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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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NASA NTRS2001

Dendritic Alloy Solidification Experiment (DASE)

A space experiment, and supporting ground-based research, is proposed to study the microstructural evolution in free dendritic growth from a supercooled melt of the transparent model alloy succinonitrile-acetone (SCN-ACE). The research is relevant to equiaxed solidification of metal alloy castings. The microgravity experiment will establish a benchmark for testing of equiaxed dendritic growth theories, scaling laws, and models in the presence of purely diffusive, coupled heat and solute transport, without the complicating influences of melt convection. The specific objectives are to: determine the selection of the dendrite tip operating state, i.e. the growth velocity and tip radius, for free dendritic growth of succinonitrile-acetone alloys; determine the growth morphology and sidebranching behavior for freely grown alloy dendrites; determine the effects of the thermal/solutal interactions in the growth of an assemblage of equiaxed alloy crystals; determine the effects of melt convection on the free growth of alloy dendrites; measure the surface tension anisotropy strength of succinon itrile -acetone alloys establish a theoretical and modeling framework for the experiments. Microgravity experiments on equiaxed dendritic growth of alloy dendrites have not been performed in the past. The proposed experiment builds on the Isothermal Dendritic Growth Experiment (IDGE) of Glicksman and coworkers, which focused on the steady growth of a single crystal from pure supercooled melts (succinonitrile and pivalic acid). It also extends the Equiaxed Dendritic Solidification Experiment (EDSE) of the present investigators, which is concerned with the interactions and transients arising in the growth of an assemblage of equiaxed crystals (succinonitrile). However, these experiments with pure substances are not able to address the issues related to coupled heat and solute transport in growth of alloy dendrites.

Beckermann, C.↗

NASA NTRS2005

Automated Rapid Prototyping of 3D Ceramic Parts

An automated system of manufacturing equipment produces three-dimensional (3D) ceramic parts specified by computational models of the parts. The system implements an advanced, automated version of a generic rapid-prototyping process in which the fabrication of an object having a possibly complex 3D shape includes stacking of thin sheets, the outlines of which closely approximate the horizontal cross sections of the object at their respective heights. In this process, the thin sheets are made of a ceramic precursor material, and the stack is subsequently heated to transform it into a unitary ceramic object. In addition to the computer used to generate the computational model of the part to be fabricated, the equipment used in this process includes: 1) A commercially available laminated-object-manufacturing machine that was originally designed for building woodlike 3D objects from paper and was modified to accept sheets of ceramic precursor material, and 2) A machine designed specifically to feed single sheets of ceramic precursor material to the laminated-object-manufacturing machine. Like other rapid-prototyping processes that utilize stacking of thin sheets, this process begins with generation of the computational model of the part to be fabricated, followed by computational sectioning of the part into layers of predetermined thickness that collectively define the shape of the part. Information about each layer is transmitted to rapid-prototyping equipment, where the part is built layer by layer. What distinguishes this process from other rapid-prototyping processes that utilize stacking of thin sheets are the details of the machines and the actions that they perform. In this process, flexible sheets of ceramic precursor material (called "green" ceramic sheets) suitable for lamination are produced by tape casting. The binder used in the tape casting is specially formulated to enable lamination of layers with little or no applied heat or pressure. The tape is cut into individual sheets, which are stacked in the sheet-feeding machine until used. The sheet-feeding machine can hold enough sheets for about 8 hours of continuous operation.

McMillin, Scott G.↗

NASA NTRS1986

Constitutive modelling of single crystal and directionally solidified superalloys

The trend towards improved engine efficiency and durability places increasing demands on materials that operate in the hot section of the gas turbine engine. These demands are being met by new coatings and materials such as single crystal and directionally solidified nickel-base superalloys which have greater creep/fatigue resistance at elevated temperatures and reduced susceptibility to grain boundary creep, corrosion and oxidation than conventionally cast alloys. Work carried out as part of a research program aimed at the development of constitutive equations to describe the elevated temperature stress-strain-time behavior of single crystal and directionally solidified turbine blade superalloys is discussed. The program involves both development of suitable constitutive models and their verification through elevated temperature tension-torsion testing of single crystals of PWA 1480.

