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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
NASA NTRS1995

Combustion of solid fuel slabs with gaseous oxygen in a hybrid motor analog

Using a high-pressure, two-dimensional hybrid motor, an experimental investigation was conducted on fundamental processes involved in hybrid rocket combustion. HTPB (Hydroxyl-terminated- Polybutadiene) fuel cross linked with diisocyanate was burned with GOX under various operating conditions. Large amplitude pressure oscillations were encountered in earlier test runs. After identifying the source of instability and decoupling the GOX feed line system and combustion chamber, the pressure oscillations were drastically reduced from +/- 20% of the localized mean pressure to an acceptable range of +/- 1.5%. Embedded fine-wire thermocouples indicated that the surface temperature of the burning fuel was around 1000 K depending upon axial locations and operating conditions. Also, except near the leading-edge region, the subsurface thermal wave profiles in the upstream locations arc thicker than those in the downstream locations since the solid-fuel regression rate, in general, increases with distance along the fuel slab. The recovered solid fuel slabs in the laminar portion of the boundary layer exhibited smooth surfaces, indicating the existence of a liquid melt layer on the burning fuel surface in the upstream region. After the transition section, which displayed distinct transverse striations, the surface roughness pattern became quite random and very pronounced in the downstream turbulent boundary-layer region. Both real time X-ray radiography and ultrasonic pulse-echo techniques were used to determine the instantaneous web thicknesses and instantaneous solid-fuel regression rates over certain portions of the fuel slabs. Globally averaged and axially dependent but time-averaged regression rates were also obtained and presented. Several tests were conducted using, simultaneously, one translucent fuel slab and one fuel slab processed with carbon black powder. The addition of carbon black did not affect the measured regression rates or surface temperatures in comparison to the translucent fuel slabs.

Chiaverini, Martin J.↗
NASA NTRS1993

Method for defect free keyhole plasma arc welding

A plasma arc welding process for welding metal of increased thickness with one pass includes operating the plasma arc welding apparatus at a selected plasma gas flow rate, travel speed and arc current, to form a weld having a penetration ratio to weld height to weld width, and maintaining the penetration ratio at less than 0.74. Parameters for the plasma gas flow rate, travel speed and arc current are adjusted to a steady state condition during a start up period and maintained during the steady state condition to complete a weld. During a terminal stopping period, the travel speed is stopped and instantaneously replaced by filler wire which adds material to fill the keyhole that had been formed by the welding process. Parameters are subsequently adjusted during the stopping period to terminate the weld in a sound manner.

Harwig, Dennis D.↗
NASA NTRS1976

An experimental and computational investigation of the flow field about a transonic airfoil in supercritical flow with turbulent boundary-layer separation

A combined experimental and computational research program is described for testing and guiding turbulence modeling within regions of separation induced by shock waves incident in turbulent boundary layers. Specifically, studies are made of the separated flow the rear portion of an 18%-thick circular-arc airfoil at zero angle of attack in high Reynolds number supercritical flow. The measurements include distributions of surface static pressure and local skin friction. The instruments employed include highfrequency response pressure cells and a large array of surface hot-wire skin-friction gages. Computations at the experimental flow conditions are made using time-dependent solutions of ensemble-averaged Navier-Stokes equations, plus additional equations for the turbulence modeling.

Rubesin, M. W.↗
NASA NTRS1976

An experimental and computational investigation of the flow field about a transonic airfoil in supercritical flow with turbulent boundary-layer separation

A combined experimental and computational research program for testing and guiding turbulence modeling within regions of separation induced by shock waves incident on turbulent boundary layers is described. Specifically, studies are made of the separated flow over the rear portion of an 18%-thick circular-arc airfoil at zero angle of attack in high Reynolds number supercritical flow. The measurements include distributions of surface static pressure and local skin friction. The instruments employed include high-frequency response pressure cells and a large array of surface hot-wire skin-friction gages. Computations at the experimental flow conditions are made using time-dependent solutions of ensemble-averaged Navier-Stokes equations, plus additional equations for the turbulence modeling.

