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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 OSTI2024

High-Energy Laser Direct Strike Assessment for NIF CryoXNBS Snout and Naiad SNM Container

An experimental IPT performed two NIF shots as an assessment of the effect of a direct laser beam strike impact on the NIF CryoXNBS snout and Naiad container. Four aligned NIF outer cone beams at best focus, 42 kJ total, struck a four millimeter thick stainless plate. In the first shot, the struck plate was followed by a 1.75 mm gap and a 2.0 millimeter stainless plate to create a surrogate geometry for the current CryoXNBS snout and Naiad container. There was minor plastic deformation of the rear plate rear surface with no evidence of bulk failure. The second shot tested a layered glass-filled polycarbonate and titanium shield placed in the gap. Nondestructive assay was sufficient to metrologize the beam strike area and the damage induced to the NIF target assemblies.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Energy-Efficient Direct Air Capture System for High Purity CO 2 Separation

The primary objective of this project is to demonstrate the University of Cincinnati’s direct air capture (DAC) sorbent technology in a monolithic structure installed in a passive air contactor (PAC). The modified amine-based sorbent technology provides reduced heat of desorption and resistance to thermal and oxidative degradations for robust and long-term performances and cost effective sorbent management. During the project period, additional amine modifications were developed and a U.S./PCT patent application was filed.

42 ENGINEERING↗
NASA NTRS1975

Direct solar energy conversion for large scale terrestrial use

Various techniques to increase the open circuit voltage are being explored. It had been previously observed that cells made on CdS deposited from a single source gave a consistently higher V sub oc. Further tests have now shown that this effect may in fact relate to differences in source and substrate temperatures. The resulting differences in CdS structure and crystallinity are being documented. Deposits of mixed CdS and ZnS are being produced and will be initially made into cells using the conventional barriering technique. Analysis of I-V characteristics at temperatures between 25 and 110 C is being perfected to provide nondestructive analysis of the Cu2S. Changes due to vacuum heat treatments and exposure to oxygen are also being monitored by the same technique. Detailed spectral response measurements are being made.

Boeer, K. W.↗
NASA NTRS1980

Minimum Energy Test Direction Design in the Control of Cryogenic Wind Tunnels

The advent of the cryogenic wind tunnel concept is attributable to the need for high Reynolds number flow in wind tunnels. The cryogenic wind tunnel concept consists of operating the test medium of a conventional tunnel at cryogenic temperatures down to 80 K. Nitrogen gas, cooled by injected liquid nitrogen, proves to be ideal for the cryogenic tunnel test medium because of its near perfect behavior in insentropic flow. Cryogenic operation of a wind tunnel results in reduced fan power consumption and no penalty in flow dynamic pressure. In a cryogenic tunnel, the flow parameters (Reynolds number, Mach number and flow dynamic pressure) can be independently controlled by separately controlling the tunnel flow variables: total temperature, test section mass flow, and the tunnel total pressure. The problem of closed-loop control of the tunnel total temperature, flow Mach number, and total pressure is addressed and reported.

Balakrishna, S.↗
NASA NTRS1985

A new direction in energy conversion - The all-electric aircraft

This paper reviews recent studies of all-electric aircraft that use electric-only secondary power and flight critical fly-by-wire flight controls, and brings to the attention of the power system designer the intrinsic advantages of such aircraft. The all-electric aircraft is made possible by the development of rare earth magnet materials and fault tolerant systems technologies. Recent studies have shown all-electric aircraft to be more efficient than conventional designs and offer substantial operating costs reductions. Compared to present aircraft, an all-electric transport can save at least 10 percent in fuel burn. The cornerstone of an all-electric aircraft is the electric secondary power system. This paper reviews the major features of flight critical electric secondary power systems. Research required to lay the foundation for an all-electric aircraft is briefly discussed.

