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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
All sourcesNASA NTRSDOE OSTI
NASA NTRS1996

Water-Based Electroplating Maskant Is Safer

Report proposes use of commercial water-based electroplating maskant Tolber 0-18 as nontoxic alternative to commercial organic-solvent-based electroplating maskant Turco 531-A. Tolber 0-18 found to be equal or superior in key properties, including suitability for application by brushing, effectiveness of sealing, and durability. In addition, exerts no adverse effect on environment or on health of workers, and enables users to comply with local and federal antipollution laws. Use of maskant proves beneficial in most, if not all, electroplating applications involving brush application of maskants to areas not to be electroplated.

Pickett, Garry M.↗
NASA NTRS1999

Electrostatic Hazard Considerations for ODC Solvent Replacement Selection Testing

ODC solvents are used to clean many critical substrates during solid rocket motor production operations. Electrostatic charge generation incidental to these cleaning operations can pose a major safety issue. Therefore, while determining the acceptability of various ODC replacement cleaners, one aspect of the selection criteria included determining the extent of electric charge generation during a typical solvent cleaning operation. A total of six candidate replacement cleaners, sixteen critical substrates, and two types of cleaning swatch materials were studied in simulated cleaning operations. Charge generation and accumulation effects were investigated by measuring the peak voltage and brush discharging effects associated with each cleaning process combination. In some cases, charge generation was found to be very severe. Using the conductivity information for each cleaner, the peak voltage data could in some cases, be qualitatively predicted. Test results indicated that severe charging effects could result in brush discharges that could potentially result in flash fire hazards when occurring in close proximity to flammable vapor/air mixtures. Process controls to effectively mitigate these hazards are discussed.

Fairbourn, Brad↗
NASA NTRS1999

Use of Several Thermal Analysis Techniques on a Hypalon Paint Coating for the Solid Rocket Booster (SRB) of the Space Shuttle

White Hypalon paint is brush-applied as a moisture barrier coating over cork surfaces on each of the two Space Shuttle SRBS. Fine cracks have been observed in the Hypalon coating three times historically on laboratory witness panels, but never on flight hardware. Recent samples of the cracked and standard ("good") Hypalon were removed from cork surfaces and were tested by Thermal Gravimetric Analysis (TGA), Thermomechanical (TMA) and Differential Scanning Calorimetry (DSC) thermal analysis techniques. The TGA data showed that at 700 C, where only paint pigment solids remain, the cracked material had about 9 weight percent more material remaining than the standard material, probably indicating incomplete mixing of the paint before it was brush-applied to produce the cracked material. Use of the TMA film tension method showed that the average static modulus vs. temperature was about 3 to 6 times higher for the cracked material than for the standard material, indicating a much higher stiffness for the cracked Hypalon. The TMA data also showed than an increased coating thickness for the cracked Hypalon was not a factor in the anomaly.

Wingard, Charles D.↗
NASA NTRS1998

Effects of Buoyancy on Lean Premixed V-Flames Part I: Laminar and Turblent Flame Structure

Laser schlieren and planar laser-induced fluorescence techniques have been used to investigate laminar and turbulent v-flames in +g, -g, and micro g under flow conditions that span the regimes of momentum domination (Ri < 0. 1) and buoyancy domination (Ri > 0.1). Overall flame features shown by schlieren indicate that buoyancy dominates the entire flow field for conditions close to Ri = 1. With decreasing Ri, buoyancy effects are observed only in the far-field regions. Analyses of the mean flame angles demonstrate that laminar and turbulent flames do not have similar responses to buoyancy. Difference in the laminar +g and -g flame angles decrease with Ri (i.e., increasing Re) and converge to the microgravity flame angle at the momentum limit (Ri - 0). This is consistent with the notion that the effects of buoyancy diminish with increasing flow momentum. The +g and -g turbulent flame angles, however, do not converge at Ri = 0. As shown by OH-PLIF images, the inconsistency in +g and -g turbulent flame angles is associated with the differences in flame wrinkles. Turbulent flame wrinkles evolve more slowly in +g than in -g. The difference in flame wrinkle structures, however, cannot be explained in terms of buoyancy effects on flame instability mechanisms. It seems to be associated with the field effects of buoyancy that stretches the turbulent flame brushes in +g and compresses the flame brush in -g. Flame wrinkling offers a mechanism through which the flame responds to the field effects of buoyancy despite increasing flow momentum. These observations point to the need to include both upstream and downstream contributions in theoretical analysis of flame turbulence interactions.

