Search NASA⌕ Search

SEARCH · Search NASA

Results for “Material processing flows”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Validation of a Polyimide Foam Model for Use in Transmission Loss Applications

The work described in this paper was focused on the use of a new polyimide foam in a double wall sound transmission loss application. Recall that polyimide foams are functionally attractive, compared to polyurethane foams, for example, owing to their fire resistance. The foam considered here was found to have a flow resistivity that was too high for conventional acoustical applications, and as a result, it was processed by partial crushing to lower the flow resistivity into an acceptable range. Procedures for measuring the flow resistivity and Young s modulus of the material have been described, as was an inverse characterization procedure for estimating the remaining Biot parameters based on standing wave tube measurements of transmission loss and absorption coefficient. The inverse characterization was performed using a finite element model implementation of the Biot poro-elastic material theory. Those parameters were then used to predict the sound transmission loss of a double panel system lined with polyimide foam, and the predictions were compared with full-scale transmission loss measurements. The agreement between the two was reasonable, especially in the high and low frequency limits; however, it was found that the SEA model resulted in an under-prediction of the transmission loss in the mid-frequency range. Nonetheless, it was concluded that the performance of polyimide foam could be predicted using conventional poro-elastic material models and that polyimide foam may offer an attractive alternative to other double wall linings in certain situations: e.g., when fire resistance is a key issue. Future work will concentrate on reducing the density of the foam to values similar to those used in current aircraft sidewall treatments, and developing procedures to improve the performance of the foam in transmission loss applications.

Hong, Kwanwoo↗
NASA NTRS2009

Analysis of Microgravity Experiments Conducted on the Apollo Spacecraft

This Technical Memorandum (TM) discusses the microgravity experiments carried out during the later missions of the Apollo program. Microgravity experiments took place during the Apollo 14, 16, and 17 missions and consisted of four experiments in various materials processing concentrations with two of the four experiments taking place over the course of two missions. Experiments consist of composite casting, electrophoresis, heat flow and convection, and liquid transfer. This TM discusses the background, the workup, execution, and results of each experiment. In addition, the historical significance of each experiment to future applications/NASA programs is discussed.

Sharpe, R. J.↗
NASA NTRS2012

Sealing Materials for Use in Vacuum at High Temperatures

Sealing materials that can be applied and left in place in vacuum over a wide range of temperatures (especially temperatures of a few thousand degrees Celsius) have been conceived and investigated for potential utility in repairing thermal-protection tiles on the space shuttles in orbit before returning to Earth. These materials are also adaptable to numerous terrestrial applications that involve vacuum processing and/or repair of structures that must withstand high temperatures. These materials can be formulated to have mechanical handling characteristics ranging from almost freely flowing liquid-like consistency through paste-like consistency to stiff puttylike consistency, and to retain these characteristics in vacuum until heated to high curing temperatures. A sealing material of this type can be formulated to be used in any of several different ways for example, to be impregnated into a high-temperature-fabric patch, impregnated into a high-temperature-fabric gasket for sealing a patch, applied under a patch, or applied alone in the manner of putty or wallboard compound. The sealing material must be formulated to be compatible with, and adhere to, the structural material(s) to be repaired. In general, the material consists of a vacuum-compatible liquid containing one or more dissolved compound(s) and/or mixed with suspended solid particles. Depending on the intended application, the liquid can be chosen to be of a compound that can remain in place in vacuum for a time long enough to be useful, and/or to evaporate or decompose in a controlled way to leave a useful solid residue behind. The evaporation rate is determined by proper choice of vapor pressure, application of heat, and/or application of ultraviolet light or other optical radiation. The liquid chosen for the original space shuttle application is a commercial silicone vacuum-pump oil.

Pettit, Donald R.↗
NASA NTRS2022

The Impacts of Freshwater Input and Surface Wind Velocity on the Strength and Extent of a Large High Latitude River Plume

Arctic Ocean physical and biogeochemical properties are strongly influenced by freshwater input from land and through the Bering Strait, where the mean currents transport water northward from the Bering Sea. The Yukon River is one of the largest rivers in North America and the Arctic, contributing large quantities of freshwater and terrigenous material to the coastal ocean in the northern Bering Sea. However, a detailed analysis of the coastal hydrodynamics at the outflow of the river has not been conducted in this remote but regionally important river. A three-dimensional hydrodynamic model was built to represent the lower Yukon River and coastal ocean for the ice-free months in 7 years. On average, a large anticyclonic eddy persisted at the main outflow of the Yukon that recirculates water back toward the coast where the currents converge to form a mean northward transport along the delta. Interannual spatial variance in salinity was relatively small, while there was substantial variance in u and v current velocity. u velocity spatial variance was correlated to the volume of freshwater discharge across years, while v velocity spatial variance was correlated to the N–S wind velocity. During strong wind events, plume structure was substantially altered: southerly winds deepened the plume and enhanced northward transport, while northerly winds shoaled and strengthened the pycnocline, and reversed the flow toward the south. The variability in plume dispersion on short time scales due to wind forcing has implications for where terrigenous material is processed in and settles out of the water column.