Jordan, E. H.↗

NASA NTRS1992

Application of information technology to the National Launch System

The approach to the development of the Unified Information System (UNIS) to provide in a timely manner all the information required to manage, design, manufacture, integrate, test, launch, operate, and support the Advanced Launch System (NLS), as well as the current and planned capabilities are described. STESYM, the Space Transportation Main Engine (STME) development program, is comprised of a collection of data models which can be grouped into two primary models: the Engine Infrastructure Model (ENGIM) and the Engine Integrated Cast Model (ENGICOM). ENGIM is an end-to-end model of the infrastructure needed to perform the fabrication, assembly, and testing of the STEM program and its components. Together, UNIS and STESYM are to provide NLS managers and engineers with the ability to access various types and files of data quickly and use that data to assess the capabilities of the STEM program.

Mauldin, W. T.↗

NASA NTRS2019

Cloud Governance at Scale

Operating and maintaining a large multi-tenant ecosystem in the cloud requires scalable solutions to unique technical and process challenges. The Cloud Computing model grants significant permissions to development teams that traditionally were reserved for Data-Center Administrators and Supply-Chain Managers. Earthdata Cloud has worked to re-cast traditional data-center management into a sensible cloud-first model. This talk discusses some of our challenges, solutions, and way ahead.

financial controls↗

NASA NTRS1975

Manufacture and static firing of X259-E6 rocket motor serial number XJ04/0001

A single motor was cast and static fired to demonstrate the performance of high energy crosslinked double base (XLDB) propellant in standard X259 rocket motor hardware. Prior to motor fabrication, the motor was analyzed to predict the results of static firing the X259 motor loaded with XLDB propellant. As a result of the analyses, a forward dome shrinkage liner was added to the design. With this design change it was determined that adequate margins of safety existed. The motor, designated the X259-E6 model with serial number XJ04/0001, was fabricated using a slurry-casting technique and was assembled with a standard X259-B4 nozzle which had the nozzle throat machined to a smaller inside diameter than the B4 model and the exit cone cut short for Bacchus Works altitude expansion. The motor was static fired on 20 February 1974 with the nozzle failing during motor operation. Nozzle failure was attributed to spalling of the throat material leading to complete nozzle break-up. However, the propellant functioned as predicted in the motor chamber, ignition was normal, and char and erosion of the internal insulator were as expected.

Robertson, D. R.↗

NASA NTRS1998

Forced Flow Flame Spreading Test: Preliminary Findings From the USMP-3 Shuttle Mission

The Forced Flow Flame spreading Test (FFFT) is a study of flame spreading over solid fuels in very low-speed air flows. The FFFT experiment is part of research entitled Solid Inflammability Boundary at Low Speeds, (SIBAL) intended for operations on the Space Station. In the FFFT experiment, a series of 15 experiments conducted aboard the space shuttle during the United States Microgravity Payload (USMP-3) mission provided information about the structure and spreading characteristics of flames in low-speed, concurrent flows. The test samples included flat sheets of cellulose and cast cylinders of cellulose, burned in air at velocities of approximately 1 to 8 cm/sec. The test results have been successfully compared to theoretical predictions of the SIBAL program, a fundamentally based numerical simulation of concurrent flow flame spread. Additionally, some guidance for the design characteristics of the SIBAL flight experiment have been obtained including some verification of the theoretical predictions of flame size versus the required size of the SIBAL flow duct, and the effect of the presence of thermocouples in the vicinity of near-limit flames in microgravity.

Sacksteder, Kurt R.↗

NASA NTRS2017

CAST Safety Enhancement Research on Airplane State Awareness and Prediction Technologies

Loss of control in flight (LOC-I) is the leading cause of fatal aircraft accidents. A study of LOC accidents and incidents, commissioned by the Commercial Aviation Safety Team (CAST) identified a growing trend in loss of Airplane State Awareness (ASA) by the flight crew. This has led to recommended safety enhancements that include flight deck technologies for improving current and predicted energy state awareness. In this talk, we discuss recent CAST motivated efforts to develop new information systems for predicting and assessing the future aircraft energy state and auto-flight configuration. The outputs from these systems can serve multiple purposes, including improved pilot alerting for anticipating and recovering from problematic flight conditions, as well as higher level flight safety assurance for autonomous operations.