Rubesin, M. W.↗
NASA NTRS1995

Evaluation of high temperature polymers

The purpose of this paper is to identify and develop arc-track resistant insulation materials that can operate reliably at 300 C. In the first phase, high performance polymers are evaluated based on structure, thermal stability and electrical properties. Next, the polymers are ranked according to performance and experimental characterization. Then, experimental evaluations in wire configuration are conducted. And selection is made based on performance and commerical potential.

Jayaraj, K.↗
NASA NTRS2018

Fabrication of a Hybrid Transition Edge Sensor Array for Lynx

Lynx is a proposed NASA X-Ray telescope flight mission aimed at achieving state-of-the-art angular and energy resolution with a 100 kilopixel array to probe the hot energetic young universe in unprecedented detail. To achieve these goals, our team plans on leveraging our current work in development of the focal plane for the Athena X-Ray Integral Field Unit (X-IFU) while advancing the state-of-the-art in transition edge sensor (TES) X-ray detector technology. The TES is an optimal technology for achieving both high energy and fine angular resolution at the same time because pixel features can be made extremely small and the absorber which dominates the heat capacity can be tuned to meet resolution requirements. Specifically, the proposed mission concept calls for a hybrid detector of three different arrays fabricated in the same planar process in one focal plane and optimized for different science goals. The main arrays consist of 5x5 hydras, 25 pixels of 4 micron thick Au absorbers each with a different thermal link to one common TES. The outer array has absorbers on a 50-micron pitch for most of the 5 arc-minute field-of-view, and the inner array has 25-micron absorbers for the central 1 arc-minute region. A high resolution array consisting of single pixel 1 micron thick Au absorbers on 50-micron pitch will lie off to the side. Reading out an array of this magnitude will likely require improvements in indium bump bonding to superconducting flexible wiring. Fabrication of absorbers of two different sizes requires electroplating through a photoresist mold by careful tuning of the current density to achieve uniform flat absorbers on a fine pitch scale, followed by ion milling to yield narrow streets separating the pixels while preserving high quantum efficiency. We report on progress made at fabricating the hybrid array with different absorber sizes and thicknesses. Further, we also report on ongoing work to adequately heat sink the pixels with backside wire bonding and copper coating. We also report on work to improve detector pixel yield and top side indium bump bonding to flexible wiring.

Focal plane array↗
NASA NTRS1990

A knowledge-based system design/information tool

The objective of this effort was to develop a Knowledge Capture System (KCS) for the Integrated Test Facility (ITF) at the Dryden Flight Research Facility (DFRF). The DFRF is a NASA Ames Research Center (ARC) facility. This system was used to capture the design and implementation information for NASA's high angle-of-attack research vehicle (HARV), a modified F/A-18A. In particular, the KCS was used to capture specific characteristics of the design of the HARV fly-by-wire (FBW) flight control system (FCS). The KCS utilizes artificial intelligence (AI) knowledge-based system (KBS) technology. The KCS enables the user to capture the following characteristics of automated systems: the system design; the hardware (H/W) design and implementation; the software (S/W) design and implementation; and the utilities (electrical and hydraulic) design and implementation. A generic version of the KCS was developed which can be used to capture the design information for any automated system. The deliverable items for this project consist of the prototype generic KCS and an application, which captures selected design characteristics of the HARV FCS.

Allen, James G.↗
NASA NTRS1985

The PIX-2 experiment: An overview

The second Plasma Interactions Experiment (PIX-2) was launched in January 1983 as a piggyback on the second stage of the Delta launch vehicle that carried IRAS into orbit. Placed in a 870 km circular polar orbit, it returned 18 hrs of data on the plasma current collection and arcing behavior of solar arrays biased to +/-1000 V in steps. The four 500 sq cm solar array segments were biased singly and in combinations. In addition to the array segments PIX-2 carried a Sun sensor, a Langmuir probe to measure electron currents, and a hot-wire filament electron emitter to control vehicle potential during positive array bias sequences. The PIX-2 experiment is reviewed from program and operational perspectives.

Purvis, C. K.↗
NASA NTRS1991

A generalized method for multiple robotic manipulator programming applied to vertical-up welding

The application is described of a weld programming algorithm for vertical-up welding, which is frequently desired for variable polarity plasma arc welding (VPPAW). The Basic algorithm performs three tasks simultaneously: control of the robotic mechanism so that proper torch motion is achieved while minimizing the sum-of-squares of joint displacement; control of the torch while the part is maintained in a desirable orientation; and control of the wire feed mechanism location with respect to the moving welding torch. Also presented is a modification of this algorithm which permits it to be used for vertical-up welding. The details of this modification are discussed and simulation examples are provided for illustration and verification.

