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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 199 records · Page 11

Discovering Dark Matter Clumps and Primordial Particles with Galaxies

Cosmological observations and galaxy dynamics seem to imply that five out of six parts in mass of all matter in the universe is composed of dark matter, which is not accounted for by the Standard Model of particles. The cold dark matter (CDM) paradigm has been extremely successful at describing observations on large-cosmological scale. However, many different dark matter candidates have the same observable effects as CDM on large-length scales. One possible avenue to distinguish between these different models is to look on much smaller-length scales, where usually dark matter models become distinguishable. This research developed the theoretical framework and statistical tools needed to map the detailed distribution of dark matter on subgalactic scales using strong gravitational lensing. A second goal of this research was to build new statistical techniques that efficiently exploit the full power of cosmic-structure data from next-generation surveys. Galaxy clustering on large scales provides significant cosmological information through the power spectrum. Additional information can be gained from higher-order statistics. This research provided new ways to understand the initial conditions of the universe from current and upcoming cosmological surveys.

79 ASTRONOMY AND ASTROPHYSICS↗

The Effect of Interlayer Delay on the Heat Accumulation, Microstructures, and Properties in Laser Hot Wire Directed Energy Deposition of Ti-6Al-4V Single-Wall

Laser hot wire directed energy deposition (LHW-DED) is a layer-by-layer additive manufacturing technique that permits the fabrication of large-scale Ti-6Al-4V (Ti64) components with a high deposition rate and has gained traction in the aerospace sector in recent years. However, one of the major challenges in LHW-DED Ti64 is heat accumulation, which affects the part quality, microstructure, and properties of as-built specimens. These issues require a comprehensive understanding of the layerwise heat-accumulation-driven process–structure–property relationship in as-deposited samples. In this study, a systematic investigation was performed by fabricating three Ti-6Al-4V single-wall specimens with distinct interlayer delays, i.e., 0, 120, and 300 s. The real-time acquisition of high-fidelity thermal data and high-resolution melt pool images were utilized to demonstrate a direct correlation between layerwise heat accumulation and melt pool dimensions. The results revealed that the maximum heat buildup temperature of the topmost layer decreased from 660 °C to 263 °C with an increase to a 300 s interlayer delay, allowing for better control of the melt pool dimensions, which then resulted in improved part accuracy. Furthermore, the investigation of the location-specific composition, microstructure, and mechanical properties demonstrated that heat buildup resulted in the coarsening of microstructures and, consequently, the reduction of micro-hardness with increasing height. Extending the delay by 120 s resulted in a 5% improvement in the mechanical properties, including an increase in the yield strength from 817 MPa to 859 MPa and the ultimate tensile strength from 914 MPa to 959 MPa. Cooling rates estimated at 900 °C using a one-dimensional thermal model based on a numerical method allowed us to establish the process–structure–property relationship for the wall specimens. The study provides deeper insight into the effect of heat buildup in LHW-DED and serves as a guide for tailoring the properties of as-deposited specimens by regulating interlayer delay.

36 MATERIALS SCIENCE↗

Arecibo radar observations of Mars surface characteristics in the Northern Hemisphere

Mars surface characteristics at and near the Viking Chryse and Tritonis Lacus landing areas were determined by radio scatter using the 12.6-cm radar at the Arecibo Observatory during 1975-76. Interpretation of each power spectrum suggests rms surface tilts of 4 deg at the final A1WNW (47.9 deg W, 22.5 deg N) site, 5 deg near the original A1 site, and 6 deg between the two. At the back-up site (A2) surface-roughness estimates were about 4 deg. Striking changes in surface texture have been found near the eastern bases of Tharsis Montes and Albor Tholus, each volcanic feature marking the western boundary of very smooth surface units. The roughness sensed at 1- to 100-m scales by radar appears to be relatively independent of the surface units defined at large scale lengths by photogeologists. Radar properties thus provide an additional means by which planetary surfaces may be characterized.

