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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Combustion synthesis of ceramic-metal composite materials - The TiC-Al2O3-Al system

Combustion synthesis was applied for producing ceramic-metal composites with reduced levels of porosity, by allowing an excess amount of liquid metal, generated by the exothermic reaction during synthesis, to infiltrate the pores. It is shown that this method, when applied to TiC-Al2O3 system, led to a decreased level of porosity in the resulting TiC-Al2O3-Al product, as compared with that of TiC-Al2O3 system. This in situ procedure is more efficient than the two-stage conventional processes (i.e., sintering followed by liquid metal infiltration), although there are limitations with respect to total penetration of the liquid metal and maintaining a stable propagation of the combustion reaction.

Feng, H. J.↗
NASA NTRS1995

Microwave Induced Combustion Synthesis of Ceramic and Ceramic-Metal Composites

In recent years, there has been a renewed interest in combustion synthesis reactions, commonly called self-propagating high-temperature synthesis. These reactions are an attractive, energy efficient approach to the synthesis of high temperature composite materials and metastable phases. Microwaves are used to induce self-propagating high temperature synthesis of ceramic and ceramic-metal composites.

high-temperature ceramics high-temperature synthes↗
NASA NTRS1995

(abstract) Microwave Induced Combustion Synthesis of Ceramic and Ceramic-Metal Composites

We have used microwaves to induce self-propagating high temperature synthesis (SHS) in the reaction 3TiO(sub 2)+3C+(4+x)Al ---> 3TiC+2Al(sub 2)O(sub 3)+xAl. The SHS process was studied for x = 0 and 4, with and without the application of uniaxial pressure. A TE102 microwave cavity mode internally ignited the samples using less than 50 watts. The resultant microstructure of the microwave processed samples were compared to SHS products obtained using a conventional hot wire ignition technique. Uniaxial stresses along the vertical axis of approximately 1400 and 200 psi were applied simultaneously as the SHS reactions were initiated in some of the conventional and microwave processed samples, respectively. SEM photomicrographs will be presented that show the different microstructural features of the products using the microwave and hot wire techniques.

ceramic microwave ceramic-metal composites microwa↗
NASA NTRS1995

Combustion synthesis of ceramic-metal composite materials in microgravity

Combustion synthesis, self-propagating high temperature synthesis (SHS) or reactive synthesis provides an attractive alternative to conventional methods of producing advanced materials since this technology is based on the ability of highly exothermic reactions to be self sustaining and, therefore, energetically efficient. The exothermic SHS reaction is initiated at the ignition temperature, T(sub ig), and generates heat which is manifested in a maximum or combustion temperature, T(sub c), which can exceed 3000 K . Such high combustion temperatures are capable of melting and/or volatilizing reactant and product species and, therefore, present an opportunity for producing structure and property modification and control through liquid-solid, vapor-liquid-solid, and vapor-solid transformations.

Moore, John↗
NASA NTRS2021

High Temperature W-band Complex Permittivity Measurements of Thermally Cycled Ceramic-Metal Composites: AlN:Mo with 0.25 vol% to 4.0 vol% Mo from 25 °C to 1000 °C in Air

An apparatus for measuring the W-band (75-110GHz) complex permittivity of dielectrics at 1000 °C was developed. This apparatus allows for measurements at approximately twice the temperature of previously published high temperature free-space measurement systems while maintaining similar precision. Challenges were addressed related to high temperature measurements, including temperature uniformity, the accuracy of temperature measurements, and preventing temperature related changes to mm-wave measurement systems. The details of complex permittivity extraction from the measured S-parameters are discussed. Sources of error related to permittivity measurement and mathematical models were identified and are discussed in detail herein. Thermally-cycled, mm-wave absorbing, aluminum nitride ceramic composites containing varying levels of molybdenum additives were measured over the range of 25-1000 °C. These measurements were compared to the same composites before thermal cycling. It was found that ceramic composites are largely stable after thermal cycling in terms of dielectric properties despite the presence of visible surface modifications.

