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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

Vaporization of droplets in premixing chambers

Detailed measurements were made of the structures of turbulent fuel sprays vaporizing in heated airstreams. The measurements show the size dependent vaporization and dispersion of the droplets and the important influence of the large eddies in the turbulence. The measurements form a data base for the development of models of fuel spray vaporization. Two laser techniques were specially developed for the investigation. A laser tomography technique converts line-of-sight light scattering measurements into time averaged 'point' measurements of droplet size distribution and volume concentration. A laser anemometer particle sizing technique was further developed to permit accurate measurements of individual particle sizes and velocities, with backscatter collection of light. The experiments are combined with heat transfer models to analyze the performance of miniature thermocouples in liquid sprays.

Yule, A. J.↗
DOE OSTI2026

A Novel Surface Restoration Method for Hydropower Steel Components: Plasma Gouging and Inconel Cold Spray Coating for Material Repair

A novel surface restoration approach combining plasma gouging with subsequent cold spray deposition is demonstrated in this study. Plasma gouging effectively removes the damaged steel surface, leaving grooves and forming a plasma gouging affected zone up to ~300?µm thick. Within this zone, a hardened martensitic layer with a peak hardness of ~370?HV—almost twice that of the base substrate (~200?HV)—is produced. Following plasma gouging, cold spray deposition is applied to rebuild the surface. Experimental results reveal that cold spray coatings deposited at low energy suffer from delamination, whereas high energy cold spray deposits yield a well-bonded coating. Microstructural analysis further shows that the martensitic layer formed by plasma gouging undergoes dynamic recrystallization during cold spray, reducing the hardness to 317?HV. These findings demonstrate the feasibility of this hybrid method for effective surface restoration of damaged steel components.

Wang, Tianhao↗
NASA NTRS1999

Method for Forming Fiber Reinforced Composite Bodies with Graded Composition and Stress Zones

A near-net, complex shaped ceramic fiber reinforced silicon carbide based composite bodies with graded compositions and stress zones is disclosed. To provide the composite a fiber preform is first fabricated and an interphase is applied by chemical vapor infiltration, sol-gel or polymer processes. This first body is further infiltrated with a polymer mixture containing carbon, and/or silicon carbide, and additional oxide, carbide, or nitride phases forming a second body. One side of the second body is spray coated or infiltrated with slurries containing high thermal expansion and oxidation resistant. crack sealant phases and the other side of this second body is coated with low expansion phase materials to form a third body. This third body consisting of porous carbonaceous matrix surrounding the previously applied interphase materials, is then infiltrated with molten silicon or molten silicon-refractory metal alloys to form a fourth body. The resulting fourth body comprises dense composites consisting of fibers with the desired interphase which are surrounded by silicon carbide and other second phases materials at the outer and inner surfaces comprising material of silicon, germanium, refractory metal suicides, borides, carbides, oxides, and combinations thereof The resulting composite fourth body has different compositional patterns from one side to the other.

Singh, Mrityunjay↗
DOE OSTI2026

3D Tomography insights on particle-particle bonding in cold spray

The conditions of the target surface during cold spray affect deformation and bonding. While surface preparation can influence the adhesion of the first particles, such modification is not relevant to the particle-particle interfaces that dominate the growth of a coating. Here we study two-particle Cu stacks produced with a single-particle launch apparatus and compare them to single-particle experiments on a clean polished substrate. Serial cross-sectioning using microtomography permits a systematic evaluation and quantification of bonding at the particle-particle interfaces. We observe that the top particle in the two-particle stacks is much more flattened compared to single impacts on the polished substrate. Although the resulting interfacial area expansion is comparable to that of single impacts at the same velocities, bonding at the particle-particle interfaces is significantly less (never exceeding 18% even around the “optimal” velocity for bonding). Lastly, we find that hydrodynamic jetting, a form of localization known to promote adhesion in cold spray, is hindered for impacts on top of a prior particle deposition. Here, the results point to a need for future studies that separately consider topography and mechanical properties of substrates in the pursuit of optimal bonding.