Simpson, R. A.↗

Comparing the results of an analytical model of the no-vent fill process with no-vent fill test results for a 4.96 cu m (175 cu ft) tank

NASA-Lewis has been investigating a no-vent fill method for refilling cryogenic storage tanks in low gravity. Analytical modeling based on analyzing the heat transfer of a droplet has successfully represented the process in 0.034 and 0.142 sq m commercial dewars using liquid nitrogen and hydrogen. Recently a large tank (4.96 sq m) was tested with hydrogen. This lightweight tank is representative of spacecraft construction. This paper presents efforts to model the large tank test data. The droplet heat transfer model is found to overpredict the tank pressure level when compared to the large tank data. A new model based on equilibrium thermodynamics has been formulated. This new model is compared to the published large scale tank's test results as well as some additional test runs with the same equipment. The results are shown to match the test results within the measurement uncertainty of the test data except for the initial transient wall cooldown where it is conservative (i.e., overpredicts the initial pressure spike found in this time frame).

Taylor, William J.↗

Comparing the results of an analytical model of the no-vent fill process with no-vent fill test results for a 4.96 cubic meters (175 cubic feet) tank

The NASA Lewis Research Center (NASA/LeRC) have been investigating a no-vent fill method for refilling cryogenic storage tanks in low gravity. Analytical modeling based on analyzing the heat transfer of a droplet has successfully represented the process in 0.034 m and 0.142 cubic m commercial dewars using liquid nitrogen and hydrogen. Recently a large tank (4.96 cubic m) was tested with hydrogen. This lightweight tank is representative of spacecraft construction. This paper presents efforts to model the large tank test data. The droplet heat transfer model is found to over predict the tank pressure level when compared to the large tank data. A new model based on equilibrium thermodynamics has been formulated. This new model is compared to the published large scale tank's test results as well as some additional test runs with the same equipment. The results are shown to match the test results within the measurement uncertainty of the test data except for the initial transient wall cooldown where it is conservative (i.e., overpredicts the initial pressure spike found in this time frame).

Taylor, William J.↗

Distributed Saturation

The Saturation algorithm for symbolic state-space generation, has been a recent break-through in the exhaustive veri cation of complex systems, in particular globally-asyn- chronous/locally-synchronous systems. The algorithm uses a very compact Multiway Decision Diagram (MDD) encoding for states and the fastest symbolic exploration algo- rithm to date. The distributed version of Saturation uses the overall memory available on a network of workstations (NOW) to efficiently spread the memory load during the highly irregular exploration. A crucial factor in limiting the memory consumption during the symbolic state-space generation is the ability to perform garbage collection to free up the memory occupied by dead nodes. However, garbage collection over a NOW requires a nontrivial communication overhead. In addition, operation cache policies become critical while analyzing large-scale systems using the symbolic approach. In this technical report, we develop a garbage collection scheme and several operation cache policies to help on solving extremely complex systems. Experiments show that our schemes improve the performance of the original distributed implementation, SmArTNow, in terms of time and memory efficiency.

Chung, Ming-Ying↗

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗

Overview on Role of the Troposphere

The troposphere is the lower boundary for the stratosphere. As such, it provides a radiative boundary that is a large source of IR flux into for the stratosphere and scattered UV-Vis energy. Planetary-scale waves that are forced in the troposphere can propagate into the stratosphere, providing a large additional source of energy for the stratosphere. This wave energy is the principal energy source for the Brewer-Dobson circulation. Medium-scale wave can also propagate into the lower stratosphere, but have a smaller effect. The final source of energy for the stratosphere comes from smaller scale disturbances such as gravity waves, mixed Rossby-gravity modes, and Kelvin waves. These smaller scale waves provide an important source of energy for the stratosphere. In this presentation we will cover these tropospheric sources of energy that effect the stratosphere. In particular, we will focus attention on planetary scale waves and their forcings.

Newman, Paul A.↗

Titanium Wire Arc Additive Manufacturing Inert Enclosure and Material Handling Safety Considerations

Wire arc additive manufacturing (WAAM) via metal inert gas (MIG)/gas metal arc welding (GMAW) is a viable option for fabrication of large-scale titanium parts; however, it introduces new safety hazards associated with both the material and the additional system hardware required for the process. Localized gas shielding of the weld arc via standard GMAW torch is inadequate for titanium due to its affinity for oxygen; thereby requiring the use of an inert enclosure to protect the weld from entraining oxygen. The use of the inert enclosure presents potential safety hazards such as operator asphyxiation and brings up discussion of confined space considerations. In addition, the titanium welding process creates pyrophoric titanium soot residue around the deposit, which can undergo deflagration during part cleaning and part removal. This paper provides an overview of the titanium WAAM process along with safety considerations for the design and operation of the inert enclosure as well as functional solutions for the safe handling of the titanium soot by-product.