Zane W Cohick↗
NASA NTRS1998

Flexible Ceramic-Metal Insulation Composite and Method of Making

A method for joining a woven flexible ceramic fabric and a thin metal sheet creating an integral metal surfaced flexible thermal protection article, which methods compress: placing multiple dots of high temperature metallic or fabric and the thin metal sheet in a random or organized pattern, with the proviso that the brazing material covers about 10% or less of the surface of one flat side of the metal sheet; heating the flexible ceramic fabric, brazing material and thin metal sheet for a predetermined period of time to integrally connect the same; and cooling the formed flexible article to ambient temperature. Preferably the flexible ceramic is selected from fibers comprising atoms of silicon, carbon, nitrogen, boron, oxygen or combinations thereof. The flexible thermal protection article produced is also part of the present invention. The thin metal sheet is comprised of titanium, aluminum, chromium, niobium or alloys or combinations thereof. The brazing material is selected from copper/silver or copper/gold or is a ceramic brazing or adhesive material.

Rasky, Daniel J.↗
DOE OSTI2024

Evaluating Iodine Immobilization Technologies: Cermets, Polycermets, and Polyhalmets

The work in this report documents the efforts conducted to assess the feasibility of some of the ideas documented in Pacific Northwest National Laboratory invention disclosure reports (IDRs) including: 1) Iodine capture in polyacrylonitrile (PAN)-containing composite sorbents (32451-E). In this work, the composites evaluated included Ag0, Bi0, Cu0, Bi2S3, and Cu2S embedded in PAN. 2) Metal iodide removal from these sorbents through dissolution in dimethyl sulfoxide (DMSO) (32729-E). In this work, PAN dissolution was evaluated for multiple types of sorbents including Ag-Pan, Bi-PAN, Cu-PAN, Bi2S3-PAN, and Cu2S-PAN. 3) Using metal-sulfide sorbents for iodine capture (32647-E). In this work, the composites evaluated under this IDR included Ag2S, Bi2S3, and Cu2S embedded in PAN. 4) Using low-melting metals to immobilize (encapsulate) iodine-loaded and polymer-containing sorbents into polymer-ceramic-metal (called polycermet) or polymer-halide-metal (called polyhalmet) composite waste forms (32625-E). In this work, the iodine-loaded PAN composites included AgI-PAN, BiI-PAN, and CuI-PAN. 5) Ceramic-metal composite waste form synthesis of polymer-containing materials using low-melting metals like bismuth, tin, or bismuth-tin alloys (32537-E). In this work, the metals evaluated included Bi, 58Bi-42Sn eutectic. 6) Cermets for immobilizing commercial sorbents loaded with radioiodine (32806-E). In this work, AgIX (iodine-loaded silver faujasite zeolite) was evaluated in cermet form.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2025

Thermophysical Properties of a Uranium Nitride–Molybdenum-Tungsten Composite Fuel for Nuclear Thermal Propulsion

The thermal conductivity of a ceramic-metal composite consisting of 60 vol % uranium nitride incorporated into a molybdenum-tungsten matrix has been measured up to a temperature of 1200°C. Compositing nuclear fuel with refractory materials is considered a viable way to improve the thermal and mechanical properties of fuels, and more recently, has been investigated as a way to improve hydrogen compatibility in a nuclear thermal propulsion rocket reactor. Here, we demonstrate that high-density composites can be produced from direct current sintering and that the resulting thermal conductivity is improved compared to the pure.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Iodine Capture with Copper-Electroplated Nickel Foams

This work explores the use of Ni0 foam scaffolds for Cu0 coatings for use as sorbents for iodine. The Cu0 electroplating was performed from aqueous copper(II) sulfate (CuSO4) solutions under different conditions to achieve a range of Cu0-layer thicknesses (4.89 ± 1.05 μm–57.32 ± 3.95 μm) with 900 A·m–2 current densities and coating times of 15–180 min. The thickest coatings resulted in Cu0-plated Ni0 foams with >89 mass % Cu0 in the final product. Iodine capture experiments showed very high Cu0 utilizations of 91.9–97.3 mass % at iodine loadings of 839–1774 mg·g–1 through the formation of CuI (marshite; space group F-43m). No evidence was found of iodine reactions taking place with the Ni0 scaffold, so it remained in iodine-loaded Cu-electroplated Ni foams as structural support to provide mechanical rigidity to the foams during the iodine loading process. Hot pressing of these materials can be used to create a CuI/Ni ceramic-metal composite waste form for disposal as demonstrated with spark plasma sintering.

