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At least 289 records · Page 16

All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Enabling Nuclear and Solar Thermal Propulsion with the Computational Laboratory: Faster and Cheaper Materials Characterization

Nuclear and solar thermal propulsion offer enhanced efficiencies for in-space travel which may open up the outer Solar System to both crewed and automated craft. However, these advanced propulsion systems require cutting-edge materials which are often not easily tested in the laboratory. Ab initio thermodynamics and other computational methods offer a way to test materials at high pressures and temperatures more quickly, and with reduced cost. Here, several case studies are presented which highlight the utility of modern simulation techniques. First, an extensive thermodynamic study was performed at the ab initio level to elucidate the role of hot hydrogen flow on the erosion of four refractory carbides to examine their appropriateness for use as channel coatings. A detailed analysis of reaction products informs estimates of erosion which are validated in comparison with heritage NERVA data. Specific material suggestions are made for both nuclear and solar designs. Secondly, we examined the mechanical behavior and chemical stability of various components of an idealized nuclear cermet core design using techniques spanning from the atomic to microscale. Next, the mechanical and chemical behavior of tungsten (a potential matrix material) and the stability of uranium mononitride (a potential ceramic fuel element), are characterized in the presence of hydrogen and at elevated temperatures with ab initio thermodynamics. Finally, the mechanical response and failure of tungsten under tensile strain is simulated at the micron scale with a combined finite element and dislocation dynamics approach. The resultant stress-strain data agrees well with experiments and leads to a workflow which can incorporate ab initio thermodynamic data into micron-scale simulations and thus provide real-world relevant estimates of erosion and stress-strain behavior. The power of this framework and our plans to use it in the future will be discussed.

William C Tucker↗

NASA NTRS1996

A Parametric Study of a Plug Nozzle, Using the Liquid Propellant Program (LPP) Code

The Liquid Propellant Program (LPP) computer code is a super-set of the industry standard Two Dimensional Kinetics (TDK) computer code. The TDK code uses a two dimensional method of characteristics solution with fully coupled finite rate kinetics for axially symmetric nozzles. The chemical reactions are modeled with a generalized reaction package that include three dimensional body efficiencies and four reaction rate forms. The code performs optional solutions for frozen or equilibrium flow. TDK evaluates discrete shocks, both attached or induced. The Transonic module models variable mixture ratio profiles from the combustion chamber injector. The Mass Addition Boundary Layer module (MABL) calculates the boundary parameters with the same chemistry options, and includes transpiration or tangential slot injection of gas at the wall. The LPP upgrades include: planar nozzle, scarfed nozzles, plug nozzles, and scramjet nozzle configurations. The code evaluates both upper and lower wall flow simulation, and includes the interaction with the external flow. The MABL module evaluates equilibrium radiation heat transfer for both upper and lower walls. In addition, LPP code models combustion effects due to injector inefficiencies with the Spray Combustion Analysis Program (SCAP) module. The LPP package provides extensive post plotting capabilities for flow visualization. The LPP is sufficiently fast and robust to provide performance predictions for extensive parametric studies and sufficiently accurate to provide flow field and performance solutions for detailed studies.

Dunn, Stuart S.↗

NASA NTRSDate not supplied

Expanding the Capability of A Legacy Combustion Flametube to Test High Temperature Engine Materials in Relevant Environments