Spitzer, C. R.↗
NASA NTRS2017

Biosignatures in the Context of Low Energy Flux

Many of the features that are thought of as biosignatures - including the mediation of chemical and physical processes with speed, specificity, and selectivity - result directly or indirectly from life's unique capability to mediate and direct energy flux. As such, it is important to consider the impact that differences in energy flux may have on the quantity and quality of evidence for life. Earth differs from every other body in our solar system in the magnitude of biologically-usable energy flux into a liquid water environment. On a global basis, the capture of light energy into photosynthesis and the flux of chemical energy represented in the products of that photosynthesis (organic material + O2) are about six and four orders of magnitude larger, respectively, than the flux of energy represented in geochemical sources. Our conception of what an inhabited world "looks like" and our intuition about how to search for life are based in this high-energy context. Energy fluxes on worlds beyond Earth may be better approximated by the million-fold smaller flux provided to Earth's biosphere by geochemical sources. As a result, the nature, abundance, and quality of evidence for life that could be expected on an inhabited extraterrestrial world within our solar system may differ profoundly from that found on Earth. Understanding this potential difference in quantitative terms provides important context for the formulation of life detection strategies. The influence of energy flux on biosignatures can be evaluated through reference to the two basic purposes into which life partitions energy flux: (1) Life expends energy to sustain existing biomass in a metabolic steady state (metabolically functional but non-growing). The formal representation of this relationship in the traditional microbiology literature equates biomass directly with energy flux. The direct implication is that worlds having lower energy flux will have correspondingly lower potential to support biomass. Life detection strategies that directly target extant organisms should therefore be prepared to encounter average biomass densities that may be many orders of magnitude smaller than those found in most of Earth's surface environments (2) Life expends energy to synthesize new biomass. An end-member case in which new biomass is created at the energy-limited rate and the corresponding cells are immediately destroyed (so that the energy partitioned to cell maintenance is minimized) establishes an upper bound on the rate at which biological material can enter a bulk global pool. For a specified bulk concentration [i] of any particular biological compound, i, or for biologically produced matter overall, this synthesis rate, R (sub i), defines a characteristic time scale tau (sub i) equals [i] divided by R (sub i). tau (sub i) can be thought of as (a) the minimum time required for biosynthesis to yield a specific bulk concentration (e.g., a detection threshold) of i, and (b) the average residence time of i within a bulk pool when [i] is held in steady state through a balance between biosynthesis and attrition by physical, chemical, or biological consumption. tau (sub i) becomes an important quantity in considering the potential utility of enantiomeric excess (as a product of homochiral biosynthesis) as a biosignature. Spontaneous racemization of amino acids acts to "erase" the signature of homochiral synthesis over time scales that may range from hundreds to hundreds of thousands of years, depending on temperature. For environments in which low energy flux translates to low rates of biosynthesis, including the synthesis of homochiral amino acids, amino acid residence times in pools having detectable concentrations may compare to or significantly exceed the time scale for racemization. This and similar consequences of long residence times should be considered in the formulation of life detection strategies based on detection of biologically-produced species. Fluxes of biologically-useful energy on potentially habitable worlds within our solar system are, at present, not well constrained. Improving such constraint has the potential to inform priorities in the formulation and targeting of search-for-life strategies, based on the implications of energy flux for the abundance and quality of biosignatures overall, and in specific categories.

ENERGY FLUX↗
NASA NTRSDate not supplied

Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap

Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.

Additive Manufacturing↗
NASA NTRSDate not supplied

Mechanisms of Interfacial Mixing in the Blown Powder Deposition of Inconel 625 to Copper Alloy for Liquid Rocket Engine Applications

There is an increasing need for functional materials to support high heat flux applications and optimize weight by using bimetallic additive manufacturing (AM). While one promising fabrication technology is the use of blown powder directed energy deposition (DED) AM, challenges remain with bi-metallic combinations. Prominent among these challenges is the need to understand mixing of materials at the bimetallic interface for forming stronger, more durable and reliable joints to extend the versatility of AM into critical applications. One application is the manufacturing of combustion chambers with copper-alloy liners and Superalloy structural jackets. In this application, material combinations are selected for effective heat dissipation, using copper, and retention of strength at high temperatures using Inconel 625. Currently, the dominant problem with this configuration is the highly variable strength of the interface and its correlation with deposition parameters. In this study, samples were fabricated at several vendors with Inconel 625 deposited onto wrought C-18150 (Cu-Cr-Zr) to form a bimetallic interface. Characterization of the interfaces were achieved through optical and electron microscopy, mechanical testing of mini tensile specimens, and electron dispersion spectroscopy to understand diffusion and bulk mixing behaviors at the joint. A theoretical framework was constructed in the context of solidification and mixing mechanisms to explain the resulting differences in the interface. This qualitative approach utilized a fluid dynamics perspective to sum the order of magnitudes of the various acting forces on the weld pool during deposition to predict convection trends based off known parameters. The predicted trends for each vendor are compared to obtain a better understanding of how mixing in the molten pool varied based on deposition parameters.

