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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Up close - Materials division of NASA-Lewis Research Center

The eight branches of the Materials Division of NASA-Lewis Research Center are described. The design and capabilities of the Microgravity Materials Science Laboratory are discussed. Consideration is given to the objectives of the ceramic branch, the advanced metallic branch, the metal science branch, and the polymer branch. Also discussed are the research and development efforts of the surface science branch, the environmental durability branch, and the analytic science branch.

Abel, Phillip↗
NASA NTRS1986

Fractographic and microstructural evaluation of 3500-hour durability specimens

Long term durability testing of candidate ceramic materials for advanced gas turbine applications was performed. Specimens of the materials were exposed to combustion atmospheres under temperature cyclic conditions for times up to 3500 hours and at peak temperatures of 1200 and 1370 C. The specimen strengths after exposure were measured at room temperature and at 1200 C. In addition, a number of physical measurements were taken; however, no microstructural examination of the specimens was performed. Materials examined include: sintered alpha silicon carbide, sintered silicon nitride, and reaction bonded silicon nitride. Sample preparation techniques were developed to provide high quality thin-section specimens which can be examined by transmitted light or thinned using an ion mill for subsequent transmission electron microscopic examination. Specimen preparation techniques and the results of optical and electron microscopic examination of the reaction interfaces of the selected specimens are presented.

Miller, A. D.↗
NASA NTRS1992

LeRC in-house experimental research

The topics covered include the following: LeRC in-house experimental research; combustion concepts; schedule for in-house experiments; lean premixed prevaporized combustion; comparisons of low NO(x) lean premixed/prevaporized data; rich burn/quick quench/lean burn (RQL); RQL combustion; fuel rich catalytic combustion; advanced diagnostics; and ceramic matrix liner test rig.

Lyons, Valerie J.↗
NASA NTRS1995

Microgravity Combustion Science: 1995 Program Update

Microgravity greatly benefits the study of fundamental combustion processes. In this environment, buoyancy-induced flow is nearly eliminated, weak or normally obscured forces and flows can be isolated, gravitational settling or sedimentation is nearly eliminated, and temporal and spatial scales can be expanded. This document reviews the state of knowledge in microgravity combustion science with the emphasis on NASA-sponsored developments in the current period of 1992 to early 1995. The subjects cover basic research in gaseous premixed and diffusion-flame systems, flame structure and sooting, liquid droplets and pools, and solid-surface ignition and flame spread. They also cover applied research in combustion synthesis of ceramic-metal composites, advanced diagnostic instrumentation, and on-orbit fire safety. The review promotes continuing research by describing the opportunities for Principal Investigator participation through the NASA Research Announcement program and the available NASA Lewis Research Center ground-based facilities and spaceflight accommodations. This review is compiled by the members and associates of the NASA Lewis Microgravity Combustion Branch, and it serves as an update of two previous overview reports.

Ross, Howard D.↗
NASA NTRS1996

Pyrolytic Carbon As A Lubricant In Hot Ceramic Bearings

Pyrolytic carbon proves useful as solid lubricant in ceramic bearings in advanced gas-turbine engines, where high temperatures destroy liquid lubricants. Ethylene gas made to flow past bearings and pyrolized to replenish carbon lubricant particles.

Lauer, J. L.↗
NASA NTRS1997

Fully Implicit Ablation and Thermal Response Program for Spacecraft Heatshield Analysis

A fully implicit ablation and thermal response program has been developed for the simulation of one-dimensional transient transport of thermal energy in a multilayer stack of isotropic materials and structure which can ablate from a front surface and decompose in-depth. Equations and numerical procedures for solution are described. Solutions are compared with those of Aerotherm Charring Material Thermal Response and Ablation Program, and with the arcjet data. The code is numerically more stable, and solves much wider range of problems compared with the existing explicit code. Applications of the code for the analysis of aeroshell heatshields of Stardust, Mars 2001, and Mars Microprobe using the advanced Light Weight Ceramic Ablators developed at the NASA Ames Research Center are presented and discussed in detail.

