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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Comprehensive Data Analysis and Analytic Method Development for PBX9501 Material (FY2019 Annual Report of Aging and Lifetimes Program)

In the polymer bonded explosive (PBX) 9501, a binder consisting of 2.5 wt% nitroplasticizer (NP) and 2.5 wt% Estane R 5703 (Estane) is combined with 94.9 wt% of the high-explosive HMX and 0.1 wt% stabilizer. Because of its flexibility and tensile strength, this binder lowers the sensitivity and improves the manufacturability of PBX 9501. However, like many plasticizers comprised of low molecular weight components, NP has a tendency to diffuse out of the PBX 9501 matrix and can decompose at moderate temperatures into reactive byproducts, such as NO, NO 2 , H 2 O, and HNO x . Through oxidation and hydrolysis, these molecules can further degrade NP and Estane, ultimately degrading the properties of PBX 9501. While gaseous molecules can readily diffuse out of the PBX 9501 charges, the intermediates with lower volatility are more likely trapped in the condensed phase inside the charges and, in a closed system, will co-exist with Estane for an extended period of time creating an ongoing reactive environment. Understanding the rates of formation for these volatiles and intermediates during the NP degradation is therefore a critical prerequisite for understanding the long-term stability of polymeric binders used in munition systems. To work toward this ultimate goal, in the past year, we have conducted comprehensive studies on the physical properties of NP and finished three-year long aging experiment to understand the aging behavior of NP under thermal treatment. Important results are summarized in this annual report. Although NP is widely used in the DOE complex, their physical properties are rather scattered and inconsistent in the open literature. For example, there are at least two widely different values, 14.5°C and -15°C, for the melting point of NP. Although it is known that NP is a eutectic 50:50 mixture of BDNPA and BDNPF, their eutectic phase diagram is not well documented. Furthermore, the effect of temperature on the miscibility between water and eutectic BDNPA/F mixture is rarely reported. To fill these knowledge gaps, a large set of BDNPA/F mixtures with BDNPA concentration ranging from 0 to 100 wt% was analyzed using DSC techniques. In addition to determining the eutectic melt point as -25°C, a phase diagram of the BDNPA/F system was constructed from -30°C to 45°C. With this phase diagram, the phase transition temperatures and composition can be readily found for the BDNPA/F mixtures with various mass ratios.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Differential scanning calorimetry of coal

Differential scanning calorimetry studies performed during the first year of this project demonstrated the occurrence of exothermic reactions associated with the production of volatile matter in or near the plastic region. The temperature and magnitude of the exothermic peak were observed to be strongly affected by the heating rate, sample mass and, to a lesser extent, by sample particle size. Thermal properties also were found to be influenced by oxidation of the coal sample due to weathering effects.

Gold, P. I.↗
NASA NTRS1992

Hypervelocity impact effects on solar cells

One of the space hazards of concern is the problem of natural matter and space debris impacting spacecraft. In addition to mechanical damage, impact velocities greater than 5 km/sec can produce shock induced ionization effects with resultant surface charging and complex chemical interactions. The upper limit of the velocity distribution for these particles is on the order of 70 km/sec. The second source of particulate matter is due to the presence of man and the machinery needed to place satellites in orbit. This 'man made' component of the space debris consists of waste, rocket exhaust, and debris caused by satellite break-up. Most of the particles are small. However as the size increases, debris purposefully thrown overboard such as garbage and human waste, combined with paint chips, plastic, wire fragments, bolts, etc., become formidable hazards which completely dominate the distribution function for some orbits. These larger fragments can produce penetration and spalling of the thick metallic structures associated with spacecraft. The particles most often encountered are aluminum oxide, associated with fuel residue, and paint chips. These debris types can have a wide range of particle sizes. It has been stated that the design of spacecraft will have to take the debris evolution into account and provide additional suitable armor for key components in the near future. The purpose of this work was to subject samples from solar power arrays, one of the key components of any spacecraft, to a debris flux typical of what might be found in space, and measure the degradation of the power panels after impact.