Fernandez, Kenneth R.↗
NASA NTRS1993

Automated Welding System

Fully automated variable-polarity plasma arc VPPA welding system developed at Marshall Space Flight Center. System eliminates defects caused by human error. Integrates many sensors with mathematical model of the weld and computer-controlled welding equipment. Sensors provide real-time information on geometry of weld bead, location of weld joint, and wire-feed entry. Mathematical model relates geometry of weld to critical parameters of welding process.

Bayless, E. O.↗
NASA NTRS2001

A Controlled Arc Welding and Separation Processes for Carbon Nanotubes

Stage 1 for the Carbon Nanotube Project has been completed. This videograph presents the proposal for Stage 2. The goals of this stage are to: (1) produce CNTs under different conditions such as cooling temperature, voltage, current, cathode and anode sizes; (2) use ferrocene to make longer CNTs; (3) characterize CNTs by spectroscopic methods; (4) develop applications of CNTs, i.e., batteries, composites, wires, etc.; and (5) complete the patent application.

Benavides, Jeannette↗
DOE OSTI2022

Interim Report on FY22 ORNL A709 Welding Research and Testing of Production Welds in Support of Developing ASME A709 Code Case Data Package

As part of the Alloy 709 ASME Code Case development effort under the Advanced Reactor Technologies (ART) Program, this work covers the development of the technical basis for weld fabrication and weld qualification of Alloy 709. This report summarizes the Alloy 709 welding research conducted at Oak Ridge National Laboratory (ORNL) in FY 2022. Two new production welds were fabricated on two commercial heats of Alloy 709 of different phosphorus (P) levels using Alloy 709 filler metal with P content less than 20 wppm with gas tungsten arc welding (GTAW). Both production welds successfully passed ASME Section IX weld qualification tests, and this concludes the Alloy 709 welding procedure development to scale up to 2-in thick plates. In FY 2022, we also demonstrated the success in welding of high P commercial Alloy 709 plates with weld wires having higher P content at 30 wppm. A test weld fabricated with the 30 wppm weld wire on the first commercial heat (140 wppm P) passed all weld qualification tests without issues. Additionally, experiment setup and testing procedure of the circular patch weldability test has been developed, for evaluating the P effect in weld wire on solidification cracking susceptibility of Alloy 709 weld, with the preliminary results summarized in this report. Research on further relaxing the P level restriction beyond 30 wppm are planned in FY 2023. The preliminary cross-weld creep tests results continue to show little or no creep strength reduction relative to the base metal.

36 MATERIALS SCIENCE↗
NASA NTRS1983

Cathode degradation and erosion in high pressure arc discharges

The various processes which control cathode erosion and degradation were identified and evaluated. A direct current arc discharge was established between electrodes in a pressure-controlled gas flow environment. The cathode holder was designed for easy testing of various cathode materials. The anode was a water cooled copper collector electrode. The arc was powered by a dc power supply with current and voltage regulated cross-over control. Nitrogen and argon were used as propellants and the materials used were two percent thoriated tungsten, barium oxide impregnated porous tungsten, pure tungsten and lanthanum hexaboride. The configurations used were cylindrical solid rods, wire bundles supported by hollow molybdenum tubes, cylindrical hollow tubes, and hollow cathodes of the type used in ion thrusters. The results of the mass loss tests in nitrogen indicated that pure tungsten eroded at a rate more than 10 times faster than the rates of the impregnated tungsten materials. It was found that oxygen impurities of less than 0.5 percent in the nitrogen increased the mass loss rate by a factor of 4 over high purity nitrogen. At power levels less than 1 kW, cathode size and current level did not significantly affect the mass loss rate. The hollow cathode was found to be operable in argon and in nitrogen only at pressures below 400 and 200 torr, respectively.