Bonding↗
NASA NTRS1976

Use of water sprays in space rescue and retrieval operations

Recent experiments involving liquid jets exhausting into a vacuum have led to significant conclusions regarding techniques for detumbling and despinning spacecraft during retrieval and rescue operations. A fine water spray directed toward a tumbling or a spinning object may quickly form ice over its surface. The added mass of water will absorb angular momentum and slow the vehicle. As this ice sublimes it carries momentum away with it. Thus, a complete detumble or despin is possible by simply spraying water at a disabled or spinning vehicle. Experimental and analytical results are presented on performance and physical properties. Although these are of a preliminary nature, the results are quite promising. Example situations are considered to illustrate potential applications.

Kaplan, M. H.↗
DOE OSTI2011

Characterization of Coordination Complexes by Desorption Electrospray Mass Spectrometry with a Capillary Target

Metal coordination complexes were formed directly from liquid surfaces using desorption electrospray ionization (DESI) mass spectrometry. The approach is attractive because it separates complexities of ESI spray droplet formation from delivery of the analyte solution, and thereby gets around difficulty resulting from alteration of the spray process by changes in solution chemistry. Cs+, Ba2+, and La3+ coordination complexes were formed using 18-crown-6 (18c6) and triethylphosphate (TEP) as ligands (L), that had the general formula [Mn+(NO3-)n-1(L)m]+. Formation of singly charged cation complexes was preferred, with charge reduction at the metal site accomplished by attachment of nitrate. Using TEP as a model phosphoryl ligand, alkali metals coordinate with up to three ligands, with Cs+ preferring fewer than Na+. Ba2+ and La3+ are formed as ion pair complexes [Ba(NO3)]+ and [La(NO3)2]+, and both will coordinate with up to four TEP ligands. Using 18c6, Cs+ forms a bis-ligand complex. In contrast, [Ba(NO3)]+ prefers a single 18c6 ligand, while La forms mainly [La(NO3)2(18c6)]+, for which DFT calculations suggested a structure in which the nitrate ligands occupy pseudo-axial positions on opposing sides of the crown. Lower abundances of bis-18c6 complexes were also formed together with doubly charged [La(NO3)(18c6)n]2+ complexes (n = 2 – 4). The results suggest an alternative strategy for probing metal speciation in solution that is less perturbed by the droplet formation and ionization mechanisms operating in conventional electrospray ionization mass spectrometry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1987

Fuel thermal stability effects on spray characteristics

The propensity of a heated hydrocarbon fuel toward solids deposition within a fuel injector is investigated experimentally. Fuel is arranged to flow through the injector at constant temperature, pressure, and flow rate and the pressure drop across the nozzle is monitored to provide an indication of the amount of deposition. After deposits have formed, the nozzle is removed from the test rig and its spray performance is compared with its performance before deposition. The spray characteristics measured include mean drop size, drop-size distribution, and radial and circumferential fuel distribution. It is found that small amounts of deposition can produce severe distortion of the fuel spray pattern. More extensive deposition restores spray uniformity, but the nozzle flow rate is seriously curtailed.

Lefebvre, A. H.↗
DOE OSTI2013

Assessment of ceramic coatings for metal fuel melting crucible

The objective of this study is to develop a coating method and material for crucibles to prevent material interactions with the U-Zr/U-TRU-Zr fuels during the manufacturing of SFR fuels. Refractory coatings were applied to niobium substrates by vacuum plasma-spray coating method. Melt dipping tests conducted were the coated rods lowered into the fuel melt at 1600 C. degrees, and withdrawn and cooled outside the crucible in the inert atmosphere of the induction furnace. Melt dipping tests of the coated Nb rods indicated that plasma-sprayed Y{sub 2}O{sub 3} coating doesn't form significant reaction layer between fuel melt and coating layer. Melt dipping tests of the coated Nb rods showed that TiC, TaC, and Y{sub 2}O{sub 3} coatings exhibited the promising performance among other ceramic coatings. These materials could be promising candidate materials for the reusable melt crucible of metal fuel for SFR. In addition, in order to develop the vacuum plasma-spray coating method for re-usable crucible of metal fuel slugs to be overcome the issue of thermal expansion mismatch between coating material and crucible, various combinations of coating conditions were investigated to find the bonding effect on the substrate in pursuit of more effective ways to withstand the thermal stresses. It is observed that most coating methods maintained sound coating state in U-Zr melt. (authors)