Schuet, Stefan↗

NASA NTRS2009

Fabrication and Testing of a Thin-Film Heat Flux Sensor for a Stirling Convertor

The NASA Glenn Research Center (GRC) has been testing high efficiency free-piston Stirling convertors for potential use in radioisotope power systems since 1999. Stirling convertors are being operated for many years to demonstrate a radioisotope power system capable of providing reliable power for potential multi-year missions. Techniques used to monitor the convertors for change in performance include measurements of temperature, pressure, energy addition, and energy rejection. Micro-porous bulk insulation is used in the Stirling convertor test set up to minimize the loss of thermal energy from the electric heat source to the environment. The insulation is characterized before extended operation, enabling correlation of the net thermal energy addition to the convertor. Aging microporous bulk insulation changes insulation efficiency, introducing errors in the correlation for net thermal energy addition. A thin-mm heat flux sensor was designed and fabricated to directly measure the net thermal energy addition to the Stirling convertor. The fabrication techniques include slip casting and using Physical Vapor Deposition (PVD). One micron thick noble metal thermocouples measure temperature on the surface of an Alumina ceramic disc and heat flux is calculated. Fabrication, integration, and test results of a thin film heat flux sensor are presented.

Wilson, Scott D.↗

NASA NTRS2004

Rapid Structured Volume Grid Smoothing and Adaption Technique

A rapid, structured volume grid smoothing and adaption technique, based on signal processing methods, was developed and applied to the Shuttle Orbiter at hypervelocity flight conditions in support of the Columbia Accident Investigation. Because of the fast pace of the investigation, computational aerothermodynamicists, applying hypersonic viscous flow solving computational fluid dynamic (CFD) codes, refined and enhanced a grid for an undamaged baseline vehicle to assess a variety of damage scenarios. Of the many methods available to modify a structured grid, most are time-consuming and require significant user interaction. By casting the grid data into different coordinate systems, specifically two computational coordinates with arclength as the third coordinate, signal processing methods are used for filtering the data [Taubin, CG v/29 1995]. Using a reverse transformation, the processed data are used to smooth the Cartesian coordinates of the structured grids. By coupling the signal processing method with existing grid operations within the Volume Grid Manipulator tool, problems related to grid smoothing are solved efficiently and with minimal user interaction. Examples of these smoothing operations are illustrated for reduction in grid stretching and volume grid adaptation. In each of these examples, other techniques existed at the time of the Columbia accident, but the incorporation of signal processing techniques reduced the time to perform the corrections by nearly 60%. This reduction in time to perform the corrections therefore enabled the assessment of approximately twice the number of damage scenarios than previously possible during the allocated investigation time.

Alter, Stephen J.↗

NASA NTRS2006

Rapid Structured Volume Grid Smoothing and Adaption Technique

A rapid, structured volume grid smoothing and adaption technique, based on signal processing methods, was developed and applied to the Shuttle Orbiter at hypervelocity flight conditions in support of the Columbia Accident Investigation. Because of the fast pace of the investigation, computational aerothermodynamicists, applying hypersonic viscous flow solving computational fluid dynamic (CFD) codes, refined and enhanced a grid for an undamaged baseline vehicle to assess a variety of damage scenarios. Of the many methods available to modify a structured grid, most are time-consuming and require significant user interaction. By casting the grid data into different coordinate systems, specifically two computational coordinates with arclength as the third coordinate, signal processing methods are used for filtering the data [Taubin, CG v/29 1995]. Using a reverse transformation, the processed data are used to smooth the Cartesian coordinates of the structured grids. By coupling the signal processing method with existing grid operations within the Volume Grid Manipulator tool, problems related to grid smoothing are solved efficiently and with minimal user interaction. Examples of these smoothing operations are illustrated for reductions in grid stretching and volume grid adaptation. In each of these examples, other techniques existed at the time of the Columbia accident, but the incorporation of signal processing techniques reduced the time to perform the corrections by nearly 60%. This reduction in time to perform the corrections therefore enabled the assessment of approximately twice the number of damage scenarios than previously possible during the allocated investigation time.

