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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 NTRS1999

Combustion and Flammability Characteristics of Solids at Microgravity in very Small Velocity Flows

Fires still remain as one of the most important safety risks in manned spacecraft. This problem will become even more important in long endurance non orbital flights in which maintenance will be non existing or very difficult. The basic process of a fire is the combustion of a solid at microgravity conditions in O2/N2 mixtures. Although a large number of research programs have been carried out on this problem, especially on flame spreading, several aspects of these processes are not yet well understood. It may be mentioned, for example, the temperature and characteristic of low emissivity flames in the visual range that take place in some conditions at microgravity; and there exists a lack of knowledge on the influence of key parameters, such as convective flow velocities of the order of magnitude of typical oxygen diffusion velocities. The "Departamento de Motopropulsion y Termofluidodinamica" of the "Universidad Politecnica de Madrid, Escuela Tecnica Superior de Ingenieros Aeronauticos" is conducting a research program on the combustion of solids at reduced gravity conditions within O2/N2 mixtures. The material utilized has been polymethylmethacrylate (PMMA) in the form of rectangular slabs and hollow cylinders. The main parameters of the process have been small convective flow velocities (including velocity angle with the direction of the spreading flame) and oxygen concentration. Some results have also been obtained on the influence of material thickness and gas pressure.

Sanchez-Tarifa, C.↗

NASA NTRS2001

Roughness-Dominated Transition on Nosetips, Attachment Lines and Lifting-Entry Vehicles

Modeling of roughness-dominated transition is a critical design issue for both ablating and non-ablating thermal protection systems (TPS). Ablating TPS, used for planetary-entry and earth-return missions, first experience recession under high-altitude, low-Reynolds-number conditions. Such laminar-flow ablation causes the formation of a surface microroughness pattern characteristic of the TPS material composition and fabrication process. For non-ablating TPS, such as the overlapping-tile, metallic heatshields proposed for future reusable launch vehicles, the surface roughness pattern is established a priori by the engineering design and assembly procedure. In both cases, these distributed surface roughness patterns create disturbances within, and alter the mean velocity profile of, the laminar boundary layer flowing over the surface. As altitude decreases, Reynolds number increases, and flow field conditions capable of amplifying these roughness-induced perturbations are eventually achieved, i.e., transition onset occurs. Boundary layer transition to turbulence results in more severe heat-transfer rates. Ablating TPS experience increased recession rates, leading to potential bum-through, while non-ablating TPS experience accelerated temperature rise, leading to potential melting of key components.

Reda, Daniel C.↗

NASA NTRS2014

Affordable Development and Optimization of CERMET Fuels for NTP Ground Testing

CERMET fuel materials for Nuclear Thermal Propulsion (NTP) are currently being developed at NASA's Marshall Space Flight Center. The work is part of NASA's Advanced Space Exploration Systems Nuclear Cryogenic Propulsion Stage (NCPS) Project. The goal of the FY12-14 project is to address critical NTP technology challenges and programmatic issues to establish confidence in the affordability and viability of an NTP system. A key enabling technology for an NCPS system is the fabrication of a stable high temperature nuclear fuel form. Although much of the technology was demonstrated during previous programs, there are currently no qualified fuel materials or processes. The work at MSFC is focused on developing critical materials and process technologies for manufacturing robust, full-scale CERMET fuels. Prototypical samples are being fabricated and tested in flowing hot hydrogen to understand processing and performance relationships. As part of this initial demonstration task, a final full scale element test will be performed to validate robust designs. The next phase of the project will focus on continued development and optimization of the fuel materials to enable future ground testing. The purpose of this paper is to provide a detailed overview of the CERMET fuel materials development plan. The overall CERMET fuel development path is shown in Figure 2. The activities begin prior to ATP for a ground reactor or engine system test and include materials and process optimization, hot hydrogen screening, material property testing, and irradiation testing. The goal of the development is to increase the maturity of the fuel form and reduce risk. One of the main accomplishmens of the current AES FY12-14 project was to develop dedicated laboratories at MSFC for the fabrication and testing of full length fuel elements. This capability will enable affordable, near term development and optimization of the CERMET fuels for future ground testing. Figure 2 provides a timeline of the development and optimization tasks for the AES FY15-17 follow on program.

