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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Joining Study for Formed Plate Heat Exchangers (CRADA Final Report)

Plate heat exchangers (PHEs) have been used in numerous industrial applications, such as HVAC systems, power generation, transportation and manufacturing. The performance of plate heat exchangers is frequently undermined by corrosion, fouling, and scaling. These phenomena not only diminish heat transfer efficiency but also lead to increased operational costs, maintenance demands, and reduced equipment lifespan. In this project, the team addressed the widespread challenges of corrosion, fouling, and scaling, and explored alternative material solutions. While commonly used materials like stainless steel and titanium offer notable benefits, they can still experience corrosion under certain operating conditions. The advancement of new materials and surface engineering technologies, such as advanced coating, ceramics, composites materials, and high entropy alloys are promising for can help solve these issues, enable longer lifetime and high performance of plate heat exchangers.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS2007

Heat Transfer in High Temperature Multilayer Insulation

High temperature multilayer insulations have been investigated as an effective component of thermal-protection systems for atmospheric re-entry of reusable launch vehicles. Heat transfer in multilayer insulations consisting of thin, gold-coated, ceramic reflective foils and Saffil(TradeMark) fibrous insulation spacers was studied both numerically and experimentally. A finite volume numerical thermal model using combined conduction (gaseous and solid) and radiation in porous media was developed. A two-flux model with anisotropic scattering was used for radiation heat transfer in the fibrous insulation spacers between the reflective foils. The thermal model was validated by comparison with effective thermal conductivity measurements in an apparatus based on ASTM standard C201. Measurements were performed at environmental pressures in the range from 1x10(exp -4) to 760 torr over the temperature range from 300 to 1300 K. Four multilayer samples with nominal densities of 48 kg/cu m were tested. The first sample was 13.3 mm thick and had four evenly spaced reflective foils. The other three samples were 26.6 mm thick and utilized either one, two, or four reflective foils, located near the hot boundary with nominal foil spacing of 1.7 mm. The validated thermal model was then used to study relevant design parameters, such as reflective foil spacing and location in the stack-up and coating of one or both sides of foils.

Daryabeigi, Kamran↗
DOE OSTI2020

Engineering lithium-ion battery cathodes for high-voltage applications using electromagnetic excitation

Microwave radiation (MWR), a type of electromagnetic excitation source, reduces the synthesis temperature and processing time for chemical reactions compared to traditional synthesis methods. Recently, we demonstrated that MWR can engineer ceramics with different crystal phases compared to traditional methods [ Journal of Materials Chemistry A 5 , 35 (2017)]. Here, we further apply the MWR-assisted technique to improve the electrochemical performance of LiCoO 2 cathodes by engineering TiO 2 and ZrO 2 ceramic coatings. Electrochemical tests suggest that the TiO 2 coating improves the rate capability of the LiCoO 2 electrode. Both TiO 2 and ZrO 2 coatings improve the high-voltage (4.5 V) cycling stability of LiCoO 2 . The capacity remaining is improved from 52.8 to 84.4% and 81.9% by the TiO 2 coating and the ZrO 2 coating, respectively, after 40 cycles. We compare these results with existing studies that apply traditional methods to engineer TiO 2 /ZrO 2 on LiCoO 2 , and find that the MWR-assisted method shows better performance improvement. X-ray photoelectron spectroscopy measurements suggest that the improved cycling stability arises from the formation of metal fluorides that protect the electrode from side reactions with electrolytes. This mechanism is further supported by the reduced Co dissolution from TiO 2 /ZrO 2 -coated LiCoO 2 electrode after cycling. This study provides a new toolbox facilitating the integration of many delicate, low melting point materials like polymers into battery electrodes.

25 ENERGY STORAGE↗
DOE OSTI2025

Support of Adhesion Mechanisms in Al 2 O 3 Aerosol Deposition Through Laser-Induced Particle Impact Testing

Aerosol deposition (AD) is a kinetic spray process capable of depositing ceramic coatings at room temperature, but AD process development is generally a laborious exploration of a large process parameter space. Here, this paper presents a case study investigating whether laser-induced particle impact testing (LIPIT) could be applied to expedite development of an alumina (Al 2 O 3 ) coating on nickel (Ni): Specifically, whether LIPIT measurements could predict critical velocities of adhesion on Ni and Al 2 O 3 , and the effect of ball milling the Al 2 O 3 powder. Because LIPIT has a diffraction-limited lower bound on imageable particle size, the usefulness of Al 2 O 3 powder agglomerates as a proxy for single particles was additionally studied. Overall, LIPIT measurements and AD sprays agreed that ball milling dramatically improves adhesion. Additionally, LIPIT measurements of critical velocity of adhesion of Al 2 O 3 powder agglomerates on Ni and Al 2 O 3 substrates (150 meters per second [m/s] and 250 m/s, respectively) quantitatively agreed with predictions from a previously published model based on picoindentation and molecular dynamics simulations. Together, these findings support the established hypothesis that Al 2 O 3 adheres via a dislocation-mediated mechanism in AD, that Al 2 O 3 powder agglomerates adhere as individual constituent particles rather than collectively, and that, for this case study, LIPIT measurements were predictive of AD process parameters.