Rose, M. Frank↗
DOE OSTI2021

Flaw-insensitive fracture of a micrometer-sized brittle metallic glass

Brittle materials, such as oxide glasses, are usually very sensitive to flaws, giving rise to a macroscopic fracture strength that is much lower than that predicted by theory. The same applies to metallic glasses (MGs), with the important difference that these glasses can exhibit certain plastic strain prior to catastrophic failure. Here we consider the strongest metallic alloy known, a ternary Co 55 Ta10B 35 MG. In this work, we show that this macroscopically brittle glass is flaw-insensitive at the micrometer scale. This discovery emerges when testing pre-cracked specimens with self-similar geometries, where the fracture stress does not decrease with increasing pre-crack size. The fracture toughness of this ultra-strong glassy alloy is further shown to increase with increasing sample size. Both these findings deviate from our classical understanding of fracture mechanics, and are attributed to a transition from toughness-controlled to strength-controlled fracture below a critical sample size.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Experimental Determination of the Relationship Between Organic Aerosol Viscosity and Ice Nucleation at Upper Free Tropospheric Conditions

Abstract This work presents measurements of the ice nucleating ability of secondary organic material recorded between −40 and −70°C and relative humidity with respect to ice (RH ice ) between 150% and 220%. For a subset of systems, temperature and humidity dependence of particle viscosity as well as dry glass transition temperature were characterized using the dual tandem differential mobility analyzer method. Eleven unique monoterpene, sesquiterpene and aromatic precursors were used to generate secondary organic material (SOM) using either an oxidation flow reactor (OFR) or an environmental chamber (EC). For the SOM for which viscosity was measured, the particle glass transition temperatures varied between 6 and 23°C ( n = 8). Measurements were performed to verify that increased relative humidity did not plasticize the particles below −10°C at residence times similar to those in the ice nucleation instrument. No heterogeneous ice nucleation was observed at the ∼0.5% onset threshold for any of the materials generated. The ice nucleation occurs by the freezing of SOM solution droplets consistent with homogeneous freezing indicating that they form an aqueous solution, or the SOM particles required water saturation to freeze, indicating that they were hydrophobic. Experiments exploring the influence of functional groups and mass loading did not reveal any obvious influence of particle chemistry or generation conditions on the results. Close structural matches between known organic ice nucleating particles as precursor or formed products did not yield materials that promoted freezing. These experiments suggest that heterogeneous ice formation of glassy secondary organic materials is likely uncommon under upper free tropospheric conditions.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2002

Thermal and Chemical Characterization of Non-Metallic Materials Using Coupled Thermogravimetric Analysis and Infrared Spectroscopy

Thermogravimetric analysis (TGA) is widely employed in the thermal characterization of non-metallic materials, yielding valuable information on decomposition characteristics of a sample over a wide temperature range. However, a potential wealth of chemical information is lost during the process, with the evolving gases generated during thermal decomposition escaping through the exhaust line. Fourier Transform-Infrared spectroscopy (FT-IR) is a powerful analytical technique for determining many chemical constituents while in any material state, in this application, the gas phase. By linking these two techniques, evolving gases generated during the TGA process are directed into an appropriately equipped infrared spectrometer for chemical speciation. Consequently, both thermal decomposition and chemical characterization of a material may be obtained in a single sample run. In practice, a heated transfer line is employed to connect the two instruments while a purge gas stream directs the evolving gases into the FT-IR. The purge gas can be either high purity air or an inert gas such as nitrogen to allow oxidative and pyrolytic processes to be examined, respectively. The FT-IR data is collected realtime, allowing continuous monitoring of chemical compositional changes over the course of thermal decomposition. Using this coupled technique, an array of diverse materials has been examined, including composites, plastics, rubber, fiberglass epoxy resins, polycarbonates, silicones, lubricants and fluorocarbon materials. The benefit of combining these two methodologies is of particular importance in the aerospace community, where newly developing materials have little available data with which to refer. By providing both thermal and chemical data simultaneously, a more definitive and comprehensive characterization of the material is possible. Additionally, this procedure has been found to be a viable screening technique for certain materials, with the generated data useful in the selection of other appropriate analytical procedures for further material characterization.