Alter, Stephen J.↗

NASA NTRS2014

Evaluation of Geopolymer Concrete for Rocket Test Facility Flame Deflectors

The current paper presents results from a combined research effort by Louisiana Tech University (LTU) and NASA Stennis Space Center (SSC) to develop a new alumina-silicate based cementitious binder capable of acting as a high performance refractory material with low heat ablation rate and high early mechanical strength. Such a binder would represent a significant contribution to NASA's efforts to develop a new generation of refractory 'hot face' liners for liquid or solid rocket plume environments. This project was developed as a continuation of on-going collaborations between LTU and SSC, where test sections of a formulation of high temperature geopolymer binder were cast in the floor and walls of Test Stand E-1 Cell 3, an active rocket engine test stand flame trench. Additionally, geopolymer concrete panels were tested using the NASA-SSC Diagnostic Test Facility (DTF) thruster, where supersonic plume environments were generated on a 1ft wide x 2ft long x 6 inch deep refractory panel. The DTF operates on LOX/GH2 propellants producing a nominal thrust of 1,200 lbf and the combustion chamber conditions are Pc=625psig, O/F=6.0. Data collected included high speed video of plume/panel area and surface profiles (depth) of the test panels measured on a 1-inch by 1-inch giving localized erosion rates during the test. Louisiana Tech conducted a microstructure analysis of the geopolymer binder after the testing program to identify phase changes in the material.

Allgood, Daniel C.↗

NASA NTRS2001

Feasibility of Actively Cooled Silicon Nitride Airfoil for Turbine Applications Demonstrated

Nickel-base superalloys currently limit gas turbine engine performance. Active cooling has extended the temperature range of service of nickel-base superalloys in current gas turbine engines, but the margin for further improvement appears modest. Therefore, significant advancements in materials technology are needed to raise turbine inlet temperatures above 2400 F to increase engine specific thrust and operating efficiency. Because of their low density and high-temperature strength and thermal conductivity, in situ toughened silicon nitride ceramics have received a great deal of attention for cooled structures. However, the high processing costs and low impact resistance of silicon nitride ceramics have proven to be major obstacles for widespread applications. Advanced rapid prototyping technology in combination with conventional gel casting and sintering can reduce high processing costs and may offer an affordable manufacturing approach. Researchers at the NASA Glenn Research Center, in cooperation with a local university and an aerospace company, are developing actively cooled and functionally graded ceramic structures. The objective of this program is to develop cost-effective manufacturing technology and experimental and analytical capabilities for environmentally stable, aerodynamically efficient, foreign-object-damage-resistant, in situ toughened silicon nitride turbine nozzle vanes, and to test these vanes under simulated engine conditions. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. With cooling, the surface temperature decreased to approximately 1910 F--a drop of approximately 440 F. This preliminary study demonstrates that a near-net-shape silicon nitride airfoil can be fabricated and that silicon nitride can sustain severe thermal shock and the thermal gradients induced by cooling and, thus, is a viable candidate for cooled components.

Bhatt, Ramakrishna T.↗

NASA NTRS1951

Investigation of Mechanisms of Blade Failure of Forged Hastalloy B and Cast Stellite 21 Turbine Blades in Turbojet Engine

An investigation was conducted to study the mechanisms of blade failure of forged Hastelloy B and cast Stellite 21. The blades were mounted in a 16-25-6 alloy rotor and subjected to 20-minute cycles consisting of 15 minutes at rated speed and approximately 5 minutes at idle. The first failures of the Hastelloy B and Stellite 21 blades were probably the result of excessive vibratory stresses and occurred after 14.25 and 16.75 hours, respectively. After 28.75 hours of operation, all but 3 of the original 25 Hastelloy B blades had either failed or contained stress-rupture-type cracks and four of the original 27 Stellite 21 blades contained stress-rupture-type cracks.

ENGINES, TURBO-JET↗

NASA NTRS2012

High-Temperature Shape Memory Polymers

physical conformation changes when exposed to an external stimulus, such as a change in temperature. Such materials have a permanent shape, but can be reshaped above a critical temperature and fixed into a temporary shape when cooled under stress to below the critical temperature. When reheated above the critical temperature (Tc, also sometimes called the triggering or switching temperature), the materials revert to the permanent shape. The current innovation involves a chemically treated (sulfonated, carboxylated, phosphonated, or other polar function group), high-temperature, semicrystalline thermoplastic poly(ether ether ketone) (Tg .140 C, Tm = 340 C) mix containing organometallic complexes (Zn++, Li+, or other metal, ammonium, or phosphonium salts), or high-temperature ionic liquids (e.g. hexafluorosilicate salt with 1-propyl-3- methyl imidazolium, Tm = 210 C) to form a network where dipolar or ionic interactions between the polymer and the low-molecular-weight or inorganic compound forms a complex that provides a physical crosslink. Hereafter, these compounds will be referred to as "additives". The polymer is semicrystalline, and the high-melt-point crystals provide a temporary crosslink that acts as a permanent crosslink just so long as the melting temperature is not exceeded. In this example case, the melting point is .340 C, and the shape memory critical temperature is between 150 and 250 C. PEEK is an engineering thermoplastic with a high Young fs modulus, nominally 3.6 GPa. An important aspect of the invention is the control of the PEEK functionalization (in this example, the sulfonation degree), and the thermal properties (i.e. melting point) of the additive, which determines the switching temperature. Because the compound is thermoplastic, it can be formed into the "permanent" shape by conventional plastics processing operations. In addition, the compound may be covalently cross - linked after forming the permanent shape by S-PEEK by applying ionizing radiation ( radiation, neutrons), or by chemical crosslinking to form a covalent permanent network. With respect to other shape memory polymers, this invention is novel in that it describes the use of a thermoplastic composition that can be thermally molded or solution-cast into complex "permanent" shapes, and then reheated or redissolved and recast from solution to prepare another shape. It is also unique in that the shape memory behavior is provided by a non-polymer additive.