36 MATERIALS SCIENCE↗
NASA NTRS1984

Abrasive tip treatment for use on compressor blades

A co-spray process was used which simultaneously but separately introduces abrasive grits and metal matrix powder into the plasma stream and entraps the abrasive grits within a molten matrix to form an abrasive coating as the matrix material solidifies on test specimen surfaces. Spray trials were conducted to optimize spray parameter settings for the various matrix/grit combinations before actual spraying of the test specimens. Rub, erosion, and bond adhesion tests were conducted on the coated specimens in the as-sprayed condition as well as on coated specimens that were aged for 100 hours at a temperature of 866K (1100 F). Microscopic examinations were performed to determine the coating abrasive-particle content, the size and shape of the adhesive particles in the coating, and the extent of compositional or morphological changes resulting from the aging process. A nickel chromium/aluminum composite with No. 150 size (0.002 to 0.005 inch) silicon carbide grits was selected as the best matrix/abrasive combination of the candidates surveyed for coating compressor blade tips.

Pedersen, H. C.↗
DOE OSTI2022

Polymer-Stabilized Liquid Metal Nanoparticles as a Scalable Current Collector Engineering Approach Enabling Lithium Metal Anodes

Dendrites and dead lithium formation over prolonged cycling have long been challenges that hinder the safe implementation of metallic Li anodes. In this study, we employ polymer-stabilized liquid metal nanoparticles (LM-P NPs) of eutectic gallium indium (EGaIn) to create uniform Li nucleation sites enabling homogeneous lithium electrodeposition. Block copolymers of poly(ethylene oxide) and poly(acrylic acid) (PEO-b-PAA) were grafted onto the EGaIn surface, forming stabilized, well-dispersed NPs. Using a scalable spray coating approach, LM-P NPs were fabricated on copper current collectors, providing lithiophilic PEO sites and interactive carboxyl groups to guide Li deposition. The Li-EGaIn alloying process greatly reduced the Li + diffusion barrier, enabling fast Li transport through the coating layer, resulting in decreased nucleation overpotential. Therefore, about five times lower Li nucleation overpotential was obtained on the LM-P modified Cu with an optimal composition of the polymers than the bare Cu substrates. DFT computations was used to reveal the binding properties between the LM-P layer and Li. Due to the regulated Li plating/stripping process, as-obtained 30 μm Li anodes paired with LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NCM8 11 ) with a negative/positive electrode capacity (N/P) ratio ~ 10 exhibited stable cycling performance at 0.5C for over 250 cycles, with an average Coulombic efficiency of 99.55%. Ultrathin Li (1 μm) anodes with an N/P ratio ~ 0.6 were also demonstrated in Li|LiFePO 4 cells, which examined the stabilization of Li by LM-P NPs and monitored practical loadings of Li anodes that are close to anode-free systems.