Huff, Timothy L.↗
DOE OSTI2020

Hydrogen Transport in a Model 9979 Shipping Package with Inner Convenience Cans

Radiolytic hydrogen production and accumulation inside containment packages is a concern at any facility responsible for their packaging, storage, transportation, and/or disposal. When hydrogen gas accumulates to concentrations above the Lower Flammability Limit (LFL) which is 4% or 40,000 ppm in air, the possibility of a deflagration or explosion increases. This concern persists over the course of the package lifetime which is unlimited when disposed of by burial or in permanent repositories. Here, we report on a numerical model used to predict the concentration of hydrogen within each layer of a Model 9979 package containing a convenience can assembly. Simulations show the hydrogen concentration to always be highest in the inner convenience can containing the radioactive source. When the radioactive source is within the Los Alamos National Laboratory (LANL) Packaging Limits, the hydrogen concentration is shown to remain well below the LFL at all times including packaging, storage, transportation, and disposal. A hydrogen transport model is presented for a Model 9979 package system containing a nested arrangement of convenience cans, which are tin oxide coated steel cans of various sizes with a slip-lid assembly. The inner convenience can contains the radioactive source material along with an unknown quantity of incidental water acquired from humid air or processing. While visible organic materials such as paper and plastics were purposely excluded from the inner can, it is not possible to claim the wastes are entirely organic free. The inner convenience can is tape sealed and placed into a plastic bag which is horsetail closed (i.e., twisted and taped). The bagged can is placed into an outer convenience can that is also tape sealed. The can assembly is then placed into the 30 gallon drum and subsequently placed inside the 55 gallon drum in the 9979 package. Here we assume hydrogen gas is produced in the inner convenience can from alpha radiolysis of water at a rate dependent on the quantity of uranium isotopes and water present. The hydrogen transport model was used to calculate hydrogen accumulations within the package’s five layers at different times and conditions. These simulations serve two purposes; (i) to build confidence in the model by comparing predicted values to measured values, and (ii) to check the steady state hydrogen concentrations that are approached at long times in the package’s lifetime. Model simulations were compared to gas samples taken from the 30 gallon drum after storage at LANL’s Chemistry and Metallurgy Research (CMR) building for around 500 days. Hydrogen concentration calculations over much longer periods (i.e., more than 270 years) included extreme storage durations, transportation at extreme cold temperatures, and disposal of packages assuming different average temperatures.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1981

Sandblasting nozzle

A nozzle for use with abrasive and/or corrosive materials is formed of sintered ceramic compositions having high temperature oxidation resistance, high hardness and high abrasion and corrosion resistance. The ceramic may be a binary solid solution of a ceramic oxide and silicon nitride, and preferably a ternary solid solution of a ceramic oxide, silicon nitride and aluminum nitride. The ceramic oxide is selected from a group consisting of Al2O3, Y2O3 and Cr2O3, or mixtures of those compounds. Titanium carbide particles are dispersed in the ceramic mixture before sintering. The nozzles are encased for protection from external forces while in use by a metal or plastic casing.

Perkins, G. S.↗
NASA NTRS1989

Detecting Residues On Grit-Blasted Surfaces

Addition of fluorescent or iridescent material to plastic grit particles proposed for detection of grit residues after grit-blast cleaning. Residual films visible by observing grit-blasted surfaces under infrared or ultraviolet light. Plastic grit contains fluorescent or iridescent additive in core and coating. Wherever grit material becomes embedded, additive makes it visible under infrared or ultraviolet light. Applicable to other grit materials, for example fluorescent or iridescent materials added to particles of glass, silicon carbide, aluminum oxide, or zirconium silicate.