New materials and component designs are needed to advance gas turbine engine technology and provide the performance and efficiency needs for future applications. In order to advance these materials, testing in combustion environments is a critical step prior to engine testing. In this work, we detail the design and the fabrication of a materials test sector in a flametube combustor facility. The facility simulates a combustion environment similar to that experienced by components in gas turbine engines. The flow regime is characterized by a combination of high-temperature, high-velocity, high-heat flux, and high-velocity that components experience in gas turbine engines. Exposure of components in this facility allows for the study of combined environmental effects and the impact on both coating and substrate durability. The test facility may operate across a wide range of pressures from 275-400 psig (1,896-2,758 kPa) and an air flow rate of 5 lb/s (2.27 kg/s). While combustion gas temperature is expected in excess of 3,000°F (1,649°C), 900°F (482°C) cooling air may be supplied to the backside of components or test articles. The flametube combustor was previously used to evaluate fuel injectors and combustion products, and the new test configuration will also allow for materials exposure to complex, engine-like conditions. The interior of the Test Section was additively manufactured from GRCop-84 and cryogenically fit and brazed to a stainless steel 304 housing. The use of a copper liner minimizes welds and with active cooling, is expected to provide better durability over traditional hardware using stainless steel or Inconel with a ceramic liner. The Test Section has two opposing removable windows approximately 230 mm x 80 mm that can accommodate articles up to 85 mm tall. This modular design allows for custom platforms to hold coupons, panels, or airfoil shapes to be tested with minimal re-engineering or fabrication. The bolted joint and sealing remains consistent, so any new testing only needs to work within the existing design footprint. This paper will provide an overview of the facility capabilities, design considerations, as well as thermal and structural analysis of the hardware. Future testing of ceramic matrix composite (CMC) airfoils and advanced environmental barrier coatings (EBCs) will also be discussed.

Combustion↗

NASA NTRS1991

Combined use of visible, reflected infrared, and thermal infrared images for mapping Hawaiian lava flows

The weathering of Hawaiian basalts is accompanied by chemical and physical changes of the surfaces. These changes have been mapped using remote sensing data from the visible and reflected infrared and thermal infrared wavelength regions. They are related to the physical breakdown of surface chill coats, the development and erosion of silica coatings, the oxidation of mafic minerals, and the development of vegetation cover. These effects show systematic behavior with age and can be mapped using the image data and related to relative ages of pahoehoe and aa flows. The thermal data are sensitive to silica rind development and fine structure of the scene; the reflectance data show the degree of oxidation and differentiate vegetation from aa and cinders. Together, data from the two wavelength regions show more than either separately. The combined data potentially provide a powerful tool for mapping basalt flows in arid to semiarid volcanic environments.

Abrams, Michael↗

DOE OSTI2025

Interaction between dissolution and precipitation during olivine carbonation: Implications for CO 2 mineralization

Large-scale carbonation of olivine is considered a promising approach for in situ mineral carbonation, offering a permanent and stable method for CO 2 storage. A critical aspect of this process is understanding how dissolution and precipitation interact, as this could drive fracturing and enhance further reactions. In this study, we conducted carbonation experiments on olivine using CO 2 -saturated aqueous solutions of NaHCO 3 and NaCl. Two experimental setups were used: one representing an open geochemical system and the other a closed system, corresponding to reaction-limited and flow-limited scenarios, respectively. Further, post-reaction textural analysis using scanning electron microscopy (SEM) revealed surface coatings of reaction products in the closed system, while etch pits and etch channels were prevalent in the open system. Although no direct evidence of reaction-driven fracturing was observed, etch pits and etch channels may serve as initiation points for subcritical crack formation and growth, potentially maintaining permeability and exposing new unreacted surfaces. Using linear elastic fracture mechanics (LEFM) model, we estimate that microcracks could propagate under a pressure of 0.1 GPa if reaction products accumulate within the etch pits. Our findings offer new insights into the mechanisms governing olivine carbonation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1976

Space shuttle L-tube radiator testing

A series of tests were conducted to support the development of the Orbiter Heat Rejection System. The details of the baseline radiator were defined by designing, fabricating, and testing representative hardware. The tests were performed in the Space Environmental Simulation Laboratory Chamber A. An IR source was used to simulate total solar and infrared environmental loads on the flowing shuttle radiators panel. The thermal and mechanical performance of L tube space radiators and their thermal coating were established.

Phillips, M. A.↗

NASA NTRS1980

High efficiency wraparound contact solar cells /HEWACS/

A cell technology, producing high efficiency wrap-around contact solar cells (HEWACS), with both electrical contacts on the back and AMO conversion efficiencies of almost 15%, is presented. A flow chart indicating the baseline process sequence along with the process changes is given. Tests checking for coating delamination and contact integrity, those measuring contact strength, and thermal cycle tests, successfully demonstrated that this cell technology is ready to be moved to the pilot production stage.

