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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 271 records · Page 15
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NASA NTRS2024

Defining the Operational Envelope for Air Flows in the Miniature Arc-Jet Research Chamber (mARC II)

The second-generation 30 kW miniature Arc-jet Research Chamber (mARC II) at NASA Ames Research Center produces high enthalpy flows relevant for entry systems ground testing. The mARC II facility has recently undergone upgrades, including the installation of a new vacuum system to address the issues preventing it from maintaining underexpanded flow under test conditions. In this work, we present data obtained from an Integrated Systems Testing campaign and provide an initial assessment of arc-jet performance following the upgrades. Air is used as the working gas for the standard mARC II arc-heater configuration with two constrictor disks. Seven runs were investigated for five test conditions to assess the lowest achievable stagnation point heat fluxes for air flow rates of 0.15 or 0.25 g s −1 . The heat flux was measured using a water-cooled Gardon gauge (Ø4.76 mm, 3/16" hemispherical) at 70 mm from the nozzle exit plane. The new vacuum system produced test box pressures in the medium (fine) vacuum range (~0.03 torr, 4 Pa) prior to gas addition and successfully maintained underexpanded flow after gas addition. The upgrade yielded a ~4X reduction in heat flux relative to the previous system for the same set test conditions. We report the lowest heat fluxes measured in mARC II to date, ranging from 26 to 81 W cm −2 , for sonic flow enthalpies of 4–14 MJ kg −1 . Bulk enthalpies estimated using an energy balance method (EB 2 ) are reported for the first time using mARC II.Initial data suggests EB 2 generally estimates lower enthalpies than sonic flow methods for mARC II. Lastly, laminar axisymmetric Navier–Stokes simulations were performed using the NASA DPLR code. Numerical heat flux results show good agreement with experiments at low arc powers (3–15% difference at the minimum set arc current), but discrepancy increases with arc power (49% difference at the maximum set arc current).

arc-jet↗
NASA NTRSDate not supplied

CFD Simulations of the AEDC H3 Arc-Jet Flow: Mach 3.3 Nozzle, Flow Surveys, Wedge Models

This paper reports computational simulations and analysis of tests in a high enthalpy arc-jet facility at Arnold Engineering Development Center. These tests were conducted using wedge models placed in a free jet downstream of a 4.5-inch diameter contoured Mach 3.3 nozzle in the H3 facility. For calibration of test conditions, one wedge calibration plate instrumented with an array of pressure and coaxial thermocouple heat flux gages, one stagnation pressure probe and two null-point heat flux calorimeters were used. The pitot pressure and null-point probe measurements give experimental surveys of the test flow, providing assessment of the flow uniformity and valuable data for flow characterization. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle, into the test box and over the wedge models, and comparisons with the experimental measurements. Several issues related to testing are considered: test flow characterization, prediction of surface quantities for three wedge models, effects of model shape change and test article recession, and prediction of surface quantities for the test articles with two circular cavities. These simulations take into account non-uniform total enthalpy profiles at the nozzle inlet as well as the expansion waves emanating from the nozzle exit and their effects on the wedge model flowfields.

Arc-jet testing↗
NASA NTRSDate not supplied

Towards Quantifying and Correlating RTV Intumescence to Entry-Relevant Conditions