Novak, H. L.↗
DOE OSTI2022

Decomposition of Irganox 1010 in plastic bonded explosives

Abstract Degradation pathways of Irganox 1010 in aged plastic bonded explosive (PBX) 9501 were investigated using ultrahigh performance liquid chromatography coupled to quadrupole time of flight mass spectrometry (UHPLC‐QTOF). Using a targeted approach, a total of 44 Irganox 1010 decomposition products were discovered. These decomposition products were formed through hydrolysis, scission, and/or oxidation of Irganox 1010. The hydrolytic decomposition of Irganox is a straightforward process resulting in the cleavage of the ester group(s) while oxidation and scission are more complicated and can happen at multiple locations on the Irganox 1010 molecule. Moreover, due to the symmetric nature of Irganox 1010, multiple decomposition reactions can occur. Indeed some decomposition products exhibited hydrolysis, oxidation, and scission. In order to probe any trends in the aged PBX 9501 samples, principal component analysis (PCA) was implemented. The greatest chemical differences between the aged PBX samples was hydrolysis of the ester functional groups on Irganox 1010. Despite the negative connotations of hydrolysis, the Irganox 1010 decomposition products are still able to function as a radical scavenger in PBX 9501 as intended.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1978

Tensile and creep properties of the experimental oxide dispersion strengthened iron-base sheet alloy MA-956E at 1365 K

A study of the 1365 K tensile properties, creep characteristics and residual room temperature properties after creep testing of the experimental oxide dispersion strengthened iron-base alloy MA-956E (Fe-20Cr-4.5Al-0.5Ti-0.5Y2O3) was conducted. The 1365 K tensile properties, particularly ductility, are strongly dependent on strain rate. It appears that MA-956E does not easily undergo slow plastic deformation. Rather than deform under creep loading conditions, the alloy apparently fails by a crack nucleation and growth mechanism. Fortunately, there appears to be a threshold stress below which crack nucleation and/or growth does not occur.

Whittenberger, J. D.↗
NASA NTRS1994

Hypersonic Engine Leading Edge Experiments in a High Heat Flux, Supersonic Flow Environment

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding the sustained high thermal loads expected during hypersonic flight. Three aerothermal load related concerns are the boundary layer transition from laminar to turbulent flow, articulating panel seals in high temperature environments, and strut (or cowl) leading edges with shock-on-shock interactions. A multidisciplinary approach is required to address these technical concerns. A hydrogen/oxygen rocket engine heat source has been developed at the NASA Lewis Research Center as one element in a series of facilities at national laboratories designed to experimentally evaluate the heat transfer and structural response of the strut (or cowl) leading edge. A recent experimental program conducted in this facility is discussed and related to cooling technology capability. The specific objective of the experiment discussed is to evaluate the erosion and oxidation characteristics of a coating on a cowl leading edge (or strut leading edge) in a supersonic, high heat flux environment. Heat transfer analyses of a similar leading edge concept cooled with gaseous hydrogen is included to demonstrate the complexity of the problem resulting from plastic deformation of the structures. Macro-photographic data from a coated leading edge model show progressive degradation over several thermal cycles at aerothermal conditions representative of high Mach number flight.

Gladden, Herbert J.↗
NASA NTRS2001

Thermal and Chemical Characterization of Non-metallic Materials Using Coupled Thermogravimetric Analysis and Infrared Spectroscopy