river plume↗
DOE OSTI2024

Process for the Recovery of Actinide and Lanthanide Oxides via Thermal Decomposition and Calcination of Loaded Diglycolamide Resin

Diglycolamide (DGA) resin, a product produced by Eichrom Technologies, Inc. employs TODGA (N,N,N',N'-tetraoctyldiglycolamide) as the active extractant, which will be used by Savannah River National Laboratory to extract trivalent actinides and lanthanides from dissolved irradiated Mark-18A targets. The final form of the extracted material will be an oxide suitable for shipment. A two-step process was developed and validated for the direct recovery of actinides and lanthanides loaded on I-grade DGA resin as nitrates by thermally drying and decomposing resin loaded with Nd(III), a surrogate for trivalent actinides and lanthanides, under inert conditions followed by calcining the resultant residue in air to provide an oxide product. Further, a stepwise heating profile up to 385°C under argon gas flow resulted in 85% to 89% mass loss during the resin drying and decomposition step, and calcination of the resultant Nd-loaded resin residue provided an overall material mass loss of ≥ 98%. Recoveries from resin saturated with Nd(III) from 7 M and 0.35 M nitric acid subjected to this process were 30.7 mg and 27.6 mg Nd/g dry resin, respectively, representing an average of 96.1% of Nd retained in the resin bed.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
NASA NTRS1998

Vacuum Plasma Spray (VPS) Forming of Solar Thermal Propulsion Components Using Refractory Metals

The Thermal Spray Laboratory at NASA's Marshall Space Flight Center has developed and demonstrated a fabrication technique using Vacuum Plasma Spray (VPS) to form structural components from a tungsten/rhenium alloy. The components were assembled into an absorption cavity for a fully-functioning, ground test unit of a solar thermal propulsion engine. The VPS process deposits refractory metal onto a graphite mandrel of the desired shape. The mandrel acts as a male mold, forming the required contour and dimensions of the inside surface of the deposit. Tungsten and tungsten/25% rhenium were used in the development and production of several absorber cavity components. These materials were selected for their high temperature (less than 2500 C) strength. Each absorber cavity comprises 3 coaxial shells with two, double-helical flow passages through which the propellant gas flows. This paper describes the processing techniques, design considerations, and process development associated with forming these engine components.

Zimmerman, Frank↗
NASA NTRS1992

Nature of buoyancy-driven flows in a reduced-gravity environment

The role of buoyancy-driven convection in reduced-gravity environments has been emphasized. It is shown that for some materials-processing experiments the values of the fundamental dimensionless parameters such as Gr or Ra are shifted from the very large (ground-based values) to moderately large (space-based values). As a consequence, in cases where approximate analytical solutions are desired, the accuracy of the usual asymptotic (boundary-layer) analysis in which infinitely large parametric ranges are assumed is reduced. Approximate analytical techniques for refinement of the asymptotic solutions are identified that will extend the accuracy to the moderately large parametric ranges associated with space-based processing.

Kassemi, Siavash A.↗
NASA NTRS2011

Composite Thermal Switch

Lithium primary and lithium ion secondary batteries provide high specific energy and energy density. The use of these batteries also helps to reduce launch weight. Both primary and secondary cells can be packaged as high-rate cells, which can present a threat to crew and equipment in the event of external or internal short circuits. Overheating of the cell interior from high current flows induced by short circuits can result in exothermic reactions in lithium primary cells and fully charged lithium ion secondary cells. Venting of the cell case, ejection of cell components, and fire have been reported in both types of cells, resulting from abuse, cell imperfections, or faulty electronic control design. A switch has been developed that consists of a thin layer of composite material made from nanoscale particles of nickel and Teflon that conducts electrons at room temperature and switches to an insulator at an elevated temperature, thus interrupting current flow to prevent thermal runaway caused by internal short circuits. The material is placed within the cell, as a thin layer incorporated within the anode and/or the cathode, to control excess currents from metal-to-metal or metal-to-carbon shorts that might result from cell crush or a manufacturing defect. The safety of high-rate cells is thus improved, preventing serious injury to personnel and sensitive equipment located near the battery. The use of recently available nanoscale particles of nickel and Teflon permits an improved, homogeneous material with the potential to be fine-tuned to a unique switch temperature, sufficiently below the onset of a catastrophic chemical reaction. The smaller particles also permit the formation of a thinner control film layer (<50 m), which can be incorporated into commercial high-rate lithium primary and secondary cells. The innovation permits incorporation in current lithium and lithium-ion cell designs with a minimal impact on cell weight and volume. The composite thermal switch (CTS(TradeMark)) coating can be incorporated in either the anode or cathode or both. The coating can be applied in a variety of different processes that permits incorporation in the cell and electrode manufacturing processes. The CTS responds quickly and halts current flow in the hottest parts of the cell first. The coating can be applied to metal foil and supplied as a cell component onto which the active electrode materials are coated.

