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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

Development and Characterization of the Bonding and Integration Technologies Needed for Fabricating Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding technology, titanium interlayers (coatings and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness, and processing time were investigated. Electron microprobe analysis was used to identify the reaction formed phases. In the diffusion bonds, an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner interlayers of pure titanium and/or longer processing times resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Nondestructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig,Michael C.↗
NASA NTRS2008

Bonding and Integration Technologies for Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding, titanium interlayers (PVD and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness (10, 20, and 50 microns), processing time and temperature, and cooling rates were investigated. Microprobe analysis was used to identify the phases in the bonded region. For bonds that were not fully reacted an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner titanium interlayers and/or longer processing times resulted in stable and compatible phases that did not contribute to microcracking and resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Non-destructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig, Michael C.↗
NASA NTRS2006

Apparatus for Hot Impact Testing of Material Specimens

An apparatus for positioning and holding material specimens is a major subsystem of a system for impact testing of the specimens at temperatures up to 1,500 C. This apparatus and the rest of the system are designed especially for hot impact testing of advanced ceramics, composites, and coating materials. The apparatus includes a retaining fixture on a rotating stage on a vertically movable cross support driven by a linear actuator. These components are located below a furnace wherein the hot impact tests are performed (see Figure 1). In preparation for a test, a specimen is mounted on the retaining fixture, then the cross support is moved upward to raise the specimen, through an opening in the bottom of the furnace, to the test position inside the furnace. On one side of the furnace there is another, relatively small opening on a direct line to the specimen. Once the specimen has become heated to the test temperature, the test is performed by using an instrumented external pressurized-gas-driven gun to shoot a projectile through the side opening at the specimen.

Pawlik, Ralph J.↗
NASA NTRS2005

Life Prediction for a CMC Component Using the NASALIFE Computer Code

The computer code, NASALIFE, was used to provide estimates for life of an SiC/SiC stator vane under varying thermomechanical loading conditions. The primary intention of this effort is to show how the computer code NASALIFE can be used to provide reasonable estimates of life for practical propulsion system components made of advanced ceramic matrix composites (CMC). Simple loading conditions provided readily observable and acceptable life predictions. Varying the loading conditions such that low cycle fatigue and creep were affected independently provided expected trends in the results for life due to varying loads and life due to creep. Analysis was based on idealized empirical data for the 9/99 Melt Infiltrated SiC fiber reinforced SiC.

Gyekenyesi, John Z.↗
NASA NTRS2004

Flexible Shields for Protecting Spacecraft Against Debris

A report presents the concept of Flexshield a class of versatile, lightweight, flexible shields for protecting spacecraft against impacts by small meteors and orbiting debris. The Flexshield concept incorporates elements of, but goes beyond, prior spacecraft-shielding concepts, including those of Whipple shields and, more recently, multi-shock shields and multi-shock blankets. A shield of the Flexshield type includes multiple outer layers (called bumpers in the art) made, variously, of advanced ceramic and/or polymeric fibers spaced apart from each other by a lightweight foam. As in prior such shields, the bumpers serve to shock an impinging hypervelocity particle, causing it to disintegrate vaporize, and spread out over a larger area so that it can be stopped by an innermost layer (back sheet). The flexibility of the fabric layers and compressibility of the foam make it possible to compress and fold the shield for transport, then deploy the shield for use. The shield can be attached to a spacecraft by use of snaps, hook-and-pile patches, or other devices. The shield can also contain multilayer insulation material, so that it provides some thermal protection in addition to mechanical protection.

Christiansen, Eric L.↗
NASA NTRS2008

Joining of Silicon Carbide: Diffusion Bond Optimization and Characterization

Joining and integration methods are critically needed as enabling technologies for the full utilization of advanced ceramic components in aerospace and aeronautics applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. In the application, several SiC substrates with different hole patterns to form fuel and combustion air channels are bonded to form the injector. Diffusion bonding is a joining approach that offers uniform bonds with high temperature capability, chemical stability, and high strength. Diffusion bonding was investigated with the aid of titanium foils and coatings as the interlayer between SiC substrates to aid bonding. The influence of such variables as interlayer type, interlayer thickness, substrate finish, and processing time were investigated. Optical microscopy, scanning electron microscopy, and electron microprobe analysis were used to characterize the bonds and to identify the reaction formed phases.

Halbig, Michael C.↗
NASA NTRS2018

Scale-Resolving Simulations of Low-Pressure Turbine Cascades with Wall Roughness Using A Spectral-Element Method

The accurate prediction of wall-roughness effects in turbomachinery is becoming critical as turbine designers address airfoil surface quality and degradation concerns arising from the shift to advanced ceramic matrix composite (CMC) or additively-manufactured airfoils operating in higher temperature environments. In this paper, a recently developed computational capability for accurate and efficient scale-resolving simulations of turbomachinery is extended to analyze the boundary- layer separation and transition characteristics in a rough-wall low-pressure turbine (LPT) cascade. The computational capability is based on an entropy-stable discontinuous-Galerkin spectral-element approach that extends to arbitrarily high orders of spatial and temporal accuracy, and is implemented in an efficient manner for a modern high performance computer architecture. Results from the scale-resolving simulations of both smooth and rough airfoil cascades are presented and compared to previous experiments and numerical simulations. The results show that the suction surface boundary layer undergoes laminar separation, transition, and turbulent reattachment for the smooth airfoil cascade, while in the presence of roughness the separation and transition behavior of the suction surface boundary layer is substantially modified. The differences between the smooth and rough airfoil cascades are then highlighted by a detailed analysis of their respective turbulent flow fields.