Cheng, Robert K.↗
NASA NTRS2000

Use of Several Thermal Analysis Techniques on a Hypalon Paint Coating for the Solid Rocket Booster (SRB) of the Space Shuttle

White Hypalon paint is brush-applied as a moisture barrier coating over cork surfaces on each of the two Space Shuttle SRBs. Fine cracks have been observed in the Hypalon coating three times historically on laboratory witness panels, but never on flight hardware. Samples of the cracked and standard ("good") Hypalon were removed from witness panel cork surfaces, and were tested in 1998 by Thermogravimetric Analysis (TGA), TMA and Differential Scanning Calorimetry (DSC) thermal analysis techniques. The TGA data showed that at 700C, where only paint pigment solids remain, the cracked material had about 9 weight percent more material remaining than the standard material, probably indicating incomplete mixing of the paint before it was brush-applied to produce the cracked material. Use of the TMA film/fiber technique showed that the average modulus (stiffness) vs. temperature was about 3 to 6 times higher for the cracked material than for the standard material. The TMA data also showed that an increase in coating thickness for the cracked Hypalon was not a factor in the anomaly.

Wingard, Charles D.↗
NASA NTRS2004

Leakage and Power Loss Test Results for Competing Turbine Engine Seals

Advanced brush and finger seal technologies offer reduced leakage rates over conventional labyrinth seals used in gas turbine engines. To address engine manufacturers concerns about the heat generation and power loss from these contacting seals, brush, finger, and labyrinth seals were tested in the NASA High Speed, High Temperature Turbine Seal Test Rig. Leakage and power loss test results are compared for these competing seals for operating conditions up to 922 K (1200 F) inlet air temperature, 517 KPa (75 psid) across the seal, and surface velocities up to 366 m/s (1200 ft/s).

Proctor, Margaret P.↗
NASA NTRS2004

The Multistage Compressor Facility

Research and developments of new aerospace technologies is one of Glenn Research Center's specialties. One facility that deals with the research of aerospace technologies is the High-speed Multistage Compressor Facility. This facility will be testing the performance and efficiency of an Ultra Efficient Engine Technology (UEET) two-stage compressor. There is a lot of preparation involved with testing something of this caliber. Before the test article can be installed into the test rig, the facility must be fully operational and ready to run. Meaning all the necessary instrumentation must be calibrated and installed in the facility. The test rig should also be in safe operating condition, and the proper safety permits obtained. In preparation for the test, the Multistage Compressor Facility went through a few changes. For instance the facility will now be utilizing slip rings, the gearbox went through some maintenance, new lubrications systems replaced the old ones, and special instrumentation needs to be fine tuned to achieve the maximum amount of accurate data. Slips rings help gather information off of a rotating device - in this case from a shaft - onto stationary contacts. The contacts (or brushes) need to be cooled to reduce the amount of frictional heat produced between the slip ring and brushes. The coolant being run through the slip ring is AK-225, a material hazardous to the ozone. To abide by the safety regulations the coolant must be run through a closed chiller system. A new chiller system was purchased but the reservoir that holds the coolant was ventilated which doesn t make the system truly closed and sealed. My task was to design and have a new reservoir built for the chiller system that complies with the safety guidelines. The gearbox had some safety issues also. Located in the back of the gearbox an inching drive was set up. When the inching drive is in use the gears and chain are bare and someone can easily get caught up in it. So to prevent anyone from getting hurt in the gears I designed a chain guard. Additional information is included in the original extended abstract.

Flegel, Ashlie↗
NASA NTRS2003

High-Speed, High-Temperature Finger Seal Test Evaluated

A finger seal, designed and fabricated by Honeywell Engines, Systems and Services, was tested at the NASA Glenn Research Center at surface speeds up to 1200 ft/s, air temperatures up to 1200 F, and pressures across the seal of 75 psid. These are the first test results obtained with NASA s new High-Temperature, High-Speed Turbine Seal Test Rig (see the photograph). The finger seal is an innovative design recently patented by AlliedSignal Engines, which has demonstrated considerably lower leakage than commonly used labyrinth seals and is considerably cheaper than brush seals. The cost to produce finger seals is estimated to be about half of the cost to produce brush seals. Replacing labyrinth seals with fingers seals at locations that have high-pressure drops in gas turbine engines, typically main engine and thrust seals, can reduce air leakage at each location by 50 percent or more. This directly results in a 0.7- to 1.4-percent reduction in specific fuel consumption and a 0.35- to 0.7-percent reduction in direct operating costs . Because the finger seal is a contacting seal, this testing was conducted to address concerns about its heat generation and life capability at the higher speeds and temperatures required for advanced engines. The test results showed that the seal leakage and wear performance are acceptable for advanced engines.