Hickman, Robert R.↗

NASA NTRS2004

Recent Advances in Synthesis and Characterization of SWCNTs Produced by Laser Oven Process

Results from the parametric study of the two-laser oven process indicated possible improvements with flow conditions and laser characteristics. Higher flow rates, lower operating pressures coupled with changes in flow tube material are found to improve the nanotube yields. The collected nanotube material is analyzed using a combination of characterization techniques including SEM, TEM, TGA, Raman and UV-VIS-NIR to estimate the purity of the samples. In-situ diagnostics of the laser oven process is now extended to include the surface temperature of the target material. Spectral emission from the target surface is compared with black body type emission to estimate the temperature. The surface temperature seemed to correlate well with the ablation rate as well as the quality of the SWCNTs. Recent changes in improving the production rate by rastering the target and using cw laser will be presented.

Aepalli, Sivaram↗

NASA NTRS1993

Advanced Turbine Technology Applications Project (ATTAP)

The Advanced Turbine Technologies Application Project (ATTAP) is in the fifth year of a multiyear development program to bring the automotive gas turbine engine to a state at which industry can make commercialization decisions. Activities during the past year included reference powertrain design updates, test-bed engine design and development, ceramic component design, materials and component characterization, ceramic component process development and fabrication, ceramic component rig testing, and test-bed engine fabrication and testing. Engine design and development included mechanical design, combustion system development, alternate aerodynamic flow testing, and controls development. Design activities included development of the ceramic gasifier turbine static structure, the ceramic gasifier rotor, and the ceramic power turbine rotor. Material characterization efforts included the testing and evaluation of five candidate high temperature ceramic materials. Ceramic component process development and fabrication, with the objective of approaching automotive volumes and costs, continued for the gasifier turbine rotor, gasifier turbine scroll, extruded regenerator disks, and thermal insulation. Engine and rig fabrication, testing, and development supported improvements in ceramic component technology. Total test time in 1992 amounted to 599 hours, of which 147 hours were engine testing and 452 were hot rig testing.

Source record↗

NASA NTRS1998

Experiments on Nucleation in Different Flow Regimes

Bayuzick, Robert J.↗

NASA NTRS1999

Experiments on Nucleation in Different Flow Regimes

The vast majority of metallic engineering materials are solidified from the liquid phase. Understanding the solidification process is essential to control microstructure, which in turn, determines the properties of materials. The genesis of solidification is nucleation, where the first stable solid forms from the liquid phase. Nucleation kinetics determine the degree of undercooling and phase selection. As such, it is important to understand nucleation phenomena in order to control solidification or glass formation in metals and alloys. Early experiments in nucleation kinetics were accomplished by droplet dispersion methods. Dilatometry was used by Turnbull and others, and more recently differential thermal analysis and differential scanning calorimetry have been used for kinetic studies. These techniques have enjoyed success; however, there are difficulties with these experiments. Since materials are dispersed in a medium, the character of the emulsion/metal interface affects the nucleation behavior. Statistics are derived from the large number of particles observed in a single experiment, but dispersions have a finite size distribution which adds to the uncertainty of the kinetic determinations. Even though temperature can be controlled quite well before the onset of nucleation, the release of the latent heat of fusion during nucleation of particles complicates the assumption of isothermality during these experiments. Containerless processing has enabled another approach to the study of nucleation kinetics. With levitation techniques it is possible to undercool one sample to nucleation repeatedly in a controlled manner, such that the statistics of the nucleation process can be derived from multiple experiments on a single sample. The authors have fully developed the analysis of nucleation experiments on single samples following the suggestions of Skripov. The advantage of these experiments is that the samples are directly observable. The nucleation temperature can be measured by noncontact optical pyrometry, the mass of the sample is known, and post processing analysis can be conducted on the sample. The disadvantages are that temperature measurement must have exceptionally high precision, and it is not possible to isolate specific heterogeneous sites as in droplet dispersions.

