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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 OSTI2024

Surface Preparation of Additively Manufactured 316H Stainless Steel for Molten Salt Applications

Additive manufacturing (AM) has the potential to revolutionize the manufacturing process and speed up deployment of advance nuclear reactors. However, more information is needed on preparing AM materials for extreme reactor environments to qualify AM materials for nuclear applications. This project studies the surface preparation of AM 316H stainless steel using acid pickling and reports a successful procedure for descaling heat-treated AM material.

316H Stainless Steel↗
DOE OSTI2022

Pit Stability Predictions of Additively Manufactured SS316 Surfaces Using Finite Element Analysis

Stainless steels are susceptible to localized forms of corrosion attack, such as pitting. The size and lifetime of a nucleated pit can vary, depending on a critical potential or current density criterion, which determines if the pit repassivates or continues growing. This work uses finite element method (FEM) modeling to compare the critical pit radii predicted by thermodynamic and kinetic repassivation criteria. Experimental electrochemical boundary conditions are used to capture the active pit kinetics. Geometric and environmental parameters, such as the pit shape and size (analogous to additively manufactured lack-of-fusion pores), solution concentration, and water layer thickness were considered to assess their impact on the pit repassivation criterion. The critical pit radius (the transition point from stable growth to repassivation) predicted for a hemispherical pit was larger when using the repassivation potential (E rp ) criteria, as opposed to the current density criteria (pit stability product). Including both the pit stability product and E rp into its calculations, the analytical maximum pit model predicted a critical radius two times more conservative than the FEA approach, under the conditions studied herein. The complex pits representing lack-of-fusion pores were shown to have minimal impact on the critical radius in atmospheric conditions.

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

Impacts of Superalloys on the Surface Quality of Additively Manufactured Channels

Abstract Gas turbines feature many components that require superalloys capable of handling extreme thermal environments. Increasing the selection of materials available for these components is important to their use in these extremely high-temperature environments. This study investigated two recently developed materials intended to be used for additive manufacturing (AM), with one superalloy based on cobalt and the other on nickel. Sets of four test coupons were built using the materials, in addition to the commonly used Inconel-718, on multiple laser powder bed fusion machines. Several build conditions were varied between coupon sets, including coupon orientation, contour settings, and upskin and downskin treatment. Each set of test coupons featured four unique cooling designs to explore how different cooling technologies would be impacted by the variations in build conditions. After being built, coupons were computed tomography (CT) scanned to determine accuracy to design intent and quantify the surface roughness. The CT scans indicated that horizontally built test coupons had a significantly higher deviation from design intent and higher surface roughness than those built vertically. Results also indicated that the cobalt-based alloy consistently had a smoother surface quality with lower surface roughness compared to the nickel-based alloy. After geometric characterization, the cooling performance of the test coupons was measured experimentally. Pressure losses were found to correlate with increases in surface roughness; however, in some cases, the convective heat transfer did not increase proportionally to the pressure loss as a result of surface features significantly blocking the flow without proportionally increasing convective heat transfer.

Engineering↗
DOE OSTI2021

Development of an anti-clogging perforated plate atomizer for a zero liquid discharge humidification-dehumidification desalination system

An anti-clogging perforated plate atomizer is designed for high temperature and salinity applications in a novel solar-powered zero liquid discharge humidification-dehumidification desalination system (US Patent Application US62882953). Herein this paper presents a detailed discussion on its design, and operation. Experiments are performed on seven atomizers to study the effect of design, and operating parameters on spray cone angle, and average droplet diameter. Spray cone angle remains constant with change in air mass flux, and increases with increasing orifice diameter, and manifold diameter. It also increases initially with water mass flow rate, and manifold height, before attaining a constant value. Average droplet diameter increases with increasing water mass flow rate, and decreasing air mass flux, orifice diameter, and manifold diameter. Further, anti-clogging performance of the atomizer is tested with hypersaline water of 100,000 ppm total dissolved solid (NaCl) at elevated temperatures such as air at 175 °C and saline water at 45 °C. Results show no clogging for 2–13 h of operation. Near-complete suppression of atomizer clogging makes our new additively-manufactured perforated plate atomizer an ideal fit for high salinity, and zero liquid discharge humidification-dehumidification desalination systems. Additionally, its open-surface design allows additional surface modifications to further reduce clogging, and enhance self-cleaning characteristics.

47 OTHER INSTRUMENTATION↗
NASA NTRS1966

Run-in with chemical additive protects gear surface

Run-in treatment provides a protective coating on turbopump gear surfaces so that they are capable of operation under marginal conditions in mineral oil and diester lubricants. This treatment protects highly loaded gears during relatively short-term operation.

Hartman, M. A.↗
NASA NTRS1973

The vestibular system of the owl

Five owls were given vestibular examinations, and two of them were sacrificed to provide serial histological sections of the temporal bones. The owls exhibited a curious variability in the postrotatory head nystagmus following abrupt deceleration; sometimes a brisk nystagnus with direction opposite to that appropriate to the stimulus would occur promptly after deceleration. It was found also that owls can exhibit a remarkable head stability during angular movement of the body about any axis passing through the skull. The vestibular apparatus in the owl is larger than in man, and a prominent crista neglecta is present. The tectorial membrane, the cupula, and the otolithic membranes of the utricle, saccule, and lagena are all attached to surfaces in addition to the surfaces hearing hair cells. These attachments are very substantial in the utricular otolithic membrane and in the cupula.