Walters, Alex↗

Cyclic Oxidation of FeCrAlY/Al2O3 Composites

Three-ply FeCrAlY/Al2O3 composites and FeCrAlY matrix-only samples were cyclically oxidized at 1000 C and 1100 C for up to 1000 1-hr cycles. Fiber ends were exposed at the ends of the composite samples. Following cyclic oxidation, cracks running parallel to and perpendicular to the fibers were observed on the large surface of the composite. In addition, there was evidence of increased scale damage and spallation around the exposed fiber ends, particularly around the middle ply fibers. This damage was more pronounced at the higher temperature. The exposed fiber ends showed cracking between fibers in the outer plies, occasionally with Fe and Cr-rich oxides growing out of the cracks. Large gaps developed at the fiber/matrix interface around many of the fibers, especially those in the outer plies. Oxygen penetrated many of these gaps resulting in significant oxide formation at the fiber/matrix interface far within the composite sample. Around several fibers, the matrix was also internally oxidized showing Al2O3 precipitates in a radial band around the fibers. The results show that these composites have poor cyclic oxidation resistance due to the CTE mismatch and inadequate fiber/matrix bond strength at temperatures of 1000 C and above.

Nesbitt, James A.↗

Stochastic-Dynamical Modeling of Space Time Rainfall

The focus of this research work is the elucidation of the physical origins of the observed extreme-rainfall variability over tropical oceans. The quantitative results of this work may be used to establish links between deterministic models of the mesoscale and synoptic scale with statistical descriptions of the temporal variability of local tropical oceanic rainfall. In addition, they may be used to quantify the influence of measurement error in large-scale forcing and cloud scale observations on the accuracy of local rainfall variability inferences, important for hydrologic studies. A simple statistical-dynamical model, suitable for use in repetitive Monte Carlo experiments, is formulated as a diagnostic tool for this purpose. Stochastic processes with temporal structure and parameters estimated from observed large-scale data represent large-scale forcing.

Georgankakos, Konstantine P.↗

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

DED↗

UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers

The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Free-Flight Zero-Lift Drag Results from a 1/5-Scale Model and Several Small-Scale Equivalent Bodies of Revolution of the Convair F-102 Configuration at Mach Numbers up to 1.34

A 1/5-scale, rocket-propelled model of the Convair F-102 configuration was tested in free flight to determine zero-lift drag at Mach numbers up to 1.34 and at Reynolds numbers comparable to those of the full-scale airplane. This large-scale model corresponded to the prototype airplane and had air flow through the duct. Additional zero-lift drag tests involved a series of small equivalent bodies of revolution which were launched by means of a helium gun. The several small-scale models tested corresponded to: the basic configuration, the 1/5-scale rocket-propelled model configuration, a 2-foot (full-scale) fuselage-extension configuration, and a 7-foot (full-scale) fuselage-extension configuration. Models designed to correspond to the area distribution at a Mach number of 1.0 were flown for each of these 'shapes and, in addition, models designed to correspond to the area distribution at a Mach number of 1.2 were flown for the 1/5-scale rocket-propelled model and the 7-foot-fuselage-extension configuration. The value of external pressure drag coefficient (including base drag) obtained from the large-scale rocket model was 0.0190 at a Mach number of 1..05 and the corresponding values from the equivalent-body tests varied from 0.0183 for the rocket-propelled model shape to 0.0137 for the 7-foot-fuselage-extension configuration. From the results of tests of equivalent bodies designed to correspond to the area distribution at a Mach number of 1.0, it is evident that the small changes in shape incorporated in the basic and 2-foot-fuselage-extension configurations from that of the rocket-propelled model configuration will provide no significant change in pressure drag. On the other hand, the data from the 7-foot-fuselage-extension model indicate a substantial reduction in pressure drag at transonic speeds.

Wallskog, Harvey A.↗

Large-scale wind tunnel tests of a sting-supported V/STOL fighter model at high angles of attack

A new sting model support has been developed for the NASA/Ames 40- by 80-Foot Wind Tunnel. This addition to the facility permits testing of relatively large models to large angles of attack or angles of yaw depending on model orientation. An initial test on the sting is described. This test used a 0.4-scale powered V/STOL model designed for testing at angles of attack to 90 deg and greater. A method for correcting wake blockage was developed and applied to the force and moment data. Samples of this data and results of surface-pressure measurements are presented.

