silicon carbide and other second phases materials at the outer and inner surfaces comprising material of silicon, germanium, refractory metal suicides, borides, carbides, oxides, and combinations thereof The resulting composite fourth body has different compositional patterns from one side to the other.

Singh, Mrityunjay↗
NASA NTRS1999

Optical Fiber Protection

F&S Inc. developed and commercialized fiber optic and microelectromechanical systems- (MEMS) based instrumentation for harsh environments encountered in the aerospace industry. The NASA SBIR programs have provided F&S the funds and the technology to develop ruggedized coatings and coating techniques that are applied during the optical fiber draw process. The F&S optical fiber fabrication facility and developed coating methods enable F&S to manufacture specialty optical fiber with custom designed refractive index profiles and protective or active coatings. F&S has demonstrated sputtered coatings using metals and ceramics and combinations of each, and has also developed techniques to apply thin coatings of specialized polyimides formulated at NASA Langley Research Center. With these capabilities, F&S has produced cost-effective, reliable instrumentation and sensors capable of withstanding temperatures up to 800? C and continues building commercial sales with corporate partners and private funding. More recently, F&S has adapted the same sensing platforms to provide the rapid detection and identification of chemical and biological agents

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