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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 sources NASA NTRS DOE OSTI

NASA NTRS1993

Friction and oxidative wear of 440C ball bearing steels under high load and extreme bulk temperatures

Unlubricated sliding friction and wear of 440C steels in an oxygen environment have been studied under a variety of load, speed, and temperature ranging from approximately -185 to 675 deg C. A specially designed test apparatus with a ball-on-flat geometry has been used for this purpose. The observed dependencies of the initial coefficient of friction, the average dynamic coefficient of friction, and the wear rate on load, speed, and test temperatures have been examined from the standpoint of existing theories of friction and wear. High contact temperatures are generated during the sliding friction, causing rapid oxidation and localized surface melting. A combination of fatigue, delamination, and loss of hardness due to tempering of the martensitic structure is responsible for the high wear rate observed and the coefficient of friction.

Chaudhuri, Dilip K.↗

NASA NTRS1954

Measurement of Heat Transfer in the Turbulent Boundary Layer on a Flat Plate in a Supersonic Flow and Comparison with Skin Friction Results

Local heat-transfer rates on the surface of a heated flat plate at zero incidence to an air stream flowing at Mach numbers of 1.69 and 2.27 are presented. The Reynolds number range for both Mach numbers was 1 million to 10 million. Surface temperatures were maintained near recovery temperature. It was found that the variation of heat transfer with Mach number was in agreement with previously reported variations of directly measured skin friction with Mach number on unheated bodies. The variation with Mach number of the average skin coefficient, as determined from impact-pressure surveys, was in agreement with that from other momentum loss measurements but differed from the variation obtained from directly measured skin friction as reported by others. (author)

Pappas, C C↗

NASA NTRS1983

Friction and wear of iron in sulfuric acid

Elemental iron sliding on aluminum oxide in aerated sulfuric acid concentrations ranging from very dilute (0.000007 N; i.e., 4 ppm) to very concentrated (96 percent acid) was studied. Load and reciprocating sliding speeds were kept constant. With the most dilute acid of 0.7 to 0.0002 N, a complex corrosion product formed that was friable and often increased friction and wear. At concentrations of 0.001 N, metal losses were essentially by wear alone. Because no buildup of corrosion products occurred, this acid concentration became the standard from which to separate metal loss from direct corrosion and mechanical wear losses. When the acid concentration was increased to 5 percent, the high corrosion rate of iron in sulfuric acid strongly dominated the total wear loss. This strong corrosion increased to 30 percent acid, and decreased somewhat at 50 percent in accordance with expectations. However, the low corrosion of iron expected at acid concentrations of 65 to 96 percent was not observed in the wear area. It is apparent that the normal passivating film was being worn away and a galvanic cell established which rapidly attached to the wear area.

Rengstorff, G. W. P.↗

NASA NTRS1985

Design of traction drives

Traction drives are among the simplest of all speed-changing mechanisms. Because of their simplicity and their ability to smoothly and continuously adjust speed, they are excellent choices for many drive system applications. They have been used in industrial service for more than 100 years. Today's traction drives have power capacities which rival the best gear and belt drives due to modern traction fluids and highly fatigue-resistant bearing steels. This report summarizes methods to analyze and size traction drives. Lubrication principles, contact kinematics, stress, fatigue life, and performance prediction methods are presented. The effects of the lubricant's traction characteristics on life and power loss are discussed. An example problem is given which illustrates the effects of spin on power loss. Loading mechanism design and the design of nonlubricated friction wheels and rings are also treated.

Loewenthal, S. H.↗

DOE OSTI2026

Elevated-Temperature Tribo-Corrosion Response of Eutectic High-Entropy Alloy

The combination of elevated temperature and tribo-corrosion leads to the accelerated degradation of structural components used in many extreme environments. Recently developed high-entropy alloys (HEAs) with multiple principal elements have the potential for superior degradation resistance compared with presently used structural alloys. Here, we demonstrate the microstructural stability, pitting resistance, and superior tribo-corrosion degradation resistance of the AlCoCrFeNi 2.1 eutectic HEA in comparison with duplex stainless steel 2205 in deionized water (controlled low-ionic-strength electrolyte) at 25 °C, 50 °C and 100 °C. The AlCoCrFeNi 2.1 HEA showed excellent microstructural stability and tribo-corrosion resistance at all three temperatures, an order-of-magnitude lower wear rate, and a lower coefficient of friction compared with duplex 2205 steel. The lowest wear volume loss and wear rate for both AlCoCrFeNi 2.1 and duplex steel were recorded at 50 °C, which was attributed to temperature-assisted passivation and formation of a comparatively stable tribological surface condition. These results suggest superior performance of eutectic HEAs in tribo-corrosion applications compared with currently used dual-phase steels and motivate future evaluation in ion-containing industrial water chemistries.