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also adopted to bond instrumentation plugs of temperature and pressure sensors into heatshield’s tiles. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Experimental data has also shown heating rate-dependent swelling (or intumescence) and shrinking of RTV, these volume changes may cause roughness-induced boundary layer transition. Outgassing and surface oxide formation of RTV upon decomposition also occur, which can be sources of contamination of heat shield sensors. This combination of detrimental effects motivates a critical need to develop a high-fidelity model for RTV ablation. As a first critical step in RTV modeling, a comprehensive material properties database for RTV was collected that account for the lack of data in properties such as pyrolysis char yield, shape change, virgin and char porosity. The next step is to quantify the volume change of RTV as a function of temperature. While this was done in previous campaigns, limited data was collected which showed a possible heating rate dependent intumescent behavior. To further understand the intumescence phenomenon of RTV, numerous dedicated experiments were performed at Beamline 8.3.2 of the Advanced Light Source, where RTV samples were heated while X-ray scans were taken in situ. Micro-Computed Tomography scans were taken in situ for low heating rates (≤ 60 °C/min), whereas continuous radiography scans were taken for higher heating rates (≤ 1500 ºC/min). Unconstrained samples and samples constrained in different holders (quartz, graphite, FiberForm and PICA) were tested to determine the change in intumescence due to confinement. Using deep learning techniques, the tomographies and radiographies are segmented to obtain volume change, porosity, pore size distributions and connectivity. From the results obtained, modifications to the previous RTV intumescence model are proposed, along with preliminary comparisons to testing RTV at high-enthalpy facilities.

RTV↗
NASA NTRSDate not supplied

Extending mARC II Arc-Jet Test Duration via Design and Implementation of Model System Cooling Sleeve

The mARC II is a 30 kW arc-jet facility at NASA Ames Research Center used to generate high-enthalpy flows for low-cost thermal protection system (TPS) technology development. Sustained operation of downstream instrumentation and material samples is constrained by thermal loading transmitted through the arc-jet test environment, limiting achievable run times and experimental throughput. This work presents the design, integration, and validation of a cooling sleeve implemented on the sweep arm drive motor feedthrough to mitigate thermal accumulation during testing. The addition of the cooling sleeve is a simple, robust upgrade that translates directly into enhanced facility capability by supporting longer run durations, reduced turnaround time, and higher throughput.

sting arm↗
NASA NTRSDate not supplied

Extending mARC II Arc-Jet Test Duration via Design and Implementation of Model System Cooling Sleeve

The mARC II is a 30 kW arc-jet facility at NASA Ames Research Center used to generate high-enthalpy flows for low-cost thermal protection system (TPS) technology development. Sustained operation of downstream instrumentation and material samples is constrained by thermal loading transmitted through the arc-jet test environment, limiting achievable run times and experimental throughput. This work presents the design, integration, and validation of a cooling sleeve implemented on the sweep arm drive motor feedthrough to mitigate thermal accumulation during testing. The addition of the cooling sleeve is a simple, robust upgrade that translates directly into enhanced facility capability by supporting longer run durations, reduced turnaround time, and higher throughput.

numerical simulations↗
NASA NTRSDate not supplied

Thermo-Poro-Mechanical Modeling of RTV Intumescence

Room temperature vulcanizing (RTV) silicone is a high-temperature adhesive used as a gap-filler between heatshield tiles in numerous entry missions. Its propensity to intumesce, or swell upon exposure to heat, is a well-known effect that needs to be carefully quantified during design. At tile interfaces of charring ablators, intumescence, combined with differential recession, could cause the gap filler to protrude past the ablator outer mold line, forming a “fence”. Fencing can in turn cause transition to turbulence of the flow wetting the heat shield, leading to augmented surface heating. Recent experiments conducted at the Plasmatron X facility, the high enthalpy wind tunnel of the Center for Hypersonics and Entry Systems Studies, have shown prominent fencing of RTV gap fillers in PICA, under both nitrogen and air plasmas. Similar observations are well known in the arcjet literature. Further experiments under controlled environment, performed using in situ X-ray micro-computed tomography (micro-CT) at the Advanced Light Source (ALS), have shown heating rate-dependent swelling and shrinkage of RTV during pyrolysis. To simulate RTV intumescence, a novel model was introduced in the Porous Materials Analysis Toolbox based on OpenFOAM, PATO, to account for pore-pressure buildup within both closed- and open-pores. The governing equation for the thermo-poro-mechanical response were developed, assuming linear elasticity for the charring silicone. A new multi-pyrolysis model that tracks non-monotonic advancement of material properties with pyrolysis was proposed. This model addresses the limitations of state-of-the-art ablator models to capture the different stages of thermal degradation and coupled thermomechanics. Swelling of RTV was simulated using the new thermo-poro-mechanical model and compared against in situ micro-CT data. Results showed good agreement in intumescence height and temperature profiles at all heating rates, indicating that the key factor contributing to RTV swelling is the internal pressure build-up within closed- and open-pores. As RTV is cured into a soft (rubbery) compound with low-porosity and permeability, initial temperature increase and pyrolysis gas production cause a significant increase of internal pressure, causing a pronounced volume growth. As thermal degradation progresses, rigidization of the silicone occurs due to char hardening which counteract volume shrinkage after gas pressure relief. Overall, our model shows that accounting for changes in properties such porosity, permeability and key thermomechanical coefficients is crucial for capturing the RTV volume change during ablation and enable a predictive capability for heatshield tile interface response. A plan for future calibration of thermomechanical properties evolution during degradation is discussed, as a key next step to close the new model.