Gillanders, M.↗

NASA NTRS1994

Powder-Curtain Feeder For Coating Filament Tow

Continuous fiber web receives powder coat first on one side, then on other. Vibrating helical screw mechanism in powder feeder provides even flow of powder to form powder curtain that descends onto moving web. Small amount of powder that falls to side or through web recovered easily. Powder-curtain feeder part of apparatus similar to one described in "System Applies Polymer Powder to Filament Tow" (LAR-14231).

Baucom, Robert M.↗

NASA NTRS1994

Ceramic Tool For Preconsolidation Of Powder-Coated Towpreg

Tool converts partly formed towpreg into preconsolidated towpreg ribbon. In technique, towpreg coated with thermoplastic powder converted into preconsolidated ribbon without use of plasticizers or solvents. Relying on melt flow and proper application of tension, friction, and cooling, technique ensures both consistent distribution of polymer within, and consistent cross section of ribbon. Ceramic preconsolidation tool includes heated and cooled halves thermally insulated from each other.

Baucom, Robert M.↗

NASA NTRS2008

Thermal Spray Formation of Polymer Coatings

This innovation forms a sprayable polymer film using powdered precursor materials and an in-process heating method. This device directly applies a powdered polymer onto a substrate to form an adherent, mechanically-sound, and thickness-regulated film. The process can be used to lay down both fully dense and porous, e.g., foam, coatings. This system is field-deployable and includes power distribution, heater controls, polymer constituent material bins, flow controls, material transportation functions, and a thermal spray apparatus. The only thing required for operation in the field is a power source. Because this method does not require solvents, it does not release the toxic, volatile organic compounds of previous methods. Also, the sprayed polymer material is not degraded because this method does not use hot combustion gas or hot plasma gas. This keeps the polymer from becoming rough, porous, or poorly bonded.

Coquill, Scott↗

NASA NTRS1985

Separation bubble behavior for a NACA 23009 airfoil

Results are reported of experiments with smoke-wire flow visualization applied to characterizing the conditions conducive to formation of a separation bubble on an airfoil in low Re flow. An airfoil was used which spanned the test channel of the wind tunnel designed for low turbulence and noise. A wire coated with mineral oil was stretched across the channel upstream of the airfoil and heated. The smoke it gave off was flash-illuminated and photographed with ASA 3000 film. Extending the airfoil over the entire section yielded photographs that gave an essentially two-dimensional perspective. Angles of attack from 0-10 deg were investigated at Re of 33,000, 66,000, 100,000 and 133,000. Sample photographs illustrate the usefulness of the technique and apparatus in the flow regimes examined, particularly when used in conjunction with pressure tap data from the airfoil surface.

Fisher, S. S.↗

NASA NTRS1995

Emplacement of Xenolith Nodules in the Kaupulehu Lava Flow, Hualalai Volcano, Hawaii

The basaltic Kaupulehu 1800-1801 lava flow of Hualalai Volcano, Hawaii contains abundant ultramafic xenoliths. Many of these xenoliths occur as bedded layers of semi-rounded nodules, each thinly coated with a veneer (typically 1 mm thick) of lava. The nodule beds are analogous to cobble deposits of fluvial sedimentary systems. Although several mechanisms have been proposed for the formation of the nodule beds, it was found that, at more than one locality, the nodule beds are overbank levee deposits. The geological occurrence of the nodules, certain diagnostic aspects of the flow morphology and consideration of the inferred emplacement process indicate that the Kaupulehu flow had an exceptionally low viscosity on eruption and that the flow of the lava stream was extremely rapid, with flow velocities of at least 10 m/s (more than 40 km/h. This flow is the youngest on Hualalai Volcano and future eruptions of a similar type would pose considerable hazard to life as well as property.