25 ENERGY STORAGE↗
DOE OSTI2016

Effect of layer thickness on the properties of nickel thermal sprayed steel

Thermal arc spray nickel coating is widely used for decorative and functional applications, by improving corrosion resistance, wear resistance, heat resistence or by modifying other properties of the coated materials. There are several properties have been studied. Layer thickness of nickel thermal sprayed steel may be make harder the substrate surface. In this study, the effect of layer thickness of nickel thermal sprayed steel has been investigated. The rectangular substrate specimens were coated by Ni–5 wt.% Al using wire arc spray method. The thickness of coating layers were in range from 0.4 to 1.0 mm. Different thickness of coating layers were conducted to investigate their effect on hardness and morphology. The coating layer was examined by using microvickers and scanning electron microscope with EDX attachment. Generally, the hardness at the interface increased with increasing thickness of coating layers for all specimens due to higher heat input during spraying process. Morphology analysis result that during spraying process aluminum would react with surrounding oxygen and form aluminum oxide at outer surface of splat. Moreover, porosity was formed in coating layers. However, presence porosity is not related to thickness of coating material. The thicker coating layer resulted highesr of hardness and bond strength.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Automated Array Assembly, Phase 2

The large scale production of silicon solar cell array panels is discussed. The cost and performance of three manufacturing sequences designed to convert silicon sheet and wafers into solar panels is analyzed. The production of ion implanted and furnace annealed solar cells made using solar grade n- and p-type wafers is examined. The performance of production size lots is examined with regard to the relationship between the ion implant and furnace anneal parameters and the ability to form consistently good thick film screen printed contacts. The spray on antireflection coating process is evaluated. The performance of several lots of cells before and after coating is measured. The structure and refractive index of the RCA I (TiO2) coating is compared with commercial solutions. Sensitivity of coated, screen printed cells to the post heat treatment required to cure the films is assessed.

Daiello, R. V.↗
NASA NTRS1984

An investigation of the existence of a surface water layer on aircraft radomes during simulated flight in heavy precipitation

An experiment to investigate the electromagnetic attenuation effects of an impacting water spray on an aircraft weather radome was conducted in Langley's 4 X 7 m. wind tunnel equipped with a water spray system. Results indicate no significant liquid water film formed at the stagnation point of the radome under the test conditions. However, a water sheath was observed standing away from the radome surface, which could possibly have significant attenuation properties of its own. Due to the lack of fidelity in modeling both the natural environment with the tunnel apparatus and the water sheath, it is recommended that further studies be undertaken to better define the water distribution in the vicinity of the radome and measure its effect on weather radar performance.

Branstetter, J. R.↗
NASA NTRS1989

The role of rapid solidification processing in the fabrication of fiber reinforced metal matrix composites

Advanced composite processing techniques for fiber reinforced metal matrix composites require the flexibility to meet several widespread objectives. The development of uniquely desired matrix microstructures and uniformly arrayed fiber spacing with sufficient bonding between fiber and matrix to transmit load between them without degradation to the fiber or matrix are the minimum requirements necessary of any fabrication process. For most applications these criteria can be met by fabricating composite monotapes which are then consolidated into composite panels or more complicated components such as fiber reinforced turbine blades. Regardless of the end component, composite monotapes are the building blocks from which near net shape composite structures can be formed. The most common methods for forming composite monotapes are the powder cloth, foil/fiber, plasma spray, and arc spray processes. These practices, however, employ rapid solidification techniques in processing of the composite matrix phase. Consequently, rapid solidification processes play a vital and yet generally overlooked role in composite fabrication. The future potential of rapid solidification processing is discussed.

Locci, Ivan E.↗
DOE OSTI2021

Method of manufacturing a reinforced nuclear fuel cladding using an intermediate thermal deposition layer

A method is described that includes the steps of making a thin walled Zr alloy tube, loading nuclear fuel pellets into the tube, compressing the tube onto the fuel pellets to substantially reduce free space around the fuel pellets, positioning end plugs at each of two ends of the tube, filling the tube with a heat transferring gas, and coating the compressed tube with a corrosion resistant material using a thermal deposition process, such as cold spray, before inserting the tube into a pre-formed SiC composite cover having at least one closed end.