Additive Manufacturing↗
NASA NTRS1987

The roles of direct input of energy from the solar wind and unloading of stored magnetotail energy in driving magnetospheric substorms

The contributions to the substorm expansive phase of direct energy input from the solar wind and from energy stored in the magnetotail which is released in an unpredictable manner are considered. Two physical processes for the dispensation of the energy input from the solar wind are identified: (1) a driven process in which energy supplied from the solar wind is directly dissipated in the ionosphere; and (2) a loading-unloading process in which energy from the solar wind is first stored in the magnetotail and then is suddenly released to be deposited in the ionosphere. The pattern of substorm development in response to changes in the interplanetary medium has been elucidated for a canonical isolated substorm.

Rostoker, G.↗
NASA NTRS1985

Energy spectrum and arrival direction of primary cosmic rays of energy above 10 to the 18th power eV

The observation of ultra high energy cosmic rays with 20 sq km array has started at Akeno. The preliminary results on energy spectrum and arrival direction of energies above 10 to the 18th eV are prsented with data accumulated for four years with the 1 sq km array, for two years with the 4 sq km array and for a half year with the new array. The energy spectrum is consistent with the previous experiments showing the flattening above 10 to the 18.5 eV.

Teshima, M.↗
DOE OSTI2023

Multiscale characterization of an additively manufactured property graded Ni-base alloy for molten-salts\supercritical-CO 2 heat exchangers

The sequential optimization of strength and corrosion resistance in conventional alloy design procedures often results in a tradeoff between environmental degradation and optimal mechanical properties. A concurrent optimization of these two material properties is essential to efficiently develop high temperature alloys that can withstand harsh environments increasingly required for carbon–neutral energy technologies. In this work, we demonstrate the feasibility of directed energy deposition (DED) to manufacture a dual-corrosion resistant Ni-based alloy (Hastelloy N and Haynes 282), that meets the high temperature operation requirements of a molten-salts\supercritical-CO 2 (sCO 2 ) heat exchanger. A combination of multiscale characterization techniques and computational thermodynamics was employed to evaluate the cracking susceptibilities during fabrication and predict the microstructural stability of the material. Very good agreement was achieved between the observed and predicted phases and phase fractions of the as-printed material. A careful characterization of the transition zone between the two terminal alloy chemistries revealed potential precipitation strengthening (γ') on the Hastelloy N side while columnar-shaped M 23 C 6 and γ' precipitates that formed at grain boundaries (GBs) of the transition zone likely minimized the local interfacial energies. Both these mechanisms are believed to increase the interfacial stability but their performance at high temperatures requires further investigation.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗
NASA NTRS1985

On method of muon spectrum measurements by the scintillation detectors of a large thickness T4t sub o

Various methods for the study of muon spectrum are presented. The direct ones include the muon energy measurements by magnetic spectrometers. The indirect ones deal with the reconstruction of the muon spectrum from the spectrum of secondary particles obtained by burst or calorimeter technique. The burst technique is based on the measurement of the number of cascade particles, mainly in the cascade maximum, by the detectors of small thickness T sub 0. The calorimeter method consist in determination of the cascade energy with help of the cascade curve shape. The multilayer detectors are used for this purpose. They are usually comprised of proportional counters, X-ray emulsion chambers or scintillation counters with the target material placed between them. The scintillation detectors of a large thickness measures the total cascade energy directly and the detector works as a true calorimeter. When the total energy is detected, the cascade spectrum differs from the muon one.

Ryazhskaya, O. G.↗
NASA NTRSDate not supplied

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