Chen, Y. K.↗
NASA NTRS2002

Micromechanics Based Design/Analysis Codes for Advanced Composites

Advanced high temperature Ceramic Matrix Composites (CMC) hold an enormous potential for use in aero and space related applications specifically for propulsion system components. Consequently, this has led to a multitude of research activities pertaining to fabrication, testing and modeling of these materials. The efforts directed at the development of ceramic matrix composites have focused primarily on improving the properties of the constituents as individual phases. It has, however, become increasingly clear that for CMC to be successfully employed in high temperature applications, research and development efforts should also focus on optimizing the synergistic performance of the constituent phases within the as-produced microstructure of the complex shaped CMC part. Despite their attractive features, the introduction of these materials in a wide spectrum of applications has been excruciatingly slow. The reasons are the high costs associated with the manufacturing and a complete experimental testing and characterization of these materials. Often designers/analysts do not have a consistent set of necessary properties and design allowables to be able to confidently design and analyze structural components made from these composites. Furthermore, the anisotropy of these materials accentuates the burden both on the test engineers and the designers by requiring a vastly increased amount of data/characterization compared to conventional materials.

Mital, Subodh K.↗
NASA NTRS1999

Parametric Weight Comparison of Current and Proposed Thermal Protection System (TPS) Concepts

A parametric weight assessment of advanced metallic panel, ceramic blanket, and ceramic tile thermal protection systems (TPS) was conducted using an implicit, one-dimensional (1 -D) thermal finite element sizing code. This sizing code contained models to ac- count for coatings, fasteners, adhesives, and strain isolation pads. Atmospheric entry heating profiles for two vehicles, the Access to Space (ATS) rocket-powered single-stage-to-orbit (SSTO) vehicle and a proposed Reusable Launch Vehicle (RLV), were used to ensure that the trends were not unique to a particular trajectory. Eight TPS concepts were compared for a range of applied heat loads and substructural heat capacities to identify general trends. This study found the blanket TPS concepts have the lightest weights over the majority of their applicable ranges, and current technology ceramic tiles and metallic TPS concepts have similar weights. A proposed, state-of-the-art metallic system which uses a higher temperature alloy and efficient multilayer insulation was predicted to be significantly lighter than the ceramic tile systems and approaches blanket TPS weights for higher integrated heat loads.

Myers, David E.↗
NASA NTRS2004

The Office of the Materials Division

I was assigned to the Materials Division, which consists of the following branches; the Advanced Metallics Branch/5120-RMM, Ceramics Branch/5130-RMC, Polymers Branch/5150-RMP, and the Durability and Protective Coatings Branch/5160-RMD. Mrs. Pamela Spinosi is my assigned mentor. She was assisted by Ms.Raysa Rodriguez/5100-RM and Mrs.Denise Prestien/5100-RM, who are both employed by InDyne, Inc. My primary assignment this past summer was working directly with Ms. Rodriguez, assisting her with setting up the Integrated Financial Management Program (IFMP) 5130-RMC/Branch procedures and logs. These duties consisted of creating various spreadsheets for each individual branch member, which were updated daily. It was not hard to familiarize myself with these duties since this is my second summer working with Ms Rodriguez at NASA Glenn Research Center. RMC ordering laboratory, supplies and equipment for the Basic Materials Laboratory (Building 106) using the IF'MP/Purchase Card (P-card), a NASA-wide software program. I entered into the IFMP/Travel and Requisitions System, new Travel Authorizations for the 5130-RMC Civil Servant Branch Members. I also entered and completed Travel Vouchers for the 5130-RMC Ceramics Branch. I assisted in the Division Office creating new Emergency Contact list for the Materials Division. I worked with Dr. Hugh Gray, the Division Chief, and Dr. Ajay Misra, the 5130-RMC Branch Chief, on priority action items, with a close deadline, for a large NASA Proposal. Another project was working closely with Ms. Rodriguez in organizing and preparing for Dr. Ajay K. Misra's SESCDP (two year detail). This consisted of organizing files, file folders, personal information, and recording all data material onto CD's and printing all presentations for display in binders. I attended numerous Branch meetings, and observed many changes in the Branch Management organization.