36 MATERIALS SCIENCE↗

NASA NTRS1988

Lab tests of a thermomechanical pump for shoot

Laboratory tests of a thermomechanical (TM) pump utilizing a commercially available porous disk have been conducted. Various size disks, heater configurations, and outlet flow impedances have been used to characterize scale models of the pump proposed for the Superfluid Helium On-Orbit Transfer (SHOOT) Flight Experiment. The results yield the scalability of the TM pump to larger diameters, and hence larger pumping rates, the dependence of flow rate on back pressure and heater power, and the limits of pumping speed due to internal losses within the porous disk due to mutual and superfluid friction. Analysis indicates that for low back pressures the flow rate is limited by the superfluid friction rather than the mutual friction. For the porous plug used in the early tests this amounts to a practical limit of 4.4 liters per hour per square centimeter. For a baselined flight plug area of 180 sq cm this yields 790 liters per hour.

Dipirro, Michael J.↗

NASA NTRS1998

Inlet Performance Analysis Code Developed

The design characteristics of an inlet very much depend on whether the inlet is to be flown at subsonic, supersonic, or hypersonic speed. Whichever the case, the primary function of an inlet is to deliver free-stream air to the engine face at the highest stagnation pressure possible and with the lowest possible variation in both stagnation pressure and temperature. At high speeds, this is achieved by a system of oblique and/or normal shock waves, and possibly some isentropic compression. For both subsonic and supersonic flight, current design practice indicates that the inlet should deliver the air to the engine face at approximately Mach 0.45. As a result, even for flight in the high subsonic regime, the inlet must retard (or diffuse) the air substantially. Second, the design of an inlet is influenced largely by the compromise between high performance and low weight. This compromise involves tradeoffs between the mission requirements, flight trajectory, airframe aerodynamics, engine performance, and weight-all of which, in turn, influence each other. Therefore, to study the effects of some of these influential factors, the Propulsion System Analysis Office of the NASA Lewis Research Center developed the Inlet Performance Analysis Code (IPAC). This code uses oblique shock and Prandtl-Meyer expansion theory to predict inlet performance. It can be used to predict performance for a given inlet geometric design such as pitot, axisymmetric, and two-dimensional. IPAC also can be used to design preliminary inlet systems and to make subsequent performance analyses. It computes the total pressure, the recovery, the airflow, and the drag coefficients. The pressure recovery includes losses associated with normal and oblique shocks, internal and external friction, the sharp lip, and diffuser components. Flow rate includes captured, engine, spillage, bleed, and bypass flows. The aerodynamic drag calculation includes drags associated with spillage, cowl lip suction, wave, bleed, and bypass.

Jules, Kenol↗

NASA NTRS1990

Response of polymer composites to high and low velocity impact

The present investigation of fiber-reinforced polymer matrix composites' impact characteristics employed a drop tower for the low-velocity impact case and a novel, projectile instantaneous velocity-measuring sensor for high-velocity impact. Attention was given to the energy loss of projectiles in composites reinforced with polyethylene, kevlar, and graphite. Two distinct energy-loss mechanisms are noted, the first of which is due to the actual fracture process while the other is due to the generation of friction heat. The drop-tower impact-test results furnish the strain-rate dependence of the energy loss.

Hsieh, C. Y.↗

NASA NTRS1986

Losses in Channels with Increased External Turbulence

An approximate method for determining the effect of the level of turbulence on the aerodynamic characteristics of convergent and diffuser channels is examined. A momentum equation for the boundary layer is in the method, introducing external flow turbulence on the basis of experimental values of the coefficient of friction and the form factor. It is found that at significant levels of external turbulence, losses must be considered not only in the boundary layer but also in the central region of the channel.

Zaryankin, A. Y.↗

NASA NTRS2004

Heat Control via Torque Control in Friction Stir Welding

In a proposed advance in friction stir welding, the torque exerted on the workpiece by the friction stir pin would be measured and controlled in an effort to measure and control the total heat input to the workpiece. The total heat input to the workpiece is an important parameter of any welding process (fusion or friction stir welding). In fusion welding, measurement and control of heat input is a difficult problem. However, in friction stir welding, the basic principle of operation affords the potential of a straightforward solution: Neglecting thermal losses through the pin and the spindle that supports it, the rate of heat input to the workpiece is the product of the torque and the speed of rotation of the friction stir weld pin and, hence, of the spindle. Therefore, if one acquires and suitably processes data on torque and rotation and controls the torque, the rotation, or both, one should be able to control the heat input into the workpiece. In conventional practice in friction stir welding, one uses feedback control of the spindle motor to maintain a constant speed of rotation. According to the proposal, one would not maintain a constant speed of rotation: Instead, one would use feedback control to maintain a constant torque and would measure the speed of rotation while allowing it to vary. The torque exerted on the workpiece would be estimated as the product of (1) the torque-multiplication ratio of the spindle belt and/or gear drive, (2) the force measured by a load cell mechanically coupled to the spindle motor, and (3) the moment arm of the load cell. Hence, the output of the load cell would be used as a feedback signal for controlling the torque (see figure).