McDonald, Robert↗
NASA NTRS2001

Effects of Traveling Magnetic Field on Dynamics of Solidification

TMF is based on imposing a controlled phase-shift in a train of electromagnets, forming a stack. Thus, the induced magnetic field can be considered to be travelling along the axis of the stack. The coupling of this traveling wave with an electrically conducting fluid results in a basic flow in a form of a single axisymmetric roll. The magnitude and direction of this flow can be remotely controlled. Furthermore, it is possible to localize the effect of this force field though activating only a number of the magnets. This force field generated in the fluid can, in principle, be used to control and modify convection in the molten material. For example, it can be used to enhance convective mixing in the melt, and thereby modify the interface shape, and macrosegregation. Alternatively, it can be used to counteract thermal and/or solutal buoyancy forces. High frequency TMF can be used in containerless processing techniques, such as float zoning, to affect the very edge of the fluid so that Marangoni flow can be counter balanced. The proposed program consists of basic fundamentals and applications. Our goal in conducting the following experiments and analyses is to establish the validity of TMF as a new tool for solidification processes. Due to its low power consumption and simplicity of design, this tool may find wide spread use in a variety of space experiments. The proposed ground based experiments are intended to establish the advantages and limitations of employing this technique. In the fundamentals component of the proposed program, we will use theoretical tools and experiments with mercury to establish the fundamental aspects of TMF-induced convection through a detailed comparison of theoretical predictions and experimental measurements of flow field. In this work, we will conduct a detailed parametric study involving the effects of magnetic field strength, frequency, wave vector, and the fluid geometry. The applications component of this work will be focused on investigating the effect of TMF on the following solidification and pre-directional solidification processes: (1) Bridgman growth of Ga:Ge with the goal of counteracting the buoyancy-driven convection; (2) Mixing of Pb-Ga and Pb-Sn alloys with the aim of initiating and maintaining a uniform melt prior to solidification processing; and (3) Float Zone growth with the aim of identifying, through simulations and model experiments, conditions needed to counteract Marangoni flow in a microgravity environment. The proposed research has strong relevance to microgravity research and the objectives of the NRA. TMF can provide a unique and accurate mechanism for generation and control of desirable flow patterns for microgravity research. These attributes have significant relevance to 1) Alloy mixing prior to solidification in a microgravity environment. TMF can provide this mixing with a low level of power consumption; (2) TMF can offset the deleterious effects of Marangoni convection in microgravity containerless processing. Thus, TMF can be instrumental in further understanding this phenomena; (3) Generation of controlled flows will allow the investigation of the effect of these flows on growth morphology and growth kinetics; and (4) On Earth, TMF has the potential to significantly counter-balance thermosolutal convection, thereby creating conditions similar to those obtained in microgravity. Once demonstrated, this new tool for use in solidification has the strong potential to find applications in a host of microgravity material research projects.

Mazuruk, Konstantin↗
NASA NTRS1995

Verification of a three-dimensional resin transfer molding process simulation model

Experimental evidence was obtained to complete the verification of the parameters needed for input to a three-dimensional finite element model simulating the resin flow and cure through an orthotropic fabric preform. The material characterizations completed include resin kinetics and viscosity models, as well as preform permeability and compaction models. The steady-state and advancing front permeability measurement methods are compared. The results indicate that both methods yield similar permeabilities for a plain weave, bi-axial fiberglass fabric. Also, a method to determine principal directions and permeabilities is discussed and results are shown for a multi-axial warp knit preform. The flow of resin through a blade-stiffened preform was modeled and experiments were completed to verify the results. The predicted inlet pressure was approximately 65% of the measured value. A parametric study was performed to explain differences in measured and predicted flow front advancement and inlet pressures. Furthermore, PR-500 epoxy resin/IM7 8HS carbon fabric flat panels were fabricated by the Resin Transfer Molding process. Tests were completed utilizing both perimeter injection and center-port injection as resin inlet boundary conditions. The mold was instrumented with FDEMS sensors, pressure transducers, and thermocouples to monitor the process conditions. Results include a comparison of predicted and measured inlet pressures and flow front position. For the perimeter injection case, the measured inlet pressure and flow front results compared well to the predicted results. The results of the center-port injection case showed that the predicted inlet pressure was approximately 50% of the measured inlet pressure. Also, measured flow front position data did not agree well with the predicted results. Possible reasons for error include fiber deformation at the resin inlet and a lag in FDEMS sensor wet-out due to low mold pressures.