RTV↗
NASA NTRS2026

Development of a One-Domain Volume-Averaged Navier–Stokes Solver

The interaction between a high-enthalpy flow and a thermal protection material is inherently multiscale and multiphysics. In conventional aerothermal analyses, the external flow and material response are generally modeled using separate computational domains coupled through boundary conditions at the material surface. Although this approach has supported many practical applications, it requires assumptions about the location and behavior of the interface and may become difficult to apply when material decomposition, internal reactions, and surface recession substantially alter the porous structure. This report presents the development of a one-domain formulation in which the free-fluid and porous-material regions are represented within a single computational domain. The formulation is based on the volume-averaged Navier–Stokes (VANS) equations, derived from the governing equations for reacting, compressible flow and condensed material. Volume averaging transfers the influence of the unresolved material microstructure to the macroscale equations through effective transport properties, interfacial source terms, and dispersion fluxes. Particular attention is given to regions in which porosity and permeability vary rapidly, including the diffuse transition between a porous material and the surrounding fluid. The resulting equations are implemented in the Porous-material Analysis Toolbox based on OpenFOAM (PATO). The report describes the pressure–velocity coupling strategy used by the solver, examines spatial filtering techniques for deriving effective properties, and evaluates the influence of a smoothly varying interface permeability. Numerical demonstrations include canonical porous-flow configurations, a flow-tube configuration representative of FiberForm® permeability experiments, and the oxidation of a porous carbon material. The purpose of this work is to establish a mathematical and computational foundation for a unified treatment of flow and thermal protection material response. The present formulation is intended to support the progressive inclusion of additional physical processes, including multicomponent transport, finite-rate gas–surface chemistry, pyrolysis, internal oxidation, and material recession. It also provides a framework for connecting pore-scale simulations and microstructural characterization with macroscale aerothermal-response calculations. This report is intended for researchers and engineers working in computational fluid dynamics, porous-media transport, material response, and thermal protection system modeling. It documents both the theoretical development and the initial numerical assessment of the one-domain approach, while identifying the closure of effective and dispersion terms as an important subject for continued investigation.