Venable, Richard↗

NASA NTRS1993

Simulation of cryogenic turbopump annular seals

San Andres employed the NBS software package MIPROPS to account for density's dependence on pressure in the simulation of liquid annular seals. His example on a LH2 seal showed a significant change in the mass coefficient compared to a constant density model. San Andres, Yang, and Childs extended this analysis by including the pressure and temperature dependence of density, specific heat, viscosity, volumetric expansion, and thermal conductivity in a coupled solution of the energy, momentum, and continuity equations. Their example showed very significant changes in stiffness and inertia for a high speed (38,000 rpm), large L/D ratio (0.5) LOX seal, as compared to their constant temperature results. The current research rederived the San Andres-Yang-Childs (SYC) analysis and extended it to include not only the Moody friction model of SYC but also the Hir's friction model. The derivation begins with obtaining the local differential equations of continuity, momentum, and energy conservation in the seal. These equations are averaged across the film thickness to obtain the resulting 'bulk flow' differential equations. Shear stress and convective heat loss through the stator (seal) and rotor are related to the Moody and Hir's friction factor model. The Holman analogy is employed to relate heat conduction in or out of the fluid film's boundary layer to the friction induced shear stress.

Palazzolo, Alan B.↗

DOE OSTI2024

Neutron Diffraction Residual Stress Study of a AA2219-T87 Self-Reacting Friction Stir Weld

2219-T87 is a precipitation hardenable aluminum-copper alloy which sees wide use in structural aerospace components. Thick panels of this alloy are joined via self-reacting friction welding (SRFSW); however, this thermomechanical process can result in significant loss of the alloy’s strengthening precipitates and large residual stresses which are detrimental to mechanical behavior and performance. High-resolution maps of the residual strain and stress states along the normal, transverse, and longitudinal directions of 2219-T87 SRFSW were obtained using neutron diffraction measurements. Residual stress had the highest tensile value in the heat-affected zone (HAZ) and the largest compressive stress in the base metal region of the normal and transverse directions. Line profile residual stress distributions displayed an “M”-shaped distribution in each direction with the longitudinal direction being the most pronounced while 2D residual stresses displayed an hourglass-shaped pattern. Further, average maximal longitudinal residual stress values ranged from 60.6 to 85.6% of yield. Microhardness testing across the transverse weld section produced a “V”-shaped curve with slight hardness recovery in the stir zone. Maximal and minimal microhardness values were observed in the base metal (154 HV) and thermomechanically affected zone (82 HV), respectively. Microstructural evolution was recorded using optical microscopy and showed decreasing grain size from the HAZ to the stir zone.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Kinetic friction attributed to enhanced radiation by cyclotron maser instability

Along the auroral field lines, a fraction of the energetic electrons injected from the magnetotail is reflected by the earth's convergent geomagnetic field. The reflected loss-cone electrons are unstable with respect to the cyclotron maser instability, resulting in the auroral kilometric radiation. This paper investigates the kinetic friction force exerted on the energetic electrons by the enhanced radiation field. It is found that the enhanced radiation results in a deceleration of reflected electrons, thereby providing an effective resistivity. In addition, the rate of decrease (increase) of effective perpendicular (parallel) kinetic temperatures is also evaluated. The analysis is carried out over various physical parameters such as the degree of loss cone, average particle energy, and the ratio of plasma frequency to cyclotron frequency.

Yoon, Peter H.↗

DOE OSTI2021

CFD Evaluation of Pressure Change Along Coolant Passages in Sodium-Cooled Fast Reactor with Nek5000

To support the design efforts of advanced sodium-cooled fast reactors (SFRs), a series of computational fluid dynamics (CFD) simulations are performed to investigate the pressure change along various flow passages in the proposed SFR system. The simulations are carried out with the state-of-the-art spectral element flow solver, Nek5000. Two specific case studies are presented in this paper: the flow exiting the axial neutron reflector channels and the flow entering the fuel pin bundle. Due to the high Reynolds numbers expected, a Reynolds-averaged Navier-Stokes (RANS) approach is necessary to model the turbulence. A newly developed regularized k-omega RANS model is adopted in the related CFD calculations. The first case study explores the effect of Reynolds number on the pressure change when flow exits the reflector channels. The pressure change in this case has two major contributors: the change due to wall friction and the Bernoulli effect. It is noted that the nondimensional pressure loss follows a log-linear trend up to Re = 10 5 , and then the trend is flattened. In the second case study, the advanced NekNek coupling capability is tested where an integral domain can be divided into multiple subdomains with coupling interfaces, which would greatly ease the meshing process of complex engineering geometries and potentially save computational resources. The preliminary results obtained so far confirm the consistency between the NekNek results and those produced by regular Nek5000 simulation. The presented work demonstrates the readiness and flexibility of the related CFD techniques, which is part of the broader effort to leverage cutting-edge CFD to inform the advanced nuclear reactor designs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1973