Proctor, Margaret P.↗
NASA NTRS2006

Seals/Secondary Fluid Flows Workshop 1997; Volume I

The 1997 Conference provided discussions and data on (a) program overviews, (b) developments in seals and secondary air management systems, (c) interactive seals flows with secondary air or fluid flows and powerstream flows, (d) views of engine externals and limitations, (e) high speed engine research sealing needs and demands, and (f) a short course on engine design development margins. Sealing concepts discussed include, mechanical rim and cavity seals, leaf, finger, air/oil, rope, floating-brush, floating-T-buffer, and brush seals. Engine externals include all components of engine fluid systems, sensors and their support structures that lie within or project through the nacelle. The clean features of the nacelle belie the minefield of challenges and opportunities that lie within. Seals; Secondary air flows; Rotordynamics; Gas turbine; Aircraft; CFD; Testing; Turbomachinery

Hendricks, Robert C.↗
NASA NTRS2006

Advanced Seal Development for Large Industrial Gas Turbines

Efforts are in progress to develop advanced sealing for large utility industrial gas turbine engines (combustion turbines). Such seals have been under developed for some time for aero gas turbines. It is desired to transition this technology to combustion turbines. Brush seals, film riding face and circumferential seals, and other dynamic and static sealing approaches are being incorporated into gas turbines for aero applications by several engine manufacturers. These seals replace labyrinth or other seals with significantly reduced leakage rates. For utility industrial gas turbines, leakage reduction with advanced sealing can be even greater with the enormous size of the components. Challenges to transitioning technology include: extremely long operating times between overhauls; infrequent but large radial and axial excursions; difficulty in coating larger components; and maintenance, installation, and durability requirements. Advanced sealing is part of the Advanced Turbine Systems (ATS) engine development being done under a cooperative agreement between Westinghouse and the US Department of Energy, Office of Fossil Energy. Seal development focuses on various types of seals in the 501ATS engine both at dynamic and static locations. Each development includes rig testing of candidate designs and subsequent engine validation testing of prototype seals. This presentation gives an update of the ongoing ATS sealing efforts with special emphasis on brush seals.

Chupp, Raymond E.↗
NASA NTRS2006

Finger Seal: A Novel Approach to Air to Air Sealing

The gas turbine industry used a variety of sealing mechanisms to contain and direct secondary flows into and around components for cooling, and to limit leakage into and from bearing and disk cavities. The function of these seals is very important to the component efficiencies and attendant engine performance. Most of these seals are labyrinth seals, which are high-leakage seals that are costly to manufacture. In recent years, brush seals have been introduced which have demonstrated significantly reduced leakage, although they are still expensive and have exhibited wear and hysteresis difficulties. A new innovative concept called finger seal, patented by AlliedSignal, has demonstrated leakage similar to brush seals and is cheaper. The finger seal is comprised of a stack of precision photo-etched sheet metal elements, which allows intricate features to be made at very low cost and with the potential to resist wear and provide the compliance necessary to accomodate rotor excursions. Initial testing in the high-speed/high-temperature seal test facility, at the NASA Lewis Research Center, has corroborated the finger seal performance. The testing also revealed hysteresis problems with the current design. A NASA funded research project is in progress to correct the functional deficiencies of the finger seal and to refine its features to provide sufficient seal life for commercial transport engines and other long-life applications. This research will benefit the aeronautical gas turbine industry as a whole in terms of fuel consumption, operational characteristics, and cost. The first phase of this research to reduce finger seal hysteresis has been in progress for the last one year. This paper presents the results of this research to date. In future the research program will address seal performance, manufacturing, cost and life issues. The research program is expected to be completed by December 1998.

Arora, Gul↗
NASA NTRS2009

Integrated Modeling of Spacecraft Touch-and-Go Sampling

An integrated modeling tool has been developed to include multi-body dynamics, orbital dynamics, and touch-and-go dynamics for spacecraft covering three types of end-effectors: a sticky pad, a brush-wheel sampler, and a pellet gun. Several multi-body models of a free-flying spacecraft with a multi-link manipulator driving these end-effectors have been tested with typical contact conditions arising when the manipulator arm is to sample the surface of an asteroidal body. The test data have been infused directly into the dynamics formulation including such information as the mass collected as a function of end-effector longitudinal speed for the brush-wheel and sticky-pad samplers, and the mass collected as a function of projectile speed for the pellet gun sampler. These data represent the realistic behavior of the end effector while in contact with a surface, and represent a low-order model of more complex contact conditions that otherwise would have to be simulated. Numerical results demonstrate the adequacy of these multibody models for spacecraft and manipulator- arm control design. The work contributes to the development of a touch-and-go testbed for small body exploration, denoted as the GREX Testbed (GN&C for Rendezvous-based EXploration). The GREX testbed addresses the key issues involved in landing on an asteroidal body or comet; namely, a complex, low-gravity field; partially known terrain properties; possible comet outgassing; dust ejection; and navigating to a safe and scientifically desirable zone.