Al2O3↗
DOE OSTI2020

On electrolyte wetting through lithium-ion battery separators

The wettability by electrolyte is a critical characteristic of lithium-ion battery separators since electrolyte absorption is essential for ionic transport. Most importantly, fast absorption of electrolyte facilitates the electrolyte filling and wetting processes during the battery assembly. However, theoretical or experimental investigation of separator wettability has rarely been reported, and thus very little quantitative data can be found in the existing literature. Here, innovative experimental techniques and associated analytical models have been developed to fully characterize the electrolyte wetting behavior through battery separators. Both in-plane and through-plane imbibition processes are investigated. The results show that, electrolyte needs significantly longer time to wet separators than it does for commercial electrodes. The wetting rate depends significantly on the pore size, porosity, and micro-structure of the separators. Electrolyte in-plane wetting is only observed in the separators manufactured by the wet process. Increasing separator porosity and pore size is shown to be substantially increasing through-plane wetting rate. In addition, ceramic coating is shown to increase in-plane wetting but retard through-plane wetting.

25 ENERGY STORAGE↗
DOE OSTI2022

High Performance Circuit Pastes for Solid Oxide Fuel Cell Applications: Final Technical Report

Using a combination of in-plane electrical conductivity measurements, electrical contact resistance measurements, tensile fracture tests, double shear lap fracture tests, rapid thermal cycling adhesion tests, in situ wetting angle measurements, 3D X-ray tomography, reduction-oxidation (RedOx) cycling, scanning electron microscopy (SEM), energy dispersive x-ray spectroscopy (EDAX), Density Functional Theory (DFT) modeling, Molecular Dynamics (MD) modeling, and Phase Field modeling, this project determined that a new brazing technique developed by the PIs (specifically the use of nickel particles to direct the wetting and spreading of molten silver) could be used to produce well-adhered, >97% dense, electrically-conductive circuits, current collectors, and/or electrical contacts on a variety of ceramic and ceramic-coated substrates (specifically lanthanum strontium manganite, yttria stabilized zirconia, sapphire, Cr2O3-passivated stainless steel, and Al2O3-passivated stainless steel). Compared to other silver-based alternatives, Ag:Ni led to less manufacturing defects and was more tolerant of the extreme environments (isothermal high-temperature aging) and occasional abuse (rapid thermal cycling and RedOx cycling) encountered during Solid Oxide Fuel Cell and/or Solid Oxide Electrolysis Cell operation. Further, in some situations (such as when to produce Ag:Ni electrical contacts to Al2O3-protected stainless steel) the Ni particles also improved operation by acting as chemical getters that removed electrically-insulating, surface-segregating substrate impurities (i.e. by lowering the contact resistance with the underlying substrate).

36 MATERIALS SCIENCE↗
DOE OSTI2023

Testing of PIP-II pre-production 650 MHz couplers in warm test stand and in cryomodule

650 MHz fundamental power couplers were developed for PIP-II project to deliver RF power for low-beta and high-beta elliptical cavities. Few prototypes were built and tested and after some modification we built 8 pre-production couplers (with few spares for vacuum side) for HB650 cryomodule. All couplers were successfully tested in pulse mode (up to 100kW) and in CW mode (up to 50kW) in test stand at full reflection at 8 phases. In baseline configuration with DC bias we do not see any multipactoring activity after short processing. We also tested power processing without bias for uncoated and TiN coated ceramic window. Results of these studies presented in this paper. One of the coupler was assembled on LB650 cavity and tested at cryogenic environment in STC cryostat at ~20kW power with full reflection at different reflection phase. We also demonstrated good result from power processing without bias for warm and cold cavity. Six couplers were assembled on HB650 cavities in pre-production cryomodule. Test results from cryomodule qualification is discussing in this paper.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Joining Study for Formed Plate Heat Exchangers (Final Report)

Plate heat exchangers (PHEs) have been used in numerous industrial applications, such as HVAC systems, power generation, transportation and manufacturing. The performance of plate heat exchangers is frequently undermined by corrosion, fouling, and scaling. These phenomena not only diminish heat transfer efficiency but also lead to increased operational costs, maintenance demands, and reduced equipment lifespan. In this project, the team addressed the widespread challenges of corrosion, fouling, and scaling, and explored alternative material solutions. While commonly used materials like stainless steel and titanium offer notable benefits, they can still experience corrosion under certain operating conditions. The advancement of new materials and surface engineering technologies, such as advanced coating, ceramics, composites materials, and high entropy alloys are promising for can help solve these issues, enable longer lifetime and high performance of plate heat exchangers.