Lahoda, Edward J.↗
DOE OSTI2013

Method and apparatus for electrokinetic co-generation of hydrogen and electric power from liquid water microjets

A method and apparatus for producing both a gas and electrical power from a flowing liquid, the method comprising: a) providing a source liquid containing ions that when neutralized form a gas; b) providing a velocity to the source liquid relative to a solid material to form a charged liquid microjet, which subsequently breaks up into a droplet spay, the solid material forming a liquid-solid interface; and c) supplying electrons to the charged liquid by contacting a spray stream of the charged liquid with an electron source. In one embodiment, where the liquid is water, hydrogen gas is formed and a streaming current is generated. The apparatus comprises a source of pressurized liquid, a microjet nozzle, a conduit for delivering said liquid to said microjet nozzle, and a conductive metal target sufficiently spaced from said nozzle such that the jet stream produced by said microjet is discontinuous at said target. In one arrangement, with the metal nozzle and target electrically connected to ground, both hydrogen gas and a streaming current are generated at the target as it is impinged by the streaming, liquid spray microjet.

42 ENGINEERING↗
DOE OSTI2012

Effect of boric acid on the properties of Li{sub 2}MnO{sub 3}·LiNi{sub 0.5}Mn{sub 0.5}O{sub 2} composite cathode powders prepared by large-scale spray pyrolysis with droplet classifier

Graphical abstract: Display Omitted Highlights: ► Spherical shape Li{sub 2}MnO{sub 3}·LiNi{sub 0.5}Mn{sub 0.5}O{sub 2} composite cathode powders are prepared by large-scale spray pyrolysis with droplet classifier. ► Boric acid improves the morphological and electrochemical properties of the composite cathode powders. ► The discharge capacity of the composite cathode powders decreases from 217 to 196 mAh g{sup −1} by the 30th cycle. -- Abstract: Spherically shaped 0.3Li{sub 2}MnO{sub 3}·0.7LiNi{sub 0.5}Mn{sub 0.5}O{sub 2} composite cathode powders with filled morphology and narrow size distribution are prepared by large-scale spray pyrolysis. A droplet classification reduces the standard deviation of the size distribution of the composite cathode powders. Addition of boric acid improves the morphological properties of the product powders by forming a lithium borate glass material with low melting temperature. The optimum amount of boric acid dissolved in the spray solution is 0.8 wt% of the composite powders. The powders prepared from the spray solution with 0.8 wt% boric acid have a mixed layered crystal structure comprising Li{sub 2}MnO{sub 3} and LiNi{sub 0.5}Mn{sub 0.5}O{sub 2} phases, thus forming a composite compound. The initial charge and discharge capacities of the composite cathode powders prepared from the 0.8 wt% boric acid spray solution are 297 and 217 mAh g{sup −1}, respectively. The discharge capacity of the powders decreases from 217 to 196 mAh g{sup −1} by the 30th cycle, in which the capacity retention is 90%.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Application of Canned Deformation to a Hard-Deformed Spray-Deposited Al-Zn-Mg-Cu Alloy

A wide variety of industrial applications require Al-Zn-Mg-Cu alloys with high strength and ductility. However, Zn-rich Al-Zn-Mg-Cu alloys prepared by rapid solidification methods usually show excellent strength but poor formability, which restricts their wide application in complex forming. In this study, we developed a new deformation method for the spray-deposited Zn-rich Al-Zn-Mg-Cu alloy to avoid crack formation and achieve isotropic properties. The microstructure evolution and crystallographic textures were analyzed and compared with the results of a normal deformation process. Crack-free forgings with the ultimate tensile strength (UTS), yield strength (YS) and elongation of 727 ± 5 MPa, 690 ± 3 MPa, 5.0 ± 0.7% along the radial direction and 735 ± 2 MPa, 693 ± 3 MPa, 6.3 ± 0.2% along the tangential direction were finally obtained. The improvement in the mechanical properties can be attributed to the larger amount of subgrains and substructures generated in the canned deformed alloy. The results of this study show excellent advantages and potential application prospects of the canned deformation to hard-deformed Al-Zn-Mg-Cu alloys.

36 MATERIALS SCIENCE↗