Ablation↗
NASA NTRSDate not supplied

Thermo-Poro-Mechanical Modeling of RTV Intumescence

Room temperature vulcanizing (RTV) silicone is a high-temperature adhesive used as a gap-filler between heatshield tiles in numerous entry missions. Its propensity to intumesce, or swell upon exposure to heat, is a well-known effect that needs to be carefully quantified during design. At tile interfaces of charring ablators, intumescence, combined with differential recession, could cause the gap filler to protrude past the ablator outer mold line, forming a “fence”. Fencing can in turn cause transition to turbulence of the flow wetting the heat shield, leading to augmented surface heating. Recent experiments conducted at the Plasmatron X facility, the high enthalpy wind tunnel of the Center for Hypersonics and Entry Systems Studies, have shown prominent fencing of RTV gap fillers in PICA, under both nitrogen and air plasmas. Similar observations are well known in the arcjet literature. Further experiments under controlled environment, performed using in situ X-ray micro-computed tomography (micro-CT) at the Advanced Light Source (ALS), have shown heating rate-dependent swelling and shrinkage of RTV during pyrolysis. To simulate RTV intumescence, a novel model was introduced in the Porous Materials Analysis Toolbox based on OpenFOAM, PATO, to account for pore-pressure buildup within both closed- and open-pores. The governing equation for the thermo-poro-mechanical response were developed, assuming linear elasticity for the charring silicone. A new multi-pyrolysis model that tracks non-monotonic advancement of material properties with pyrolysis was proposed. This model addresses the limitations of state-of-the-art ablator models to capture the different stages of thermal degradation and coupled thermomechanics. Swelling of RTV was simulated using the new thermo-poro-mechanical model and compared against in situ micro-CT data. Results showed good agreement in intumescence height and temperature profiles at all heating rates, indicating that the key factor contributing to RTV swelling is the internal pressure build-up within closed- and open-pores. As RTV is cured into a soft (rubbery) compound with low-porosity and permeability, initial temperature increase and pyrolysis gas production cause a significant increase of internal pressure, causing a pronounced volume growth. As thermal degradation progresses, rigidization of the silicone occurs due to char hardening which counteract volume shrinkage after gas pressure relief. Overall, our model shows that accounting for changes in properties such porosity, permeability and key thermomechanical coefficients is crucial for capturing the RTV volume change during ablation and enable a predictive capability for heatshield tile interface response. A plan for future calibration of thermomechanical properties evolution during degradation is discussed, as a key next step to close the new model.

silicone intumescence↗
NASA NTRS1993

Development of a high specific 1.5 to 5 kW thermal arcjet

A research and development project on the experimental study of a 1.5-5 kW thermal arcjet thruster was started in 1992 at the IRS. Two radiation cooled thrusters were designed, constructed, and adapted to the test facilities, one at each end of the intended power range. These thrusters are currently subjected to an intensive test program with main emphasis on the exploration of thruster performance and thruster behavior at high specific enthalpy and thus high specific impulse. Propelled by simulated hydrazine and ammonia, the thruster's electrode configuration such as constrictor diameter and cathode gap was varied in order to investigate their influence and to optimize these parameters. In addition, test runs with pure hydrogen were performed for both thrusters.

Riehle, M.↗
NASA NTRS1992

Increase of stagnation pressure and enthalpy in shock tunnels

High stagnation pressures and enthalpies are required for the testing of aerospace vehicles such as aerospace planes, aeroassist vehicles, and reentry vehicles. Among the most useful ground test facilities for performing such tests are shock tunnels. With a given driver gas condition, the enthalpy and pressure in the driven tube nozzle reservoir condition can be varied by changing the driven tube geometry and initial gas fill pressure. Reducing the driven tube diameter yields only very modest increases in reservoir pressure and enthalpy. Reducing the driven tube initial gas fill pressure can increase the reservoir enthalpy significantly, but at the cost of reduced reservoir pressure and useful test time. A new technique, the insertion of a converging section in the driven tube is found to produce substantial increases in both reservoir pressure and enthalpy. Using a one-dimensional inviscid full kinetics code, a number of different locations and shapes for the converging driven tube section were studied and the best cases found. For these best cases, for driven tube diameter reductions of factors of 2 and 3, the reservoir pressure can be increased by factors of 2.1 and 3.2, respectively and the enthalpy can be increased by factors of 1.5 and 2.1, respectively.

Bogdanoff, David W.↗
NASA NTRS1988

Enthalpies of formation of CaAl4O7 and CaAl12O19 (hibonite) by high temperature, alkali borate solution calorimetry

Enthalpies of formation were determined for two calcium aluminate phases, CaAl4O7 and CaAl12O19, using high-temperature alkali borate solution calorimetry. The aluminates were synthesized by multiple-cycle heating and grinding stoichiometric mixtures of CaCO3 and Al2O3, and the products were characteized by X-ray diffraction and SEM microbeam analysis. The data on impurities (CaAl4O7 was found to be about 89.00 percent pure by weight and the CaAl12O19 samples about 91.48 percent pure) were used to correct the heat of solution values of the synthetic products. The enthalpies of formation, at 1063 K, from oxides, were found to be equal to -(25.6 + or - 4.7) kJ/g.f.w. for CaAl4O7 and -(33.0 + or - 9.7) kJ/g.f.w. for CaAl12O19; the respective standard enthalpies of formation from elements, at 298 K, were estimated to be -4007 + or - 5.2 kJ/g.f.w. and -10,722 + or - 12 kJ/g.f.w.