36 MATERIALS SCIENCE↗
NASA NTRS1973

Spectral and Total Normal Emittance of Reusable Surface Insulation Materials

Measurements of spectral and total normal emittance have been made on three types of reusable external insulation materials proposed for space shuttles. Emittances were measured in the spectral range 1 to 15 micrometer at temperatures of 800 K and 1100 K using a radiometric measurement technique. Results indicated that the total normal emittance of these materials was less than 0.8 between 800 K and 1300 K. The total normal emittance decreased with increasing temperature. The three ceramic coating candidate materials exhibited a similar spectral emittance distribution.

Kantsios, A. G.↗
NASA NTRS1973

A Non Rigid Reusable Surface Insulation Concept for the Space Shuttle Thermal Protection System

A reusable thermal protection system concept was developed for the space shuttle that utilizes a flexible, woven ceramic mat insulation beneath an aerodynamic skin and moisture barrier consisting of either a dense ceramic coating or a super alloy metallic foil. The resulting heat shield material has unique structural characteristics. The shear modulus of the woven mat is very low such that bending and membrane loads introduced into the underlying structural panel remain isolated from the surface skin.

Alexander, J. G.↗
NASA NTRS1976

Results and progress on the NASA Lewis H2-O2 MHD program

It was found that flame sprayed ceramic coatings on combustion chamber and nozzle walls permit operation with hot walls, thereby eliminating possible problems associated with seed condensation. However, under the conditions of experiment the net heat transfer was unexpectedly increased over that of cold copper walls. Pressure disturbances associated with oblique pressure waves were measured in a MHD channel. These disturbances are due to a rocket-type nozzle which was designed to achieve low weight rather than perfectly parallel flow at the exit. A new nozzle with parallel flow at the exit was designed. Electrical conductivity measurements agreed well with theory except at low combustion pressures and/or high ratios of seed/oxygen mass flows (seed was injected into oxygen flow line). The discrepancy is believed to be the result of poor atomization of the seed at high ratios of seed/oxygen mass flows which results in droplet sizes which do not completely vaporize the combustor.

Smith, J. M.↗
NASA NTRS1976

Results and progress on the NASA Lewis H2-O2 MHD program

A rocket test facility at the NASA Lewis Research Center has been used to develop interelectrode insulating materials, measure heat losses, and determine the fluid dynamic and electrical properties of MHD ducts and the cesium-seeded H2-O2 working fluid. Test results show that flame sprayed ceramic coatings on combustion chamber and nozzle walls permit operation with hot walls, eliminating problems associated with seed condensation; however, the net heat transfer was unexpectedly increased over that of cold copper walls. Pressure disturbances associated with oblique pressure waves were measured in a rocket nozzle designed to achieve low weight rather than perfectly parallel flow at the exit. Electrical conductivity measurements were in good agreement with theory except at low combustion pressures and/or high seed/oxygen mass flow ratios. The discrepancy is thought to result from poor atomization of the seed, producing droplets which do not completely vaporize during their residence time.

Smith, J. M.↗
NASA NTRS1978

An overview of aerospace gas turbine technology of relevance to the development of the automotive gas turbine engine

Technology areas related to gas turbine propulsion systems with potential for application to the automotive gas turbine engine are discussed. Areas included are: system steady-state and transient performance prediction techniques, compressor and turbine design and performance prediction programs and effects of geometry, combustor technology and advanced concepts, and ceramic coatings and materials technology.

Evans, D. G.↗
NASA NTRS1976

Dip-coated sheet silicon solar cells

A cost-effective method is being developed for producing solar cell quality sheet silicon by dip coating inexpensive ceramic substrates with a thin layer of large grain silicon. Mullite (Aluminum Silicate) ceramic substrates coated with a thin layer of graphite have been dipped into molten silicon to produce 20-150 micron thick layers having grain sizes as large as .4 cm x 4 cm. With these silicon layers photovoltaic diodes have been fabricated with measured and inherent conversion efficiencies of 4% and 7%, respectively.

Heaps, J. D.↗
NASA NTRS1978

An overview of aerospace gas turbine technology of relevance to the development of the automotive gas turbine engine

The NASA-Lewis Research Center (LeRC) has conducted, and has sponsored with industry and universities, extensive research into many of the technology areas related to gas turbine propulsion systems. This aerospace-related technology has been developed at both the component and systems level, and may have significant potential for application to the automotive gas turbine engine. This paper summarizes this technology and lists the associated references. The technology areas are system steady-state and transient performance prediction techniques, compressor and turbine design and performance prediction programs and effects of geometry, combustor technology and advanced concepts, and ceramic coatings and materials technology.

Evans, D. G.↗
NASA NTRS1980

Longer shelf life for ceramic slurries

Viscosity of ceramic-coating slurries containing organic acrylate viscosity-control agent is stabilized for over 2 months by addition of ammonium hydroxide without significant changes.

Izu, Y. D.↗