Bayuzick, R. J.↗

NASA NTRS1999

Experiments on Nucleation in Different Flow Regimes

The vast majority of metallic engineering materials are solidified from the liquid phase. Understanding the solidification process is essential to control microstructure, which in turn, determines the properties of materials. The genesis of solidification is nucleation, where the first stable solid forms from the liquid phase. Nucleation kinetics determine the degree of undercooling and phase selection. As such, it is important to understand nucleation phenomena in order to control solidification or glass formation in metals and alloys. Early experiments in nucleation kinetics were accomplished by droplet dispersion methods [1-6]. Dilitometry was used by Turnbull and others, and more recently differential thermal analysis and differential scanning calorimetry have been used for kinetic studies. These techniques have enjoyed success; however, there are difficulties with these experiments. Since materials are dispersed in a medium, the character of the emulsion/metal interface affects the nucleation behavior. Statistics are derived from the large number of particles observed in a single experiment, but dispersions have a finite size distribution which adds to the uncertainty of the kinetic determinations. Even though temperature can be controlled quite well before the onset of nucleation, the release of the latent heat of fusion during nucleation of particles complicates the assumption of isothermality during these experiments. Containerless processing has enabled another approach to the study of nucleation kinetics [7]. With levitation techniques it is possible to undercool one sample to nucleation repeatedly in a controlled manner, such that the statistics of the nucleation process can be derived from multiple experiments on a single sample. The authors have fully developed the analysis of nucleation experiments on single samples following the suggestions of Skripov [8]. The advantage of these experiments is that the samples are directly observable. The nucleation temperature can be measured by noncontact optical pyrometry, the mass of the sample is known, and post processing analysis can be conducted on the sample. The disadvantages are that temperature measurement must have exceptionally high precision, and it is not possible to isolate specific heterogeneous sites as in droplet dispersions.

Bayuzick, Robert J.↗

NASA NTRS1995

Demonstration of a stabilized alumina/ethanol colloidal dispersion technique for seeding high temperature air flows

Laser anemometry enables the measurement of complex flow fields via the light scattered from small particles entrained in the flow. In the study of turbomachinery, refractory seed materials are required for seeding the flow due to the high temperatures encountered. In this work we present a pH stabilization technique commonly employed in ceramic processing to obtain stable dispersions for generating aerosols of refractory seed material. By adding submicron alumina particles to a preadjusted pH solution of ethanol, a stable dispersion is obtained which when atomized, produces a high quality aerosol. Commercial grade alumina powder is used with a moderate size distribution. Other metal oxide powders in various polar solvents could also be used once the point of zero charge (pH(pzc)) of the powder in the solvent has been determined. Laser anemometry measurements obtained using the new seeding technique are compared to measurements obtained using Polystyrene Latex (PSL) spheres as the seed material.

Wernet, Mark P.↗

DOE OSTI2024

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBS

The increasing demand for lithium-ion batteries (LIBs ) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCam).During this project ,samples of high-purity recycled NMC hydroxide (~2kg each) were received from Nth Cycle. In the first received batch some impurities like cadmium, calcium, and sodium are present in quantities that would negatively impact battery performance. Nth Cycle indicated that the impurities such as cadmium are present due to poor battery separation and co-shredding of NiCd batteries with with LIB. Cadmium was not present in the two subsequent batches as Nth Cycle processed cadmium free black mass. Thus, effective recycled battery sorting is critical to closed-loop LIB recycling into active electrode materials.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBS

The increasing demand for lithium-ion batteries (LIBs) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCam). During this project , samples of high-purity recycled NMC hydroxide (~2 kg each) were received from Nth Cycle. In the first received batch some impurities like cadmium, calcium, and sodium are present in quantities that would negatively impact battery performance. Nth Cycle indicated that the impurities such as cadmium are present due to poor battery separation and co-shredding of NiCd batteries with with LIB. Cadmium was not present in the two subsequent batches as Nth Cycle processed cadmium free black mass. Thus, effective recycled battery sorting is critical to closed-loop LIB recycling into active electrode materials.