Hardy, T. L.↗
NASA NTRS1984

Cathode degradation and erosion in high pressure arc discharges

The various processes which control cathode erosion and degradation were identified and evaluated. A direct current arc discharge was established between electrodes in a pressure-controlled gas flow environment. The cathode holder was designed for easy testing of various cathode materials. The anode was a water cooled copper collector electrode. The arc was powered by a dc power supply with current and voltage regulated cross-over control. Nitrogen and argon were used as propellants and the materials used were two percent thoriated tungsten, barium oxide impregnated porous tungsten, pure tungsten and lanthanum hexaboride. The configurations used were cylindrical solid rods, wire bundles supported by hollow molybdenum tubes, cylindrical hollow tubes, and hollow cathodes of the type used in ion thrusters. The results of the mass loss tests in nitrogen indicated that pure tungsten eroded at a rate more than 10 times faster than the rates of the impregnated tungsten materials. It was found that oxygen impurities of less than 0.5 percent in the nitrogen increased the mass loss rate by a factor of 4 over high purity nitrogen. At power levels less than 1 kW, cathode size and current level did not significantly affect the mass loss rate. The hollow cathode was found to be operable in argon and in nitrogen only at pressures below 400 and 200 torr, respectively.

Hardy, T. L.↗
NASA NTRS2016

Deep Charging Evaluation of Satellite Power and Communication System Components

A set of deep charging tests has been carried out by NASA's Marshall Space Flight Center on subscale flight-like samples developed by Space Systems/Loral, LLC. The samples, which included solar array wire coupons, a photovoltaic cell coupon, and a coaxial microwave transmission cable, were placed in passive and active (powered) circuit configurations and exposed to electron radiation. The energy of the electron radiation was chosen to deeply penetrate insulating (dielectric) materials on each sample. Each circuit configuration was monitored to determine if potentially damaging electrostatic discharge events (arcs) were developed on the coupon as a result of deep charging. The motivation for the test, along with charging levels, experimental setup, sample details, and results will be discussed.

Schneider, T. A.↗
DOE OSTI2020

Solar panel field array support system and apparatus and method for construction use

A combined PV panel assembly jig and forklift transport pallet is used to assemble PV panels for transport to a field array from a protected manufacturing environment. The panels are assembled to have adhesively applied rails for transport by a robotic drone on a ground-support rack and are pre-wired. The PV panel assembly jig holds, protects, and aligns the PV panels in an upside down position, opposite to their operational position, for ease of wiring in order to decrease the manual labor required in the field. Once the pallet is transported to the load station at the end of a row of solar panel racks in the field array, a robotic loader lifts the upside down PV panels from the combined PV panel assembly jig and forklift transport pallet in an arcing overhead motion that lifts, tilts, and deposits the PV panels in an upright position at the loading station of a railed rack support as ground-mounted in a solar panel field array.

14 SOLAR ENERGY↗
NASA NTRS1978

Arc termination cracks in Inconel 718 and Incoloy 903

The welding of the nickel base, heat resistant alloys that are used extensively for welded Shuttle engine components revealed solidification cracking characteristics at weld termination points. If not detected and removed, these crater cracks may cause costly component failure. To better understand this characteristic, welding termination techniques were studied and methods developed to eliminate crater cracks. It was determined that weld termination solidification cracking can be eliminated by controlled decrease of welding current, welding voltage, wire feed, and travel speed.

Bayless, E.↗
NASA NTRS1984

Variable polarity plasma arc welding on the Space Shuttle external tank

Variable polarity plasma arc (VPPA) techniques used at NASA's Marshall Space Flight Center for the fabrication of the Space Shuttle External Tank are presentedd. The high plasma arc jet velocities of 300-2000 m/s are produced by heating the plasma gas as it passes through a constraining orifice, with the plasma arc torch becoming a miniature jet engine. As compared to the GTA jet, the VPPA has the following advantages: (1) less sensitive to contamination, (2) a more symmetrical fusion zone, and (3) greater joint penetration. The VPPA welding system is computerized, operating with a microprocessor, to set welding variables in accordance with set points inputs, including the manipulator and wire feeder, as well as torch control and power supply. Some other VPPA welding technique advantages are: reduction in weld repair costs by elimination of porosity; reduction of joint preparation costs through elimination of the need to scrape or file faying surfaces; reduction in depeaking costs; eventual reduction of the 100 percent-X-ray inspection requirements. The paper includes a series of schematic and block diagrams.

Nunes, A. C., Jr.↗