Quadrelli, Marco↗
NASA NTRS2003

Contactless Rotary Electrical Couplings

Rotary electrical couplings based on induction (transformer action) rather than conduction between rotating and stationary circuitry have been invented. These couplings provide an alternative to slip rings and contact brushes. Mechanical imperfections of slip-ring and brush contact surfaces and/or dust particles trapped between these surfaces tend to cause momentary interruptions in electrical contact and thereby give rise to electrical noise. This source of noise can be eliminated in the inductive rotary couplings because no direct contact is necessary for transformer action.

Kumagai, Hiroyuki↗
NASA NTRS2012

Self-Cleaning Particulate Prefilter Media

A long-term space mission requires efficient air revitalization performance to sustain the crew. Prefilter and particulate air filter media are susceptible to rapid fouling that adversely affects their performance and can lead to catastrophic failure of the air revitalization system, which may result in mission failure. For a long-term voyage, it is impractical to carry replacement particulate prefilter and filter modules due to the usual limitations in size, volume, and weight. The only solution to this problem is to reagentlessly regenerate prefilter and filter media in place. A method was developed to modify the particulate prefilter media to allow them to regenerate reagentlessly, and in place, by the application of modest thermocycled transverse or reversed airflows. The innovation may allow NASA to close the breathing air loop more efficiently, thereby sustaining the vision for manned space exploration missions of the future. A novel, self-cleaning coatings technology was developed for air filter media surfaces that allows reagentless in-place regeneration of the surface. The technology grafts thermoresponsive and nonspecific adhesion minimizing polymer nanolayer brush coatings from the prefilter media. These polymer nanolayer brush architectures can be triggered to contract and expand to generate a "pushing-off" force by the simple application of modestly thermocycled (i.e. cycling from ambient cabin temperature to 40 C) air streams. The nonspecific adhesion-minimizing properties of the coatings do not allow the particulate foulants to adhere strongly to the filter media, and thermocycled air streams applied to the media allow easy detachment and in-place regeneration of the media with minimal impact in system downtime or astronaut involvement in overseeing the process.

Weber, Olivia↗
NASA NTRS2016

Localized and Areally Extensive Alterations in Marathon Valley, Endeavour Crater Rim, Mars

Mars Exploration Rover Opportunity is exploring the rim of 22 km diameter, Noachian-aged Endeavour crater. Marathon Valley cuts through the central region of the western rim providing a window into the local lower rim stratigraphic record. Spectra from the Compact Reconnaissance Imaging Spectrometer for Mars show evidence for the occurrence of Fe-Mg smectite in this valley, indicating areally extensive and distinct lithologic units and/or styles of aqueous alteration. The Alpha Particle X-ray Spectrometer has determined the compositions of 59 outcrop targets on untreated, brushed and abraded surfaces. Rocks in the Marathon Valley region are soft breccias composed of mm- to cm-sized darker clasts set in a lighter-toned, finegrained matrix. They are basaltic in non-volatile-element composition and compositionally similar to breccias investigated elsewhere on the rim. Alteration styles recorded in the rocks include: (1) Enrichments in Si, Al, Ti and Cr in more reddish-colored rock, consistent with leaching of more soluble cations and/or precipitation of Si +/- Al, Ti, Cr from fluids. Coprecipitation of Ge-rich phases with Si occurred in the western area only; high water:rock is indicated. Pancam multispectral observations indicate higher nanophase ferric oxide contents, but the rocks have lower Fe contents. The highly localized nature of the red zones indicate they cannot be the source of the widespread smectite signature observed from orbit. (2) Outcrops separated by approximately 65 m show common compositional changes between brushed and abraded (approximately 1 mm deep) targets: increases in S and Mg; decreases in Al, Cl and Ca. These changes are likely due to relatively recent, surface-related alteration of valley rocks and formation of surface coatings under low water:rock. (3) One target, from the center of a region of strong CRISM smectite signature, shows modest differences in composition (higher Si, K; lower Mn) compared to most Marathon Valley rocks, while another target approximately 40 cm away on the same outcrop does not; a change towards smectite bulk compositions is not observed. The smectite signature likely resulted from alteration under low water:rock such that primary minerals were partially altered to phyllosilicates, but wholesale leaching of cations by fluids did not occur.