Thermogravimetric analysis (TGA) is widely employed in the thermal characterization of non-metallic materials, yielding valuable information on decomposition characteristics of a sample over a wide temperature range. However, a potential wealth of chemical information is lost during the process, with the evolving gases generated during thermal decomposition escaping through the exhaust line. Fourier Transform-Infrared spectroscopy (FT-IR) is a powerful analytical technique for determining many chemical constituents while in any material state, in this application, the gas phase. By linking these two techniques, evolving gases generated during the TGA process are directed into an appropriately equipped infrared spectrometer for chemical speciation. Consequently, both thermal decomposition and chemical characterization of a material may be obtained in a single sample run. In practice, a heated transfer line is employed to connect the two instruments while a purge gas stream directs the evolving gases into the FT-IR, The purge gas can be either high purity air or an inert gas such as nitrogen to allow oxidative and pyrolytic processes to be examined, respectively. The FT-IR data is collected real-time, allowing continuous monitoring of chemical compositional changes over the course of thermal decomposition. Using this coupled technique, an array of diverse materials has been examined, including composites, plastics, rubber, fiberglass epoxy resins, polycarbonates, silicones, lubricants and fluorocarbon materials. The benefit of combining these two methodologies is of particular importance in the aerospace community, where newly developing materials have little available data with which to refer. By providing both thermal and chemical data simultaneously, a more definitive and comprehensive characterization of the material is possible. Additionally, this procedure has been found to be a viable screening technique for certain materials, with the generated data useful in the selection of other appropriate analytical procedures for further material characterization.

Huff, Timothy L.↗
DOE OSTI2022

Leak-tight crack repair for 304L stainless steel using friction surfacing

Here, friction surfacing (FS) was investigated as a method for sealing 50 μm wide thru-cracks in 3-mm-thick 304L stainless steel (304L) plate. Friction surfacing was performed using two sizes of 304L consumable rod, with diameters of 9.52 mm and 12.7 mm, on two substrate conditions (clean and oxidized). Friction surfacing was able to deposit a 600 μm thick coating and repair cracks to a depth of 100 μm - 200 μm below the original surface, when using the 12.7-mm-diameter consumable rod for both substrate conditions. Helium leak rates of 10 -10 atm-cc/s were achieved on crack repairs, designating them as leak-tight by the ANSI N14.5 standard. Optical and scanning electron microscopy were used to investigate the coating microstructure and bond interfaces. In this study, the 12.7-mm-diameter rod performed better with disruption of the oxide layer on the oxidized substrate and providing a more homogenous coating. Mechanical properties of the coated samples were evaluated by performing micro-indentation, tensile, bending, and adhesion testing. Higher hardness in the coatings was observed due to the fine equiaxed grains resulting from dynamic recrystallization. Complete consolidation of plastically deformed material on the substrate and a strong diffusion bond across the interface was observed. This was reflected in tensile and bending properties of the FS coatings being comparable to those of uncoated specimen. No delamination of the FS coating was observed during adhesion testing. The results demonstrate that friction surfacing is a viable option to seal cracks in stainless steels.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Atomic Layer Deposition Overcoating Improves Catalyst Selectivity and Longevity in Propane Dehydrogenation

Propylene, a precursor for commodity chemicals and plastics, is produced by propane dehydrogenation (PDH). An increase in PDH yield via added catalyst activity, lifetime, or selectivity represents significant energy and economic savings. Using Pt dispersed on Al2O3 extrudate supports as a commercially relevant model system, we demonstrate that atomic layer deposition (ALD) metal oxide overcoats, used to tailor metal-active sites, can increase PDH yield and selectivity. We investigate the interplay of Pt loading, ALD overcoat thickness, and Al 2 O 3 support surface area on PDH activity, selectivity, and catalyst stability to show that applying a 6-8 A thick layer of Al 2 O 3 on low-surface area Al 2 O 3 supports of similar to 90 m 2 /g surface area yields the optimal combination of stability and activity, while increasing propylene selectivity from 91 to 96%. Increased stability upon steaming deactivation occurs because the Al 2 O 3 overcoat prevents the Pt nanoparticles from sintering. We speculate that the ALD overcoat selectively binds to the undercoordinated sites on the Pt nanoparticles, while leaving the more selective terrace sites available for dehydrogenation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Use of Lignin-Based Admixture as Water Reducer (WRA) for Tailoring the Rheological Properties of Mortars for 3D-Printing