Ramsey, amanda J.↗
NASA NTRS2002

Deformation, Failure, and Fatigue Life of SiC/Ti-15-3 Laminates Accurately Predicted by MAC/GMC

NASA Glenn Research Center's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) (ref.1) has been extended to enable fully coupled macro-micro deformation, failure, and fatigue life predictions for advanced metal matrix, ceramic matrix, and polymer matrix composites. Because of the multiaxial nature of the code's underlying micromechanics model, GMC--which allows the incorporation of complex local inelastic constitutive models--MAC/GMC finds its most important application in metal matrix composites, like the SiC/Ti-15-3 composite examined here. Furthermore, since GMC predicts the microscale fields within each constituent of the composite material, submodels for local effects such as fiber breakage, interfacial debonding, and matrix fatigue damage can and have been built into MAC/GMC. The present application of MAC/GMC highlights the combination of these features, which has enabled the accurate modeling of the deformation, failure, and life of titanium matrix composites.

Bednarcyk, Brett A.↗
NASA NTRS2006

Solid Oxide Fuel Cell APU Feasibility Study for a Long Range Commercial Aircraft Using UTC ITAPS Approach: Aircraft Propulsion and Subsystems Integration Evaluation - Volume 1

The objective of this contract effort was to define the functionality and evaluate the propulsion and power system benefits derived from a Solid Oxide Fuel Cell (SOFC) based Auxiliary Power Unit (APU) for a future long range commercial aircraft, and to define the technology gaps to enable such a system. The study employed technologies commensurate with Entry into Service (EIS) in 2015. United Technologies Corporation (UTC) Integrated Total Aircraft Power System (ITAPS) methodologies were used to evaluate system concepts to a conceptual level of fidelity. The technology benefits were captured as reductions of the mission fuel burn and emissions. The baseline aircraft considered was the Boeing 777-200ER airframe with more electric subsystems, Ultra Efficient Engine Technology (UEET) engines, and an advanced APU with ceramics for increased efficiency. In addition to the baseline architecture, four architectures using an SOFC system to replace the conventional APU were investigated. The mission fuel burn savings for Architecture-A, which has minimal system integration, is 0.16 percent. Architecture-B and Architecture-C employ greater system integration and obtain fuel burn benefits of 0.44 and 0.70 percent, respectively. Architecture-D represents the highest level of integration and obtains a benefit of 0.77 percent.

Srinivasan, Hari↗
NASA NTRS2013

Motorized Beam Alignment of a Commercial X-ray Diffractometer

X-ray diffraction (XRD) is a powerful analysis method that allows researchers to noninvasively probe the crystalline structure of a material. This includes the ability to determine the crystalline phases present, quantify surface residual stresses, and measure the distribution of crystallographic orientations. The Structures and Materials Division at the NASA Glenn Research Center (GRC) heavily uses the on-site XRD lab to characterize advanced metal alloys, ceramics, and polymers. One of the x-ray diffractometers in the XRD lab (Bruker D8 Discover) uses three different x-ray tubes (Cu, Cr, and Mn) for optimal performance over numerous material types and various experimental techniques. This requires that the tubes be switched out and aligned between experiments. This alignment maximizes the x-ray tube s output through an iterative process involving four set screws. However, the output of the x-ray tube cannot be monitored during the adjustment process due to standard radiation safety engineering controls that prevent exposure to the x-ray beam when the diffractometer doors are open. Therefore, the adjustment process is a very tedious series of blind adjustments, each followed by measurement of the output beam using a PIN diode after the enclosure doors are shut. This process can take up to 4 hr to perform. This technical memorandum documents an in-house project to motorize this alignment process. Unlike a human, motors are not harmed by x-ray radiation of the energy range used in this instrument. Therefore, using motors to adjust the set screws will allow the researcher to monitor the x-ray tube s output while making interactive adjustments from outside the diffractometer. The motorized alignment system consists of four motors, a motor controller, and a hand-held user interface module. Our goal was to reduce the alignment time to less than 30 min. The time available was the 10-week span of the Lewis' Educational and Research Collaborative Internship Project (LERCIP) summer internship program and the budget goal was $1200. In this report, we will describe our motorization design and discuss the results of its implementation.

Van Zandt, Noah R.↗
NASA NTRS1993

High-Temperature, Flexible, Pressure-Assisted Brush Seal

Ceramic-fibers brush and integral spring clip block hot, engine flows. High-temperature, pressure-assisted brush seal installed in movable panel in advanced hypersonic engine. Seal prevents flow of hot engine gas from penetrating gap between movable panel and adjacent stationary panel. Potential applications include sealing gaps in variable-geometry two-dimensional turbojet exhaust nozzles or sealing control surface gaps of hypersonic vehicles. Ceramic brush seals also used as structural seals in high-temperature furnaces or advanced ceramic heat exchangers.