Riley, Brian [Pacific Northwest National Laborator↗
NASA NTRS1993

Combustion synthesis of advanced composite materials

Self-propagating high temperature (combustion) synthesis (SHS), has been investigated as a means of producing both dense and expanded (foamed) ceramic and ceramic-metal composites, ceramic powders and whiskers. Several model exothermic combustion synthesis reactions were used to establish the importance of certain reaction parameters, e.g., stoichiometry, green density, combustion mode, particle size, etc. on the control of the synthesis reaction, product morphology and properties. The use of an in situ liquid infiltration technique and the effect of varying the reactants and their stoichiometry to provide a range of reactant and product species i.e., solids, liquids and gases, with varying physical properties e.g., volatility and thermal conductivity, on the microstructure and morphology of synthesized composite materials is discussed. Conducting the combustion synthesis reaction in a reactive gas environment to take advantage of the synergistic effects of combustion synthesis and vapor phase transport is also examined.

Moore, John J.↗
NASA NTRS1992

Combustion synthesis of advanced materials

The combustion synthesis of ceramic-metal composites using an in-situ liquid infiltration technique is described. The effect of varying the reactants and their stoichiometry to provide a range of reactant and product species i.e. solids, liquids and gases, with varying physical properties e.g. thermal conductivity, on the microstructure and morphology of synthesized products is also described. Alternatively, conducting the combustion synthesis reaction in a reactive gas environment is also discussed, in which advantages can be gained from the synergistic effects of combustion synthesis and vapor phase transport. In each case, the effect of the presence or absence of gravity (density) driven fluid flow and vapor transport is discussed as is the potential for producing new and perhaps unique materials by conducting these SHS reactions under microgravity conditions.

Moore, J. J.↗
NASA NTRS1995

Microgravity Combustion Science: 1995 Program Update

Microgravity greatly benefits the study of fundamental combustion processes. In this environment, buoyancy-induced flow is nearly eliminated, weak or normally obscured forces and flows can be isolated, gravitational settling or sedimentation is nearly eliminated, and temporal and spatial scales can be expanded. This document reviews the state of knowledge in microgravity combustion science with the emphasis on NASA-sponsored developments in the current period of 1992 to early 1995. The subjects cover basic research in gaseous premixed and diffusion-flame systems, flame structure and sooting, liquid droplets and pools, and solid-surface ignition and flame spread. They also cover applied research in combustion synthesis of ceramic-metal composites, advanced diagnostic instrumentation, and on-orbit fire safety. The review promotes continuing research by describing the opportunities for Principal Investigator participation through the NASA Research Announcement program and the available NASA Lewis Research Center ground-based facilities and spaceflight accommodations. This review is compiled by the members and associates of the NASA Lewis Microgravity Combustion Branch, and it serves as an update of two previous overview reports.

Ross, Howard D.↗
NASA NTRS2007

Ceramic Integration Technologies for Aerospace and Energy Systems: Technical Challenges and Opportunities

Ceramic integration technology has been recognized as an enabling technology for the implementation of advanced ceramic systems in a number of high-temperature applications in aerospace, power generation, nuclear, chemical, and electronic industries. Various ceramic integration technologies (joining, brazing, attachments, repair, etc.) play a role in fabrication and manufacturing of large and complex shaped parts of various functionalities. However, the development of robust and reliable integrated systems with optimum performance requires the understanding of many thermochemical and thermomechanical factors, particularly for high temperature applications. In this presentation, various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Experimental results for bonding and integration of SiC based LDI fuel injector, high conductivity C/C composite based heat rejection system, solid oxide fuel cells system, ultra high temperature ceramics for leading edges, and ceramic composites for thermostructural applications will be presented. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be discussed.