Efforts towards decarbonizing construction materials and industrial processes related to cement and concrete can be aided via multifaceted approaches that target alternative admixtures as well as precision control of fabrication. Chemical admixtures for water reduction have played a crucial role in the development of advanced mortar and concrete mixtures. Newer biomass processing techniques developed for aviation fuel production from corn stover biomass produce a highly reactive lignin byproduct that is suitable for chemical modifications to mimic the properties of commonly used polycarboxylate ethers (PCEs) with a smaller carbon footprint. These lignin-based plasticizers developed at NREL can be used in place of petrochemical-derived superplasticizers to tailor the rheological properties of cement-based systems for applications such as additive manufacturing while reducing the carbon intensity of the concrete mix. Lignosulfonates derived from paper pulping were historically used as water reducers only to be displaced with the rise of PCEs. The present study examines the use of a NREL produced lignin-based water reducing admixture (WRA), in cement pastes and mortar mixtures for 3D-printing at small- (mm) scale. The experimental program consisted of different formulations of oxidized lignin-based WRAs added in variable dosages to cement pastes with a fixed water-to-cement ratio. The objective is to achieve an appropriate workability, extrudability and buildability of mortar mixtures to produce 3D-printed specimens. The rheological characterization was performed to compare the initial yield stress and viscosity of the different mixtures with lignin-based admixture with respect to conventional PCE superplasticizers. The rheological characterization shows that the proposed material act as an effective water-reducer in cement systems, affecting the yield stress, plastic viscosity, and structuration rate of the mixtures evaluated. On the other hand, the effect on early hydration process of the cement pastes containing lignin-based admixtures is comparable to conventional superplasticizers.

3D-printing↗
NASA NTRS1975

Value contamination avoidance devices

Mechanical redesign methods were used to minimize contamination damage of conventional fluid components and a contamination separator device was developed for long term reusable space vehicles. These were incorporated into an existing 50.8 mm poppet valve and tested for damage tolerance in a full size open loop flow system with gaseous and liquid nitrogen. Cyclic and steady flow conditions were tested with particles of 125 to 420 micrometers aluminum oxide dispersed in the test fluids. Nonflow life tests (100,000 cycles) were made with two valve configurations in gaseous hydrogen. The redesigned valve had an acceptable cycle life and improved tolerance to contamination damage when the primary sealing surfaces were coated with thin coatings of hard plastic (Teflon S and Kynar). Analytical studies and flow testing were completed of four different versions of the separator. overall separation efficiencies in the 55-90% range were measured with these non-optimum configurations.

Endicott, D. L.↗
NASA NTRS2015

Effect of Notches on Creep-Fatigue Behavior of a P/M Nickel-Based Superalloy

A study was performed to determine and model the effect of high temperature dwells on notched low cycle fatigue (NLCF) and notch stress rupture behavior of a fine grain LSHR powder metallurgy (PM) nickel-based superalloy. It was shown that a 90 second dwell applied at the minimum stress (min dwell) was considerably more detrimental to the NLCF lives than similar dwell applied at the maximum stress (max dwell). The short min dwell NLCF lives were shown to be caused by growth of small oxide blisters which caused preferential cracking when coupled with high concentrated notch root stresses. The cyclic max dwell notch tests failed mostly by a creep accumulation, not by fatigue, with the crack origin shifting internally to a substantial distance away from the notch root. The classical von Mises plastic flow model was unable to match the experimental results while the hydrostatic stress profile generated using the Drucker-Prager plasticity flow model was consistent with the experimental findings. The max dwell NLCF and notch stress rupture tests exhibited substantial creep notch strengthening. The triaxial Bridgman effective stress parameter was able to account for the notch strengthening by collapsing the notched and uniform gage geometry test data into a singular grouping.

Dwell Notch Fatigue↗