25 ENERGY STORAGE↗

DOE OSTI2026

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBs

The increasing demand for lithium-ion batteries (LIBs) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as well as waste production as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCAM). For this project, two samples of high purity recycled NMC hydroxide (~1 kg each) were received from N th Cycle’s Ohio demonstration facility. The NMC compositions of the two materials are similar, and the levels of impurities have been confirmed. Indeed, impurities like copper, boron and sodium are present in quantities that could negatively impact battery performance. However, some studies have demonstrated that the control of the quantity of elements like copper or boron may improve the electrochemistry properties of Lithium-NMC batteries. The principal objective is to determine the electrochemical performance of these 2 NMC hydroxide batches and clearly determine the effect of the impurities on the performance.

25 ENERGY STORAGE↗

NASA NTRS2004

Supersonic Rocket Thruster Flow Predicted by Numerical Simulation

Despite efforts in the search for alternative means of energy, combustion still remains the key source. Most propulsion systems primarily use combustion for their needed thrust. Associated with these propulsion systems are the high-velocity hot exhaust gases produced as the byproducts of combustion. These exhaust products often apply uneven high temperature and pressure over the surfaces of the appended structures exposed to them. If the applied pressure and temperature exceed the design criteria of the surfaces of these structures, they will not be able to protect the underlying structures, resulting in the failure of the vehicle mission. An understanding of the flow field associated with hot exhaust jets and the interactions of these jets with the structures in their path is critical not only from the design point of view but for the validation of the materials and manufacturing processes involved in constructing the materials from which the structures in the path of these jets are made. The hot exhaust gases often flow at supersonic speeds, and as a result, various incident and reflected shock features are present. These shock structures induce abrupt changes in the pressure and temperature distribution that need to be considered. In addition, the jet flow creates a gaseous plume that can easily be traced from large distances. To study the flow field associated with the supersonic gases induced by a rocket engine, its interaction with the surrounding surfaces, and its effects on the strength and durability of the materials exposed to it, NASA Glenn Research Center s Combustion Branch teamed with the Ceramics Branch to provide testing and analytical support. The experimental work included the full range of heat flux environments that the rocket engine can produce over a flat specimen. Chamber pressures were varied from 130 to 500 psia and oxidizer-to-fuel ratios (o/f) were varied from 1.3 to 7.5.

Davoudzadeh, Farhad↗

NASA NTRS1999

Bubble Dynamics on a Heated Surface

In this work, we study steady and oscillatory thermocapillary and natural convective flows generated by a bubble on a heated solid surface. The interaction between gas and vapor bubbles with the surrounding fluid is of interest for both space and ground-based processing. A combined numerical-experimental approach is adopted here. The temperature field is visualized using Mach-Zehnder and/or Wollaston Prism Interferometry and the flow field is observed by a laser sheet flow visualization technique. A finite element numerical model is developed which solves the transient two-dimensional continuity, momentum, and energy equations and includes the effects of temperature-dependent surface tension and bubble surface deformation. Below the critical Marangoni number, the steady state low-g and 1-g temperature and velocity fields predicted by the finite element model are in excellent agreement with both the visualization experiments in our laboratory and recently published experimental results in the literature. Above the critical Marangoni number, the model predicts an oscillatory flow which is also closely confirmed by experiments. It is shown that the dynamics of the oscillatory flow are directly controlled by the thermal and hydrodynamic interactions brought about by combined natural and thermocapillary convection. Therefore, as numerical simulations show, there are considerable differences between the 1-g and low-g temperature and flow fields at both low and high Marangoni numbers. This has serious implications for both materials processing and fluid management in space.