Guest, J. E.↗

NASA NTRS1997

Mechanotransduction in bone: osteoblasts are more responsive to fluid forces than mechanical strain

Mechanical force applied to bone produces two localized mechanical signals on the cell: deformation of the extracellular matrix (substrate strain) and extracellular fluid flow. To study the effects of these stimuli on osteoblasts, MC3T3-E1 cells were grown on type I collagen-coated plastic plates and subjected to four-point bending. This technique produces uniform levels of physiological strain and fluid forces on the cells. Each of these parameters can be varied independently. Osteopontin (OPN) mRNA expression was used to assess the anabolic response of MC3T3-E1 cells. When fluid forces were low, neither strain magnitude nor strain rate was correlated with OPN expression. However, higher-magnitude fluid forces significantly increased OPN message levels independently of the strain magnitude or rate. These data indicate that fluid forces, and not mechanical stretch, influence OPN expression in osteoblasts and suggest that fluid forces induced by extracellular fluid flow within the bone matrix may play an important role in bone formation in response to mechanical loading.

Non-NASA Center↗

DOE OSTI2024

Debris-induced consequences on turbulence and vorticity in solar photovoltaic module-generated array wakes

Particle-laden flows in solar photovoltaic (PV) systems are inevitable, where wind-swept debris in open environments are carried by high winds and turbulence, coating panel surfaces or damaging structures. Particle deposition, or soiling, is a well-known issue for large-scale plants which rely on uninhibited solar rays for optimal production. But understanding the mechanisms leading to soiling requires a physical and fluid dynamics-centered focus, since turbulence dominates PV panel wakes and is also known to alter particle concentration and trajectories. This study presents an experimental campaign toward consequences of particle-laden flow between two model PV panels using time-resolved particle image velocimetry. The model array was subjected to varied particle volume fractions, including a tracer particle case and a water droplet case. Characterization of mean velocity, turbulence statistics, and mean kinetic energy within the single phase and, separately, particle phase flows showed modified features due to particle inertia. Images captured at a frequency of 1 kHz in the near wake of the upstream panel allow for a first experimental look at vorticity and convective velocity of vortex structures for single-phase and particle-phase flows which are crucial to debris transport and soiling in PV environments.

Energy & Fuels↗

NASA NTRS1981

Ceramic and coating applications in the hostile environment of a high temperature hypersonic wind tunnel

A Mach 7, blowdown wind tunnel was used to investigate aerothermal structural phenomena on large to full scale high speed vehicle components. The high energy test medium, which provided a true temperature simulation of hypersonic flow at 24 to 40 km altitude, was generated by the combustion of methane with air at high pressures. Since the wind tunnel, as well as the models, must be protected from thermally induced damage, ceramics and coatings were used extensively. Coatings were used both to protect various wind tunnel components and to improve the quality of the test stream. Planned modifications for the wind tunnel included more extensive use of ceramics in order to minimize the number of active cooling systems and thus minimize the inherent operational unreliability and cost that accompanies such systems. Use of nonintrusive data acquisition techniques, such as infrared radiometry, allowed more widespread use of ceramics for models to be tested in high energy wind tunnels.

Puster, R. L.↗

NASA NTRS2001

Thermal Processing Effects on the Adhesive Strength of PS304 High Temperature Solid Lubricant Coatings