Fingerson, John C.↗
NASA NTRS1990

Advanced Turbine Technology Applications Project (ATTAP)

Advanced Turbine Technology Application Project (ATTAP) activities during the past year were highlighted by test-bed engine design and development activities; ceramic component design; materials and component characterization; ceramic component process development and fabrication; component rig testing; and test-bed engine fabrication and testing. Although substantial technical challenges remain, all areas exhibited progress. Test-bed engine design and development activity included engine mechanical design, power turbine flow-path design and mechanical layout, and engine system integration aimed at upgrading the AGT-5 from a 1038 C metal engine to a durable 1371 C structural ceramic component test-bed engine. ATTAP-defined ceramic and associated ceramic/metal component design activities include: the ceramic combustor body, the ceramic gasifier turbine static structure, the ceramic gasifier turbine rotor, the ceramic/metal power turbine static structure, and the ceramic power turbine rotors. The materials and component characterization efforts included the testing and evaluation of several candidate ceramic materials and components being developed for use in the ATTAP. Ceramic component process development and fabrication activities are being conducted for the gasifier turbine rotor, gasifier turbine vanes, gasifier turbine scroll, extruded regenerator disks, and thermal insulation. Component rig testing activities include the development of the necessary test procedures and conduction of rig testing of the ceramic components and assemblies. Four-hundred hours of hot gasifier rig test time were accumulated with turbine inlet temperatures exceeding 1204 C at 100 percent design gasifier speed. A total of 348.6 test hours were achieved on a single ceramic rotor without failure and a second ceramic rotor was retired in engine-ready condition at 364.9 test hours. Test-bed engine fabrication, testing, and development supported improvements in ceramic component technology that will permit the achievement of program performance and durability goals. The designated durability engine accumulated 359.3 hour of test time, 226.9 of which were on the General Motors gas turbine durability schedule.

Source record↗
NASA NTRS1983

Influence of thermomechanical processing on elevated temperature slow plastic flow properties of B2 aluminide Fe-39.8at.% Al

A study of the elevated temperature slow plastic flow properties of the B2 aluminide Fe-39.8at.% Al was undertaken. Polycrystalline materials possessing several different microstructures were produced by the hot extrusion of prealloyed powder and, in some cases, postextrusion heat treatments. Compression tests were conducted in air at 1200, 1300 and 1400 K. Such testing revealed that the extrusion temperature affected the active deformation mechanisms where material extruded at 1505 K had a stress exponent about twice that of the intermetallic extruded at 1200 K. Grain size refinement to about 10 microns was found to strengthen the Fe-39.8at.% Al material; unfortunately, the effectiveness of such strengthening is limited to a homologous temperature of about 0.75 for strain rates of commercial interest (less than 10 to the -7th/sec).

Whittenberger, J. D.↗
NASA NTRS1998

Arcjet Semi-Elliptic Nozzle Simulations and Validation in Support of TPS Testing

Much of the ground based testing of advanced thermal protection system (TPS) components for the X33 program is done in arc-heated wind tunnels such as those located in the Arc-Jet Complex at NASA Ames Research Center. These facilities are capable of simulating the high temperature, chemically reacting flow environment experienced by the vehicle during flight. This allows one to test critical design issues such as maximum reuse temperatures, seals, gaps, and increases in heating due to interfaces between different materials. Computational fluid dynamics (CFD) has evolved to the point where it now can be used in the vehicle design process for accurate and timely prediction of trajectory based aerothermal heating environments for re-entry vehicles. It can also be used for simulation of the flow environments in ground based facilities such as arcjets. By utilization of the same CFD code and solution methodology, the important differences between ground test and flight may be quantified. The goal of this paper is to utilize CFD to provide validated simulations of the flow environment in the NASA-Ames semi elliptic nozzle arcjet facilities. The validation of the ground simulations will come From comparison to existing calibration data. Specific tests in support of the X33 TPS test program will ilso be simulated. In this manner, the differences between the ground test simulation and the flight environment can be identified for a measure of ground test to flight traceability.