Kassemi, M.↗

NASA NTRS1999

Approaches to New Endcaps for Improved Oxidation Resistance

Norbornenyl-end capped PMR polyimide resins are widely used as polymer matrix composite materials for aircraft engine applications, since they combine ease of processing with good oxidative stability up to 300 C. PMR resins are prepared by a two-step approach involving the initial formation of oligomeric pre-polymers capped at both ends by a latent reactive end cap. The end cap undergoes cross-linking during higher temperature processing, producing the desired low density, high specific strength materials, for PMR- 15. The end cap facilitates processing by controlling the molecular weight of the oligomer and allowing flow before it cross-links. However, after cross-linking, this very end cap accounts for much of the weight loss in the polymer on aging in air at elevated temperatures. Understanding this degradation provides clues for designing new end caps to slow down degradation, and prolong the lifetime of the material.

Meador, Mary Ann B.↗

NASA NTRS1985

Neutron-rich nuclei in cosmic rays and Wolf-Rayet stars

Wolf-Rayet stars figure prominently in astrophysical research. As a bonus, they seem to offer, in the recent past, an interesting connection between classical astronomy and high energy astrophysics due to their unusual composition and their huge mechanical power. The material flowing from WC stars (carbon-rich WR stars) contains gas which has been processed through core-helium burning, i.e., considerably enriched into 12C,16O, 22Ne, and 25,26Mg. This composition is reminiscent of the cosmic ray source anomalies. Encouraging agreement is obtained with observation in the mass range 12 A 26 assuming acceleration of wind particles at the shock that delineates the WR cavity, and adequate dilution with normal cosmic rays, but silicon poses.

Prantzos, N.↗

NASA NTRS1992

Mass movements on Venus - Preliminary results from Magellan cycle 1 observations

A preliminary assessment of mass movements and their geomorphic characteristics as determined from visual inspection of Magellan cycle 1 synthetic aperture radar images is described. The primary data set was a catalog of over 200 ten-inch square photographic prints of full-resolution mosaic image data records. Venus exhibits unambiguous evidence of mass movements at a variety of scales. Mass movements appear mostly in the form of block and rock movements; there is little evidence of regolith and sediment movements. Unique Venusian conditions may play a role in the creation of some mass movement features. Dark (smooth) surfaces surrounding many rockslide avalanches are probably fine materials emplaced as part of the mass movement process, as airfall, surface-hugging density flows, or coarse-depleted debris flows. The size and efficiency of emplacement of landslide deposits on Venus are comparable to those seen on Mars, which in turn generally resemble terrestrial occurrences.

Malin, Michael C.↗

NASA NTRS2000

Practical Considerations of Waste Heat Reuse for a Mars Mission Advanced Life Support System

Energy conservation is a key issue in design optimization of Advanced Life Support Systems (ALSS) for long-term space missions. By considering designs for conservation at the system level, energy saving opportunities arise that would otherwise go unnoticed. This paper builds on a steady-state investigation of system-level waste heat reuse in an ALSS with a low degree of crop growth for a Mars mission. In past studies, such a system has been defined in terms of technology types, hot and cold stream identification and stream energy content. The maximum steady-state potential for power and cooling savings within the system was computed via the Pinch Method. In this paper, several practical issues are considered for achieving a pragmatic estimate of total system savings in terms of equivalent system mass (ESM), rather than savings solely in terms of power and cooling. In this paper, more realistic ESM savings are computed by considering heat transfer inefficiencies during material transfer. An estimate of the steady-state mass, volume and crewtime requirements associated with heat exchange equipment is made by considering heat exchange equipment material type and configuration, stream flow characteristics and associated energy losses during the heat exchange process. Also, previously estimated power and cooling savings are adjusted to reflect the impact of such energy losses. This paper goes one step further than the traditional Pinch Method of considering waste heat reuse in heat exchangers to include ESM savings that occur with direct reuse of a stream. For example, rather than exchanging heat between crop growth lamp cooling air and air going to a clothes dryer, air used to cool crop lamps might be reused directly for clothes drying purposes. When thermodynamically feasible, such an approach may increase ESM savings by minimizing the mass, volume and crewtime requirements associated with stream routing equipment.

Levri, Julie↗