Stoll, F.↗

Growth-induced Donnan exclusion influences swelling kinetics in highly charged dynamic polymerization hydrogels

Polymeric gels crosslinked by DNA sequences can exploit DNA strand-displacement reactions to promote swelling through dynamic polymerization. The degree of swelling and the rate of swelling must be directly tunable to achieve the promise of programmable soft matter. Though the kinetics of the strand-displacement reaction provide insertion rates up to 10 4 /Molar/second as measured in bulk solution, DNA hydrogel swelling can take upwards of 30 h to complete. Computational modeling of the reaction-induced swelling of these gels with our recently-developed reactive electrochemomechanical theory (Zimmerman et al., 2024) suggests that their extraordinarily slow swelling is partly due to a scaling mismatch between the addition of charge and the addition of fluid volume, leading to a large transient increase in the fixed charge density. The significant increase in the gel’s fixed charge density, due to the binding of negatively charged DNA, sharply restricts the concentration of mobile hairpins through the phenomenon of Donnan charge exclusion, an effect commonly exploited in nanofiltration applications using polymeric membranes. The scaling problem is overcome when the mean additional swelling provided to the hydrogel by addition of a crosslink is above a critical value, thus the swelling outpaces the charge accumulation, leading the fixed charge density to drop and significantly accelerating the swelling process. This study shows that Donnan exclusion can explain the kinetics of DNA hydrogel swelling, and studies ways to modulate the reaction speed by either modifying the salt concentration or increasing or decreasing the number of base pairs in each DNA sequence.

42 ENGINEERING↗

Cold Metal Transfer (CMT) Wire-Arc Additive Manufacturing (WAAM)

Aluminum has been identified as a compound within regolith and is likely to become a core component of our infrastructure on the lunar surface as in-situ resource utilization (ISRU) capabilities are advanced Large-scale components, outfitting, and repairs of aluminum materials can be fabricated with robotic wire arc additive manufacturing (WAAM) in order to inhabit the moon’s surface long term WAAM is a high value process for lunar advanced manufacturing as it does not require special containment to reduce explosion hazards such as powder-based additive processes and feedstock The welding process of cold metal transfer (CMT) is a relatively new variation of gas metal arc welding (GMAW, also known as MIG) that relies on the detection of a short circuit in the welding process to control the deposition droplet action, resulting in lower heat input and splatter compared to conventional MIG welding The past year was spent developing the CMT-WAAM process for aluminum materials, tested specialty feedstock, tested within the high vacuum environment, and advanced the MSFC capability to perform complex toolpathing from solid models Upcoming and future work includes large depositions working towards material certification for multiple feedstocks, in-situ monitoring, work to use recycled materials for the AM feedstock, and the design and fabrication of a parabolic flight experiment payload.

cold metal transfer↗

Direct Simulation of a Self-Similar Turbulent Mixing Layer

Three direct numerical simulations of incompressible turbulent plane mixing layers have been performed. All the simulations were initialized with the same two velocity fields obtained from a direct numerical simulation of a turbulent boundary layer with a momentum thickness Reynolds number of 300 computed by Spalart (J. Fluid Mech. 187, 61, 1988). In addition to a baseline case with no additional disturbances, two simulations were begun with two-dimensional disturbances of varying strength in addition to the boundary layer turbulence. After a development stage, the baseline case and the case with weaker additional two-dimensional disturbances evolve self-similarly, reaching visual thickness Reynolds numbers of up to 20 000. This self-similar period is characterized by a lack of large-scale organized pairings, a lack of streamwise vortices in the 'braid' regions, and scalar mixing that is characterized by 'marching' Probability Density Functions (PDFs). The case begun with strong additional two-dimensional disturbances only becomes approximately self-similar, but exhibits sustained organized large-scale pairings, clearly defined braid regions with streamwise vortices that span them, and scalar PDFs that are 'nonmarching.' It is also characterized by much more intense vertical velocity fluctuations than the other two cases. The statistics and structures in several experiments involving turbulent mixing layers are in better agreement with those of the simulations that do not exhibit organized pairings.

Rogers, Michael M.↗