Loomis, Mark↗
DOE OSTI2025

A code-to-code benchmark for magneto-convection in a horizontal duct

Liquid metals and magnetic fields are used in many technical applications such as metallurgy, crystal growth and nuclear fusion reactors. When an electrically conducting fluid moves in a magnetic environment, electric currents and electromagnetic forces are generated that affect velocity and pressure losses in the flow. These magnetohydrodynamic (MHD) interactions have to be investigated to optimize the engineering processes. The characteristics of MHD flows depend on the geometrical configuration, the strength of the applied magnetic field, the electrical properties of fluid and structural materials and the thermal conditions. In the so-called blankets for fusion reactors, where liquid metals are used to breed the plasma fuel component tritium and to extract the generated heat, magneto-convective flows play a crucial role in determining heat and mass transfer. Therefore, the availability of numerical codes to simulate this type of flow is mandatory and their validation is a necessary step to guarantee the reliability of the results. For that reason, a benchmark problem has been defined to simulate liquid metal flows in a horizontal rectangular duct heated from below and exposed to a non-uniform magnetic field. Results obtained by five research groups using different codes are compared.

benchmark↗
NASA NTRS1978

Automatic welding of stainless steel tubing

The use of automatic welding for making girth welds in stainless steel tubing was investigated as well as the reduction in fabrication costs resulting from the elimination of radiographic inspection. Test methodology, materials, and techniques are discussed, and data sheets for individual tests are included. Process variables studied include welding amperes, revolutions per minute, and shielding gas flow. Strip chart recordings, as a definitive method of insuring weld quality, are studied. Test results, determined by both radiographic and visual inspection, are presented and indicate that once optimum welding procedures for specific sizes of tubing are established, and the welding machine operations are certified, then the automatic tube welding process produces good quality welds repeatedly, with a high degree of reliability. Revised specifications for welding tubing using the automatic process and weld visual inspection requirements at the Kennedy Space Center are enumerated.

Clautice, W. E.↗
NASA NTRS1987

Low power arcjet life issues

The present evaluation of the results of arcjet engine lifetime testing attempts to deepen understanding of the electrode erosion process, with a view to its minimization. Attention is given to the compatibility of materials with N2H4, the dependence of electrode erosion on geometry and flow field, and the erosive effects associated with the arcjet power supply. Results are presented for thrusters employing either decomposed N2H4 or cold mixed gases, over a power range of 900 to 2000 W.

Simon, M. A.↗
NASA NTRS2008

Air Flow and Pressure Drop Measurements Across Porous Oxides

This report summarizes the results of air flow tests across eight porous, open cell ceramic oxide samples. During ceramic specimen processing, the porosity was formed using the sacrificial template technique, with two different sizes of polystyrene beads used for the template. The samples were initially supplied with thicknesses ranging from 0.14 to 0.20 in. (0.35 to 0.50 cm) and nonuniform backside morphology (some areas dense, some porous). Samples were therefore ground to a thickness of 0.12 to 0.14 in. (0.30 to 0.35 cm) using dry 120 grit SiC paper. Pressure drop versus air flow is reported. Comparisons of samples with thickness variations are made, as are pressure drop estimates. As the density of the ceramic material increases the maximum corrected flow decreases rapidly. Future sample sets should be supplied with samples of similar thickness and having uniform surface morphology. This would allow a more consistent determination of air flow versus processing parameters and the resulting porosity size and distribution.

Fox, Dennis S.↗
DOE OSTI2025

Low-metallicity Nova Explosions: A Site for Weak rp -process Nucleosynthesis

Classical novae are common cataclysmic events involving a binary system of a white dwarf and a main-sequence or red giant companion star. In metal-poor environments, these explosions produce ejecta differently from their solar counterparts due to the accretion of subsolar-metallicity material onto the white dwarf. In particular, it has been suggested that the nucleosynthesis flow in such low-metallicity nova explosions extends up to the Cu–Zn region, much beyond the expected endpoint, around Ca, predicted for solar-metallicity classical novae. This behavior resembles a weak rp-process, and such nuclear activity has never been observed in accreting white dwarf binaries with typical accretion flows. In this work, we study the characteristics of the weak rp-process for four nova models with metallicities Z = 2 × 10 −9 , 10 −7 , 2 × 10 −6 , and 2 × 10 −5 , and explore the impact of the nuclear physics uncertainties via a Monte Carlo sensitivity study. We identify nuclear reactions whose uncertainties affect the production of intermediate-mass nuclei under these conditions. These reactions and relevant nuclear quantities are targets for measurements at stable or radioactive beam facilities to reduce their rate uncertainties.

Classical novae↗