Singh, Mrityunjay↗
NASA NTRS2015

Revised Point of Departure Design Options for Nuclear Thermal Propulsion

In an effort to further refine potential point of departure nuclear thermal rocket engine designs, four proposed engine designs representing two thrust classes and utilizing two different fuel matrix types are designed and analyzed from both a neutronics and thermodynamic cycle perspective. Two of these nuclear rocket engine designs employ a tungsten and uranium dioxide cermet (ceramic-metal) fuel with a prismatic geometry based on the ANL-200 and the GE-710, while the other two designs utilize uranium-zirconium-carbide in a graphite composite fuel and a prismatic fuel element geometry developed during the Rover/NERVA Programs. Two engines are analyzed for each fuel type, a small criticality limited design and a 111 kN (25 klbf) thrust class engine design, which has been the focus of numerous manned mission studies, including NASA's Design Reference Architecture 5.0. slightly higher T/W ratios, but they required substantially more 235U.

Nuclear Thermal Rockets↗
NASA NTRS2018

Demonstration of Subscale Cermet Fuel Specimen Fabrication Approach Using Spark Plasma Sintering and Diffusion Bonding

Nuclear thermal propulsion (NTP) has the potential to expand the limits of human space exploration by enabling crewed missions to Mars and beyond. The viability of NTP hinges on the development of a robust nuclear fuel material that can perform in the harsh operating environment (> or = 2500K, reactive hydrogen) of a nuclear thermal rocket (NTR) engine. Efforts are ongoing to develop fuel material and to assemble fuel elements that will be stable during the service life of an NTR. Ceramic-metal (cermet) fuels are being actively pursued by NASA Marshall Space Flight Center (MSFC) due to their demonstrated high-temperature stability and hydrogen compatibility. Building on past cermet fuel development research, experiments were conducted to investigate a modern fabrication approach for cermet fuel elements. The experiments used consolidated tungsten (W)-60vol%zirconia (ZrO2) compacts that were formed via spark plasma sintering (SPS). The consolidated compacts were stacked and diffusion bonded to assess the integrity of the bond lines and internal cooling channel cladding. The assessment included hot hydrogen testing of the manufactured surrogate fuel and pure W for 45 minutes at 2500 K in the compact fuel element environmental test (CFEET) system. Performance of bonded W-ZrO2 rods was compared to bonded pure W rods to access bond line integrity and composite stability. Bonded surrogate fuels retained structural integrity throughout testing and incurred minimal mass loss.

Barnes, Marvin W.↗
DOE OSTI2025

Current-Activated Reactive Ultrafast Joining (CARUJ)

We have demonstrated Current Activated Reactive Ultrafast Joining (CARUJ) as a novel approach for rapid fabrication of similar and dissimilar materials, such as ceramic-ceramic and ceramic-metal joint assemblies. The CARUJ technology utilizes resistive heating of carbon-based materials to apply localized heat at, (through or around) joint zones at rates of 10 1 -10 2 ˚C/min, enabling joining at time scales considerably shorter (several minutes as opposed to hours) than conventional approaches for similar systems. Herein, we present our findings while evaluating the CARUJ concept. Three methods of heat application were evaluated: (i) using carbon joule heating elements to apply heat directly through the joint interface; (ii) using flexible joule heating elements to locally apply heat around the assembly interface; and (iii) non-contact heating of the joint assembly using inductive power. Schemes (ii) and (iii) proved to be the most effective in producing mechanically sound reliable joints. We demonstrated single-step fabrication of dense SiC-SiC joints with a Si- SiC interface using minimal pressure (1–2 MPa) in under 30 minutes. Measured average joint strengths of about 15 MPa are initially achieved for joined bodies when tested in single lap offset (SLO) compressive shear, while tuning of the interfacial composition along with a reduction in interlayer thickness, results in improved joint strengths of approximately 43 MPa. We further demonstrated SiC-SiC joining using Active Brazing Alloys (ABAs) proof of concept joining of tubular geometries. The versatility of CARUJ is demonstrated by utilizing non-contact heating via induction, to join dissimilar materials systems of SiC, SS316 and MAX phase ceramics with ABA interlayers. The localized and rapid heat application realizes a versatile material joining technique that can be extended for joining components at the plant site.

36 MATERIALS SCIENCE↗