Money, K. E.↗
NASA NTRS1982

Enhanced erythrocyte suspension layer stability achieved by surface tension lowering additives

In connection with a fractionation procedure involving the separation of particles, a dilute suspension of these particles in a liquid is carefully layered on a dense liquid. Under ideal conditions, the suspension forms a zone of finite thickness with a 'sharp' interface between the suspension layer and the supporting liquid. Under an applied field, e.g., gravitational or electrical, the particles in the suspension layer migrate to form different layers according to their size and/or density or according to their electrophoretic mobilities. However, in many cases the ideal conditions necessary for the fractionation process are not obtained. Many studies have been conducted to explore the reasons for suspension layer 'instability'. The present investigation represents an extension of a study conducted by Omenyi et al. (1981). An electrostatic repulsion-van der Waals mechanism was used to study the stability of fixed erythrocyte suspensions layered on a D2O cushion.

Omenyi, S. N.↗
NASA NTRS1986

Ion-Deposited Polished Coatings

Polished, dense, adherent coatings relatively free of imperfections. New process consists of using broad-beam ion source in evacuated chamber to ion-clean rotating surface that allows grazing incidence of ion beam. This sputter cleans off absorbed gases, organic contaminants, and oxides of mirror surface. In addition to cleaning, surface protrusions sputter-etched away. Process particularly adaptable to polishing of various substrates for optical or esthetic purposes.

Banks, B. A.↗
NASA NTRS2016

The Pilatus Unmanned Aircraft System for Lower Atmospheric Research

This paper presents details of the University of Colorado (CU) "Pilatus" unmanned research aircraft, assembled to provide measurements of aerosols, radiation and thermodynamics in the lower troposphere. This aircraft has a wingspan of 3.2 m and a maximum take-off weight of 25 kg, and it is powered by an electric motor to reduce engine exhaust and concerns about carburetor icing. It carries instrumentation to make measurements of broadband up- and downwelling shortwave and longwave radiation, aerosol particle size distribution, atmospheric temperature, relative humidity and pressure and to collect video of flights for subsequent analysis of atmospheric conditions during flight. In order to make the shortwave radiation measurements, care was taken to carefully position a high-quality compact inertial measurement unit (IMU) and characterize the attitude of the aircraft and its orientation to the upward-looking radiation sensor. Using measurements from both of these sensors, a correction is applied to the raw radiometer measurements to correct for aircraft attitude and sensor tilt relative to the sun. The data acquisition system was designed from scratch based on a set of key driving requirements to accommodate the variety of sensors deployed. Initial test flights completed in Colorado provide promising results with measurements from the radiation sensors agreeing with those from a nearby surface site. Additionally, estimates of surface albedo from onboard sensors were consistent with local surface conditions, including melting snow and bright runway surface. Aerosol size distributions collected are internally consistent and have previously been shown to agree well with larger, surface-based instrumentation. Finally the atmospheric state measurements evolve as expected, with the near-surface atmosphere warming over time as the day goes on, and the atmospheric relative humidity decreasing with increased temperature. No directional bias on measured temperature, as might be expected due to uneven heating of the sensor housing over the course of a racetrack pattern, was detected. The results from these flights indicate that the CU Pilatus platform is capable of performing research-grade lower tropospheric measurement missions.

de Boer, Gijs↗
NASA NTRS1973

Effect of lubricant extreme pressure additives on rolling element fatigue life

The effects of surface active additives on rolling-element fatigue life were investigated with the five-ball fatigue tester at conditions where classical subsurface initiated rolling-element fatigue is the sole mode of failure. Test balls of AISI 52100, AISI M-50, and AISI 1018 were run with an acid-treated white oil containing either 2.5 percent sulfurized terpene, 1 percent didodecyl phosphite, or 5 percent chlorinated wax. In general, it was found that the influence of surface active additives was detrimental to rolling-element fatigue life. The chlorinated-wax additive significantly reduced fatigue life by a factor of 7. The base oil with the 2.5 percent sulfurized-terpene additive can reduce fatigue life by as much as 50 percent. No statistical change in fatigue life occurred with the base oil having the 1 percent didodecyl-phosphite additive. The additives used with the base oil did not change the ranking of the bearing steels where rolling-element fatigue life was of subsurface origin.

Parker, R. J.↗
DOE OSTI2026

Identifying the Accuracy of Surface Roughness for Metal Additive Manufacturing Parts Captured with Computed Tomography Scanning

Conventional surface roughness measurement techniques require direct access to internal surfaces, often necessitating destructive sectioning of test articles. Computed tomography (CT) offers a non-destructive alternative for internal surface characterization, but its application in metrology remains unstandardized and sensitive to machine resolution and operator technique. This study investigates the feasibility of using CT scanning to quantify areal surface roughness in metal AM heat exchanger tubes with three distinct internal geometries: ribbed, discrete W, and featureless. CT-derived surface parameters were extracted using custom Python scripts and compared to measurements obtained from a focus variation microscope calibrated against a known standard. Results show that CT-based roughness measurements closely matched microscope values for the discrete W specimen, deviations between CT and microscope measurements were minimal—less than 1 µm—indicating reliable reconstruction. In contrast, the ribbed and featureless specimens, with lower roughness values showed greater discrepancies. The findings suggest that CT scanning can be a viable non-destructive metrology tool for AM parts with surface roughness above approximately 8 µm. For smoother surfaces, current CT capabilities may not provide sufficient accuracy, highlighting the need for resolution-aware workflows and further standardization in CT-based surface metrology.

36 MATERIALS SCIENCE↗