In this paper the effects of post deposition heat treatments on the cohesive and adhesive strength properties of PS304, a plasma sprayed nickel-chrome based, high temperature solid lubricant coating deposited on stainless steel, are studied. Plasma spray deposited coating samples were exposed in air at temperatures from 432 to 650 C for up to 500 hr to promote residual stress relief, enhance particle to particle bonding and increase coating to substrate bond strength. Coating pull-off strength was measured using a commercial adhesion tester that utilizes 13 mm diameter aluminum pull studs attached to the coating surface with epoxy. Pull off force was automatically recorded and converted to coating pull off strength. As deposited coating samples were also tested as a baseline. The as-deposited (untreated) samples either delaminated at the coating-substrate interface or failed internally (cohesive failure) at about 17 MPa. Samples heat treated at temperatures above 540 C for 100 hr or at 600 C or above for more than 24 hr exhibited strengths above 31 MPa, nearly a two fold increase. Coating failure occurred inside the body of the coating (cohesive failure) for nearly all of the heat-treated samples and only occasionally at the coating substrate interface (adhesive failure). Metallographic analyses of heat-treated coatings indicate that the Nickel-Chromium binder in the PS304 appears to have segregated into two phases, a high nickel matrix phase and a high chromium precipitated phase. Analysis of the precipitates indicates the presence of silicon, a constituent of a flow enhancing additive in the commercial NiCr powder. The exact nature and structure of the precipitate phase is not known. This microstructural change is believed to be partially responsible for the coating strength increase. Diffusion bonding between particles may also be playing a role. Increasing the heat treatment temperature, exposure time or both accelerate the heat treatment process. Preliminary measurements indicate that the heat treatment also results in a one time, permanent coating thickness increase of about 3%. Based upon these results, the incorporation of a heat treatment prior to final finishing has been incorporated in the application process of this coating technology.

DellaCorte, Christopher↗

DOE OSTI2026

Towards a Unified Low-Cost Flow Plate, Flow-Field, PTL Solution for Proton Exchange Membrane Electrolyzers

Proton exchange membrane (PEM) water electrolysis is a highly efficient method for hydrogen production. Research cells typically consist of one proton exchange membrane, two catalyst layers, two porous transport layers, two flow-field plates, and two endplates. In commercial systems, the machined flow-field plates that are employed in research cells are typically replaced by stamped parts or open mesh material solutions to reduce manufacturing cost at scale. Nonetheless, the cell contains about 8 total interfaces: bipolar plate / flow plate material / porous transport medium / electrode / membrane / electrode / porous transport medium / flow plate material / bipolar plate. All these materials and interfaces need to be optimized for maximum performance and efficiency. Reducing the amount of interfaces by combining individual cell components directly benefits the fabrication cost (by reducing the parts count and the needs for surface coatings) and the electrochemical performance (by reducing ohmic losses). We have designed a novel PEM electrolysis cell with a piece of channeled titanium felt functioning as both the anode flow-field and the PTL, referred to as the channeled diffusion layer (CDL). The pores of the felt facilitate both in-plane and through-plane diffusion, ensuring maximum catalyst utilization while also minimizing mass transport loss. The titanium felt can be mass manufactured with existing stamping and forming methods and is therefore a promising candidate to reduce the capital cost of PEM electrolyzers whilst improving hydrogen production efficiency. Experiments conducted with 3mg IrOx/cm2 loading MEAs have shown a approximately 40% boost in peak current by implementing the CDL design. Low catalyst-loading MEAs are being tested in ongoing experiments and their results will be discussed and compared.

08 HYDROGEN↗

DOE OSTI2026

Scalable Fabrication of a Fibrous Amine-functionalized Matrix (FAM) Sorbent for Critical Mineral Recovery

We report a novel flat sheet Fibrous Amine-functionalized Matrix (FAM) sorbent platform designed for efficient and selective capture of CM from dilute solutions. The FAM sorbent features crosslinked amine microfilms coated onto/within a glass fiber matrix, providing fast mass transfer and excellent mechanical stability. Systematic batch and flow-through tests with FAM revealed rapid metal uptake kinetics and high capacity for representative species, achieving ~90 mg/g of Gallium, ~100 mg/g of Cobalt, and ~90 mg/g for Neodymium. Moreover, multiple eluents, including mineral acids and complexing agents, enabled highly effective desorption of adsorbed metals, demonstrating the feasibility of regenerating FAM sorbents. Importantly, tests with authentic coal ash leachate demonstrated strong selectivity toward U.S. Department of Energy (DOE)-listed CM and rare earth elements over abundant base cations, confirming the robustness of FAM in realistic complex solutions. The flat sheet geometry was amenable to scaling into durable spiral wound modules, highlighting the potential for future regeneration and reuse. This work establishes FAM sorbents as a promising platform for the recovery of CM from wastewaters, advancing both resource sustainability and environmental stewardship.

critical mineral recovery↗