Geiger, C. A.↗
NASA NTRS1995

Internal and surface phenomena in metal combustion

Combustion of metals has been widely studied in the past, primarily because of their high oxidation enthalpies. A general understanding of metal combustion has been developed based on the recognition of the existence of both vapor-phase and surface reactions and involvement of the reaction products in the ensuing heterogeneous combustion. However, distinct features often observed in metal particle combustion, such as brightness oscillations and jumps (spearpoints), disruptive burning, and non-symmetric flames are not currently understood. Recent metal combustion experiments using uniform high-temperature metal droplets produced by a novel micro-arc technique have indicated that oxygen dissolves in the interior of burning particles of certain metals and that the subsequent transformations of the metal-oxygen solutions into stoichiometric oxides are accompanied with sufficient heat release to cause observed brightness and temperature jumps. Similar oxygen dissolution has been observed in recent experiments on bulk iron combustion but has not been associated with such dramatic effects. This research addresses heterogeneous metal droplet combustion, specifically focusing on oxygen penetration into the burning metal droplets, and its influence on the metal combustion rate, temperature history, and disruptive burning. A unique feature of the experimental approach is the combination of the microgravity environment with a novel micro-arc Generator of Monodispersed Metal Droplets (GEMMED), ensuring repeatable formation and ignition of uniform metal droplets with controllable initial temperature and velocity. The droplet initial temperatures can be adjusted within a wide range from just above the metal melting point, which provides means to ignite droplets instantly upon entering an oxygen containing environment. Initial droplet velocity will be set equal to zero allowing one to organize metal combustion microgravity experiments in a fashion similar to usual microgravity liquid fuel droplet combustion studies. In addition, the internal compositions of rapidly quenched metal particles will be analyzed using SEM technique. Such compositions are similar to those existing during the combustion and provide new insight on metal combustion processes. The results of this experimental work will be used to model the fundamental mechanisms of metal combustion. Preliminary experimental results on Al and Zr particle combustion at normal gravity are discussed here.

Dreizin, Edward L.↗
NASA NTRS1984

A thermodynamic model for subsolidus equilibria in the system CaO-MgO-Al2O3-SiO2

It is shown that the high temperature enthalpy of solution data for pure phases and solid solutions in the CMAS system are, for 'gabbroic' and 'peridotitic' compositions, consistent with available phase equilibrium data for the MAS, CAS and CMAS systems. A refined set of values of thermodynamic properties for these phases and solid solutions is tabulated. The small differences between the new data set and that of Helgeson et al. (1978) arise from new data on heat capacity and enthalpy being incorporated. The important constraints applied and the major difficulties in fitting which arose are summarized.

Wood, B. J.↗
NASA NTRS1987

The rationale for an aeroassist flight experiment

The states of several technologies are reviewed which are critical to the design of an aeroassisted orbital transfer vehicle. In these technologies, advancements are needed which hinge on obtaining new flight data. While some of the work can be done with the wind tunnel and computational disciplines, much of the required new data are tied to finite chemical reaction rates, possible thermal nonequilibrium, high flow enthalpy, and strong viscous effects. Because these effects cannot be modeled adequately in ground-based facilities, computational methods lack adequate verification to allow committing to the design of an aeroassist vehicle. Thus a new flight experiment is being planned by NASA to gather the required data. The flight experiment and associated instrumentation which NASA is proposing is discussed briefly.

Jones, Jim J.↗