Mittlefehldt, David W.↗
DOE OSTI2024

Organic nanoparticles with tunable size and rigidity by hyperbranching and cross-linking using microemulsion ATRP

Unlike inorganic nanoparticles, organic nanoparticles (oNPs) offer the advantage of “interior tailorability,” thereby enabling the controlled variation of physicochemical characteristics and functionalities, for example, by incorporation of diverse functional small molecules. In this study, a unique inimer-based microemulsion approach is presented to realize oNPs with enhanced control of chemical and mechanical properties by deliberate variation of the degree of hyperbranching or cross-linking. The use of anionic cosurfactants led to oNPs with superior uniformity. Benefitting from the high initiator concentration from inimer and preserved chain-end functionality during atom transfer radical polymerization (ATRP), the capability of oNPs as a multifunctional macroinitiator for the subsequent surface-initiated ATRP was demonstrated. This facilitated the synthesis of densely tethered poly(methyl methacrylate) brush oNPs. Detailed analysis revealed that exceptionally high grafting densities (~1 nm −2 ) were attributable to multilayer surface grafting from oNPs due to the hyperbranched macromolecular architecture. The ability to control functional attributes along with elastic properties renders this “bottom-up” synthetic strategy of macroinitiator-type oNPs a unique platform for realizing functional materials with a broad spectrum of applications.

ATRP↗
DOE OSTI2026

Tailored Silicone Network Architecture for Ultimate Mechanical Reinforcement

Hydrosilylation cured silicone elastomers are subject to reaction inefficiency, leading to incomplete and non-uniform crosslink networks, restricting the potential of mechanical reinforcement. This work investigates pre-synthesized, functional PDMS architectures as additives to improve ultimate mechanical performance relative to conventional single-step curing. Three custom, functional structures were prepared: a partially crosslinked PDMS scaffold (Structure A), a bottle-brush PDMS (Structure B), and a star-shaped PDMS derived from an MQ resin (Structure C). Rheological characterization was used to identify the ultimate design space and proper stoichiometric ratio for Structure A, and confirm successful formation of all structures for suitable incorporation into a base silicone formulation at 30wt%. Mechanical tests indicated that all three structures increased in ultimate tensile strength relative to their single-step counterparts, with Structure A providing additional improvements to toughness (432 vs. 258 kJ/m3) and ultimate elongation (158 vs. 115%). Furthermore, Structure B remained very soft in the unfilled state, while Structure C provided hardness (23 vs. 18 Shore A) and stiffness (780 vs. 420 kPa Young’s modulus) increases. In silica filled systems, Structure A retained increased strength but reduced elongation, while Structure B indicated strong reinforcement in terms of strength, toughness, and stiffness. Thermal analysis on the cure profiles of these materials suggested that pre-formation of network architectures enable a more complete reaction than a single-step process (15.9 vs. 15.1 J/g). Ultimately, these results indicate that tailoring PDMS architecture before the final cure can improve ultimate mechanical properties via improved network development in silicone elastomers. Furthermore, this work offers a promising strategy for designing higher-performance, more tunable silicone formulations.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Polymer-iron oxide hybrid films for controlling electrokinetic properties

Electrokinetic phenomena at polymer-water interfaces are central to technologies for water purification, ion separations, and energy conversion, yet the ability to systematically control polymer surface charge and associated electrokinetic processes remains limited. Here, we demonstrate a simple liquid-phase infiltration (LPI) method to synthesize polymer–metal oxide hybrid films with controllable interfacial properties. Hydroxy-terminated poly(2-vinylpyridine) (P2VP-OH) brushes grafted to silicon substrates were infiltrated with iron nitrate from ethanolic solution, followed by low-temperature thermal treatment to convert the infiltrated precursor into iron oxide. Spectroscopic ellipsometry, X-ray photoelectron spectroscopy, and thermogravimetric analysis confirmed oxide incorporation and hybrid film formation without polymer degradation. Electrokinetic measurements reveal that the hybrid films acquire the electrokinetic properties of the infiltrated oxide, with concentration-dependent streaming potentials and surface conductivities closely matching those of pure iron oxide films. These results establish metal oxide infiltration as a scalable and low-cost strategy for controlling interfacial charge in polymer surfaces. The approach introduces new materials and design parameters for tailoring ion selectivity, transport, and energy conversion, with broad implications for the development of advanced membranes, electrokinetic harvesting devices, and polymer-supported oxide electrodes.

36 MATERIALS SCIENCE↗