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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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Solitosynthesis: Cosmological evolution of non-topological solitons

The thermal creation, fusion, evaporation, and destruction of non-topological solitons (NTS) after a phase transition in the early universe is considered. By defining and following NTS statistical equilibrium and departures from it, and depending on particle physics parameters, one of three possible scenarios occurs. If reaction rates are high enough, a period of equilibrium occurs and relic abundances are determined by the freeze-out temperature. Equilibrium first drives most NTS's into their constituents (free phi particles) and then causes rapid fusion into large NTS's. If freeze-out occurs during the first phase, the NTS's are almost entirely destroyed, while if it occurs during the second phase, solitosynthesis occurs and NTS's may be cosmically relevant. For slow reaction rates the NTS's are born frozen out and have the abundance determined by the phase transition. Analytic approximations for determining the abundances are developed, and tested by numerically integrating a reaction network in an expanding universe. Unfortunately, for most of the parameter space considered, solito-destruction/evaporation occurs.

Griest, Kim↗

Fragmentation of Comet Shoemaker-Levy 9's Nuclei During Flight Through the Jovian Atmosphere

Evidence on meteors and bolides shows that fragmentation is a major ablation process for all impactors penetrating the Earth's atmosphere, surpassing evaporation and fusion for impactors of the 'soft' cometary type. This model and data from plumes detected by the Hubble Space Telescope were used to estimate the size of the Shoemaker-Levy 9 nucleus.

comets meteors bolides Shoemaker-Levy↗

Vaporization by shock loading of albite, jadeite, and pyrex glass: Experimental study

Produced by shock experiments impact melts of albite, jadeite, and Pyrex glass demonstrate a loss of both Na and Al relative to Si, which can be due to selective vaporization. It is suggested that the high volatility of Al is related to volatility of a Na-Al compound of proposed NaAlO2 composition. The similar loss of Al and Na seems to be possible during tektite-forming processes. A degree of selective vaporization and modification of a melt chemical composition during impact processes is still poorly understood. The selective vaporization of some elements has been shown by shock experiments. The vaporization and condensation processes can take place in the lunar regolith. On this basis, there are hypotheses explaining differentiation of planetary bodies through the impact vaporization. On the other hand, studies of tektites, impact glasses, and lunar soils show that bulk compositions of impact melts are not modified significantly. In order to estimate degree of the vaporization during shock fusion, chemical compositions of experimentally produced impact melts were studied. We chose Al-containing compositions, because a high volatilization of Al during unequlibrated evaporization had been demonstrated.

Badjukov, D. D.↗

High Energy Plasma Space Propulsion

In order to meet NASA's challenge on advanced concept activity in the propulsion area, we initiated a new program entitled "High Energy Plasma Space Propulsion Studies" within the current cooperative agreement in 1998. The goals of this work are to gain further understanding of the engine of the AIMStar spacecraft, a concept which was developed at Penn State University, and to develop a prototype concept for the engine. The AIMStar engine concept was developed at Penn State University several years ago as a hybrid between antimatter and fusion technologies. Because of limited amounts of antimatter available, and concurrently the demonstrated ability for antiprotons to efficiently ignite nuclear fusion reactions, it was felt that this was a very good match. Investigations have been made concerning the performance of the reaction trap. This is a small Penning-like electromagnetic trap, which is used to simultaneously confine antiprotons and fusion fuels. Small DHe3 or DT droplets, containing a few percent molar of a fissile material, are injected into the trap, filled with antiprotons. We have found that it is important to separate the antiprotons into two adjacent wells, to inject he droplet between them and to simultaneously bring the antiprotons to the center of the trap, surrounding the droplet. Our previous concept had the droplet falling onto one cloud of antiprotons. This proved to be inefficient, as the droplet tended to evaporate away from the cloud as it interacted on its surface.