Spectral-Element↗
NASA NTRS2019

Slow Crack Growth of Boron Nitrides for Electric Propulsion Components

The Deep Space Gateway requires thruster systems to maintain spatial position. One control system being considered involves Hall thrusters. Historically, Hall thruster discharge channels have used several grades of hot-pressed hexagonal boron nitride. This study compliments data presented at ICACC (International Conference and Expo on Advanced Ceramics and Composites) 2018 and investigates the fracture toughness and slow crack growth parameters of several commercially available boron nitride grades including HP, M, M26, and Shapal Hi-M. The prior work revealed that some grades of BN absorb water and change strength thus presenting a philosophical conundrum on crack growth test methods. Advantages of different test methods will be discussed. The grades selected for this study are of interest because their available billet size is sufficient for Hall thruster discharge channels, or because they have heritage in Hall thruster applications. Ultimately, the data will be used to perform material selection, system design and reliability analyses.

Ceramics↗
NASA NTRS2020

Lot-to-lot Variability of BN Grades for Space Electric Propulsion Applications

Historically, several grades of hot pressed hexagonal boron nitride have been used for space electric propulsion applications. This study investigates the material properties of a selection of commercially available boron nitride grades including HP, M26, M, BNXX, and Shapal Hi-M. This work complements data which was presented at JANNAF 2018. The grades selected for this study are of interest because their available billet size is sufficient for space electric propulsion. This research investigates a range of material properties, tailored and focused on enhancing performance, reliability, and economics of electric propulsion thrusters. This work builds upon previous efforts by studying lot-to-lot variability of some of the properties of interest. Coefficient of friction, moisture absorption, moisture sensitivity, hot press directionality, flexural strength, compression strength, elastic modulus, thermal conductivity, thermal emissivity, thermal expansion, density, X-ray diffraction phase, microstructure, and chemical composition were all investigated across two lots of materials to help guide the selection of advanced ceramics. Variability between lots is the critical concern of the study.

Mackey, Jonathan A.↗
NASA NTRSDate not supplied

Protective Coatings for Mitigating Lunar Dust Abrasion and Adhesion

Materials resistant to the harsh lunar environment are needed to support long duration, sustainable missions on the Moon’s surface. Lunar dust poses a significant threat to the durability of components and vehicles due to its fine, jagged morphology and highly abrasive nature. These characteristics result in particles eroding, adhering and/or embedding onto component surfaces and into device confined geometries (e.g., gear housing, interlocking systems, etc.) potentially leading to premature failure. The aim of this work is to identify and characterize wear-resistant materials, including advanced ceramics, for use as protective coatings to minimize abrasion and adhesion caused by lunar dust. Results from testing and evaluation methods devised to elucidate and mimic aspects of lunar dust degradation, including adhesion, abrasion and erosion, as well as the lunar environment, will be presented. Discussion on balancing the need for dust management and tolerance versus dust adhesion mitigation will be shared in context of relevant lunar applications within the NASA Lunar Occupancy Dust Surface Separation Technologies effort, which is part of a NASA-wide effort to enable a sustained lunar presence through the Lunar Surface Innovation Initiative.

lunar dust mitigation↗
NASA NTRS2023

Protective Coatings for Lunar Dust Tolerance

Materials capable of withstanding the harsh lunar environment are critically needed to support long duration, sustainable missions on the Moon’s surface. Lunar dust significantly threatens the durability and reusability of components and vehicles due to possessing a fine, jagged morphology and highly abrasive nature. These characteristics result in the particles eroding, adhering and/or embedding onto component surfaces and into device confined geometries (e.g., gear housing, interlocking systems, etc.) potentially leading to premature failure. The aim of this study is to identify and characterize wear-resistant commercial-off-the-shelf (COTS) materials, including advanced ceramics, for use as protective coatings to minimize abrasion and adhesion caused by lunar dust. Preliminary testing that mimics various aspects of lunar dust degradation, such as abrasive wear and adhesion, suggests that COTS ceramic coatings can improve lunar dust tolerance and protect underlying metallic substrates.

Valerie. L. Wiesner↗
DOE OSTI2023

Using simulation to study solid oxide cell degradation

Slides of the presentation given by Harry Abernathy from the National Energy Technology Laboratory at the 2023 International Conference and Expo on Advanced Ceramics and Composites. The presentation was an overview of NETL's solid oxide cell performance degradation modeling, including a demonstration of the impact of microstructural analysis methods on the resulting degradation simulations.

Abernathy, Harry↗
DOE OSTI2024

Developing higher performing solid oxide cells through simulation

Presentation given by NETL solid oxide cell (SOC) group leader Harry Abernathy reviewing NETL's SOC modeling capabilities for an invited talk at the 48th International Conference and Expo on Advanced Ceramics and Composites January 28 - February 2, 2024.

Abernathy, Harry↗