Review of drag measurements from flight tests of manned aircraft with comparisons to wind-tunnel predictions

In-flight studies of the overall and local components of drag of many types of aircraft were conducted. The primary goal of these studies was to evaluate wind-tunnel and semiempirical prediction methods. Some evaluations are presented in this paper which may be summarized by the following observations: Wind-tunnel predictions of overall vehicle drag can be accurately extrapolated to flight Reynolds numbers, provided that the base drag is removed and the boattail areas on the vehicle are small. The addition of ablated roughness to lifting body configurations causes larger losses in performance and stability than would be expected from the added friction drag due to the roughness. Successful measurements of skin friction have been made in flight to Mach numbers above 4. A reliable inflatable deceleration device was demonstrated in flight which effectively stabilizes and decelerates a lifting aircraft at supersonic speeds.

Pyle, J. S.↗

DOE OSTI2020

Robust foil regenerator flow loss and heat transfer tests under oscillating flow condition

A regenerator works as an energy storage component in a Stirling engine. Thus, it is one of the most critical components that makes the Stirling engine highly efficient. Traditionally, the regenerators are made of wire media such as woven screens and random fibers. These wire regenerators experience considerably high flow losses through the regenerator due to the flow separation and the resulting vortices. The high flow losses associated with the flow separation and vortices result in a lower engine efficiency. This research is to test a new robust foil regenerator to investigate its feasibility for free-piston Stirling engine applications. The robust foil regenerator is configured with parallel flow channels and stiffening ribs. Comparing to complex flows patterns in woven screen and random fiber regenerators, the flows in the parallel plates are simple and the flow losses are considerably small, and the heat transfer coefficient is also relatively small. To test the regenerator experimentally, a regenerator test rig was manufactured. To verify the accuracy of the test rig, a woven screen regenerator was made and tested prior to the robust foil regenerator test. The friction factor correlation of the woven screen regenerator shows a good agreement with the published regenerator correlations. The robust foil regenerator tests were conducted under the oscillating flow condition with different Reynolds numbers. The flow losses were measured with dynamic pressure transducers and the friction coefficient was derived from measured pressure drop. The measured temperature difference over the regenerator was used to calculate the heat transfer coefficient and Nusselt number. The figure of merit with two methods of NPH/NTU ratio and j/f ratio was calculated to evaluate the suitability of the robust foil regenerator. The results show that the robust foil regenerator has considerably higher figure of merit and therefore, better performance than other types of regenerator.

42 ENGINEERING↗

DOE OSTI2024

Development of a self-lubricating high-efficiency hybrid seal composed of carbon nanotube-coated metal meshes for CSP turbomachinery (SETO CPS #36333 Final Report)

In turbomachinery, internal leakage flow accounts for up to 3% of the total thermodynamic cycle energy loss. Tradeoff must be made between the sealing efficiency (smaller clearance) and the friction and wear issues for interfering with the shaft (larger clearance). This ORNL-Danfoss joint effort developed a novel hybrid seal composed of carbon nanotube (CNT)-coated metal meshes. The CNT growth process was based on a self-catalyzing chemical vapor deposition and these multiwall CNTs were well aligned with high crystallinity. This hybrid material structure takes advantage of the CNT’s low-friction nature and uses the metal mesh as an extendable backbone. Full-scale experimental seals were designed, fabricated, and optimized for sealing performance and durability. The CNT-coated metal mesh seal demonstrated superior gas sealing efficiency to the baseline labyrinth seal and significantly improved shaft surface protection compared with the state-of-the-art superalloy brush seal on the static rig and full-scale compressor dynamometer tests. The CNT-metal mesh seal is low-cost and scalable and can potentially benefit wide applications, including CSP and other power generation, marine, automotive, and HVAC.

36 MATERIALS SCIENCE↗

NASA NTRS1921

Factors of airplane engine performance

This report is based upon an analysis of a large number of airplane-engine tests. It contains the results of a search for fundamental relations between many variables of engine operation. The data used came from over 100 groups of tests made upon several engines, primarily for military information. The types of engines were the Liberty 12 and three models of the Hispano-Suiza. The tests were made in the altitude chamber, where conditions simulated altitudes up to about 30,000 feet, with engine speeds ranging from 1,200 to 2,200 r.p.m. The compression ratios of the different engines ranged from under 5 to over 8 to 1. The data taken on the tests were exceptionally complete, including variations of pressure and temperature, besides the brake and friction torques, rates of fuel and air consumption, the jacket and exhaust heat losses.

Gage, Victor R↗