Wu, S. T.↗

Polymer morphologh

All polymeric materials in their final application are aggregates of many molecules. For linear macromolecules, these aggregates are highly entangled and their macroscopic properties are affected in a little-known way by the interpenetration and entanglements of the molecules. Over the years, we have done occasional investigations of single molecule single crystals and found that there are many unsolved questions about their nucleation, growth, kinetically determined shape, and ultimate path to equilibrium morphology on annealing. This initial work could be extended by a study of the applicability of microgravity methods for the production and study of the formation of single molecule particles. The production of separated molecules of sufficient size to produce phase-like behavior would involve perhaps a spray of solutions containing single molecules, followed by evaporation of the volatiles, or precipitation out of dispersion droplets. Other methods may involve Langmuir films etc., as shown in our prior work. The microgravity environment should enhance the efficiency of any of these methods by avoiding the joining of growing particles by reduction of convection and settling due to density differences. Once produced, the single molecule droplets are to be quenched into the glassy state and analyzed morphologically and thermally. Their shape alone can be used for molecular mass determination (an old problem that suffered from the need to estimate the shape of collapsed (flat) droplets on a surface). Next would be the study of changes of properties as a function of time, temperature, and molecular mass (and distribution) on fusion to macroscopic single phases.

Wunderlich, Bernhard↗

Additive Manufacturing and Experimental Characterization of Nickel-Titanium Shape-Memory Alloy Wick Structures and Heat Pipes for Spacecraft Thermal Control

Shape memory alloys (SMA), such as those based on nickel-titanium (NiTi), are increasingly being applied as multifunctional spacecraft components. For thermal management applications, NiTi flow tubing hinges and self-deploying loop heat pipes have been demonstrated. Emerging additive manufacturing (AM) processes are enabling more complex SMA devices than can be formed from conventional plain wire, tubing, and sheet stock materials. This paper presents our progress toward applying powder bed fusion AM to producing porous NiTi wicks and NiTi-H2O heat pipes, which could be embedded in thermally deploying radiators for spacecraft thermal management. AM near-equiatomic NiTi (55.1 wt% Ni) porous wick specimens were produced with a range of deposition parameters. Transient acetone rate-of-rise experiments were performed to estimate wick permeability (K) and average pore radius (r_pore) values and identify parameter sets with high capillary performance. Surface treatments were evaluated to achieve hydrophilic wick structures. Evaluated treatments included chemical oxide growth with H2O2, oxide and sodium titanate growth with NaOH solution, and ultrasonic cleaning with specialty detergents that can remove hydrocarbon contaminants. The most durable hydrophilic surface conditions were obtained with the NaOH treatment. High performing wick deposition parameters were used to produce a full AM NiTi heat pipe, which was treated with NaOH solution to activate the wick. This heat pipe was operated on a test stand in the inverted configuration (upper evaporator and lower condenser), and demonstrated stable nearly isothermal operation for 150 hrs.

Thermal management↗

Additive Manufacturing and Experimental Characterization of Nickel-Titanium Shape-Memory Alloy Wick Structures and Heat Pipes for Spacecraft Thermal Control

Shape memory alloys (SMA), such as those based on nickel-titanium (NiTi), are increasingly being applied as multifunctional spacecraft components. For thermal management applications, NiTi flow tubing hinges and self-deploying loop heat pipes have been demonstrated. Emerging additive manufacturing (AM) processes are enabling more complex SMA devices than can be formed from conventional plain wire, tubing, and sheet stock materials. This paper presents our progress toward applying powder bed fusion AM to producing porous NiTi wicks and NiTi-H2O heat pipes, which could be embedded in thermally deploying radiators for spacecraft thermal management. AM near-equiatomic NiTi (55.1 wt% Ni) porous wick specimens were produced with a range of deposition parameters. Transient acetone rate-of-rise experiments were performed to estimate wick permeability (K) and average pore radius (r_pore) values and identify parameter sets with high capillary performance. Surface treatments were evaluated to achieve hydrophilic wick structures. Evaluated treatments included chemical oxide growth with H2O2, oxide and sodium titanate growth with NaOH solution, and ultrasonic cleaning with specialty detergents that can remove hydrocarbon contaminants. The most durable hydrophilic surface conditions were obtained with the NaOH treatment. High performing wick deposition parameters were used to produce a full AM NiTi heat pipe, which was treated with NaOH solution to activate the wick. This heat pipe was operated on a test stand in the inverted configuration (upper evaporator and lower condenser), and demonstrated stable nearly isothermal operation for 150 hrs.

Thermal management↗

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

additive manufacturing↗