Steinetz, Bruce M.↗
NASA NTRS1995

An Investigation of Theories of Failure for Ceramic Matrix Composites

In order to further advance the understanding of the mechanical behavior of ceramic matrix composites (CMCs), acoustic emission (AE) techniques were imple mented to monitor and identify damage mechanisms in CMCs under tensile loading. In addition to real-time AE monitoring techniques, a data acquisition system was developed and implemented in order to capture AE waveforms resulting from stress-induced damage. Waveforms were inspected for multiple events, separated in distinct events, and then analyzed to determine waveform characteristics in the time and frequency domains. Waveform characteristics included peak amplitude, event duration, MARSE, energy, and dominant and centroidal frequency. In addition to conventional methods for determining a damage discrimination criteria, a study of the distribution and correlation the waveform characteristics was performed to aid in the determination of a damage discrimination criteria. The damage discrimination criteria was tested for "uniqueness", i.e., the effectiveness of the criteria to identify and monitor damage independent of the stress-strain relationship. Insitu radiography was used to substantiate the damage accumulation.

Hemann, John H.↗
DOE OSTI2024

UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers

The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Advanced Fuel Cycle Cost Basis Report: Module D1-4 and Module D1-5 Ceramic Pelletized Sodium-Cooled Fast Reactor (SFR) Fuel Fabrication Ceramic Vibrocompacted Fuel Fabrication

This is a cost module that is part of the Advanced Fuel Cycle -- Cost Basis Report. Module D1-4: Nature of this module update (Rev 1) from previous advanced fuel cycle cost basis reports (AFCCBRs): new life cycle cost data on U,Pu SFR mixed oxide (MOX) fuels is derived from the Nonproliferation Assessment Systems Analysis Program (NASAP) conducted in the late 1970s. Highassay low-enriched uranium (HALEU) ceramic fuel is also discussed in more detail compared to earlier AFC-CBRs, since some advanced SFR concepts currently under development will require this HALEU fuel type for startup. Module D1-5: Nature of this FY-21 module update from previous AFC-CBRs: this module includes a few new references and a somewhat expanded discussion of vibrocompaction fuel fabrication technology. The WIT values for VIPAC are pegged directly to those for conventional LWR and SFR pelletized U,Pu MOX (note that this module now includes VIPAC MOX fuel for LWRs in addition to SFRs). Based on information from Russia, where VIPAC has been studied extensively, the unit costs are expressed as a percentage of those in the new updated Module D1-2 (pelletized U,Pu MOX) and new updated Module D1-4 (pelletized U,Pu MOX) for large NOAK fabrication facilities of the same production capacity. Since both ceramic pelletized MOX Modules D1-2 and D1-4 benefitted from analysis of 1970s NASAP data, by extension this Module D1-5 also benefits.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Compression Response of Silicone-Based Composites with Integrated Multifunctional Fillers

Polydimethylsiloxane (PDMS) is known for its exceptional mechanical properties, chemical stability, and flexibility. Recent advancements have focused on developing functional PDMS composites by integrating various functional fillers, including polymers, ceramics, and metals, for advanced applications such as electronics, medical devices, and aerospace. Consequently, there is a growing need to investigate PDMS composites to achieve higher filler loadings offering enhanced mechanical performance. This study addresses this need by utilizing the high molecular weight (MW) PDMS resin we have developed, offering its high elongation capacity of up to >6500%. We incorporated boron (B), hollow glass microballoons (HGMs), and tungsten-coated hollow glass microballoons (WHGMs) into the developed high MW PDMS. The resulting composites demonstrated excellent elastic properties and significant compression resilience (35–80%) and elastic modulus (1.28–10.15 MPa) at high filler loadings (~60 vol.%). Specifically, B/PDMS composites achieved up to 67.6 vol.% of B, HGM/PDMS composites held up to 68.6 vol.% of HGM, and WHGM/PDMS composites incorporated up to 54.0 vol.% of WHGM. These findings highlight the potential of high MW PDMS for developing high-performance PDMS composites suitable for advanced applications such as aerospace, automotive, and medical devices.

36 MATERIALS SCIENCE↗