Yoonessi, Mitra↗

NASA NTRS1994

Scanning and Transmission Electron Microscopy of High Temperature Materials

Software and hardware updates to further extend the capability of the electron microscope were carried out. A range of materials such as intermetallics, metal-matrix composites, ceramic-matrix composites, ceramics and intermetallic compounds, based on refractory elements were examined under this research. Crystal structure, size, shape and volume fraction distribution of various phases which constitute the microstructures were examined. Deformed materials were studied to understand the effect of interfacial microstructure on the deformation and fracture behavior of these materials. Specimens tested for a range of mechanical property requirements, such as stress rupture, creep, low cycle fatigue, high cycle fatigue, thermomechanical fatigue, etc. were examined. Microstructural and microchemical stability of these materials exposed to simulated operating environments were investigated. The EOIM Shuttle post-flight samples were also examined to understand the influence of low gravity processing on microstructure. In addition, fractographic analyses of Nb-Zr-W, titanium aluminide, molybdenum silicide and silicon carbide samples were carried out. Extensive characterization of sapphire fibers in the fiber-reinforced composites made by powder cloth processing was made. Finally, pressure infiltration casting of metal-matrix composites was carried out.

Source record↗

NASA NTRS1970

Thermodynamics of the internal combustion engine

The ubiquitous automobile has played both the role of hero and villain during the course of its history. At the present time it is being cast as the villain with increasing frequency because it has been indicted as a major source of air pollution. It is just this characterization that is responsible for our renewed interest in the automobile. When we speak of the automobile as a source of air pollution, we really mean the heart of the automobile, the internal combustion engine. The prototype of the modern internal combustion engine was first successfully operated by Nicholas August Otto in 1876. In spite of its long history, the internal combustion engine is still poorly understood in terms of the details of the physical processes that take place during its operations. The internal combustion engine operates on what is known as the Otto cycle, and Otto cycle calculations have been with us for many years. The emphasis in earlier calculations was usually on the performance rather than on the pollution aspects. Performance characteristics can often be estimated reasonably accurately even with a considerable degree of simplification. We are interested in the pollution aspects of the internal combustion engine, and therefore the calculations must be performed with more care. Our extensive experience with equilibrium calculations places us in a position to carry out such careful calculations. We have just recently begun such an analysis, and its objective is the prediction of exhaust gas properties. I will describe our progress by first reviewing the Otto cycle, and then I will illustrate the effect of various assumptions on the calculated results.

Frank J. Zeleznik↗

NASA NTRS1986

Machine vision and the OMV

The orbital Maneuvering Vehicle (OMV) is intended to close with orbiting targets for relocation or servicing. It will be controlled via video signals and thruster activation based upon Earth or space station directives. A human operator is squarely in the middle of the control loop for close work. Without directly addressing future, more autonomous versions of a remote servicer, several techniques that will doubtless be important in a future increase of autonomy also have some direct application to the current situation, particularly in the area of image enhancement and predictive analysis. Several techniques are presentet, and some few have been implemented, which support a machine vision capability proposed to be adequate for detection, recognition, and tracking. Once feasibly implemented, they must then be further modified to operate together in real time. This may be achieved by two courses, the use of an array processor and some initial steps toward data reduction. The methodology or adapting to a vector architecture is discussed in preliminary form, and a highly tentative rationale for data reduction at the front end is also discussed. As a by-product, a working implementation of the most advanced graphic display technique, ray-casting, is described.

Mcanulty, M. A.↗