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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

VPS Process for Copper Components in Thrust Chamber Assemblies

For several years, NASA's Marshall Space Flight Center (MSFC) has been working with Plasma Processes, Inc., (PPI) to fabricate thrust chamber liners with GRCop-84. Using the vacuum plasma spray (VPS) process, chamber liners of a variety of shapes and sizes have been created. Each has been formed as a functional gradient material (FGM) that creates a unique protective layer of NiCrAlY on the GRCop-84 liner s hot wall surface. Hot-fire testing was successfully conducted on a subscale unit to demonstrate the liner's durability and performance. Similar VPS technology has also been applied to create functional gradient coatings (FGC) on copper injector faceplates. Protective layers of NiCrAlY and zirconia were applied to both coaxial and impinging faceplate designs. Hot-fire testing is planned for these coated injectors in April 2005. The resulting material systems for both copper alloy components allows them to operate at higher temperatures with improved durability and operating margins.

Elam, Sandra↗
DOE OSTI2014

Fracture toughness of plasma-sprayed thermal barrier ceramics: Influence of processing, microstructure, and thermal aging

Fracture toughness has become one of the dominant design parameters that dictates the selection of materials and their microstructure to obtain durable thermal barrier coatings (TBCs). Much progress has been made in characterizing the fracture toughness of relevant TBC compositions in bulk form, and it has become apparent that this property is significantly affected by process-induced microstructural defects. In this investigation, a systematic study of the influence of coating microstructure on the fracture toughness of atmospheric plasma sprayed (APS) TBCs has been carried out. Yttria partially stabilized zirconia (YSZ) coatings were fabricated under different spray process conditions inducing different levels of porosity and interfacial defects. Fracture toughness was measured on free standing coatings in as-processed and thermally aged conditions using the double torsion technique. Results indicate significant variance in fracture toughness among coatings with different microstructures including changes induced by thermal aging. Comparative studies were also conducted on an alternative TBC composition, Gd 2 Zr 2 O 7 (GDZ), which as anticipated shows significantly lower fracture toughness compared to YSZ. Furthermore, the results from these studies not only point towards a need for process and microstructure optimization for enhanced TBC performance but also a framework for establishing performance metrics for promising new TBC compositions.

36 MATERIALS SCIENCE↗
DOE OSTI2011

In-flight alloying of nanocrystalline yttria-stabilized zirconia using suspension spray to produce ultra-low thermal conductivity thermal barriers.

Previous researchers have shown that it is possible to combine rare-earth oxides with the standard thermal barrier coating material (4.5 mol% Y{sub 2}O{sub 3}-ZrO{sub 2} or YSZ) to form ultra-low thermal conductivity coatings using a standard powder manufacturing route. A similar approach to making low thermal conductivity coatings by adding rare-earth oxides is discussed presently, but a different manufacturing route was used. This route involved dissolving hydrated ytterbium and neodymium nitrates into a suspension of 80 nm diameter 4.5 mol% YSZ powder and ethanol. Suspension plasma spray was then used to create coatings in which the YSZ powders were alloyed with rare-earth elements while the plasma transported the melted powders to the substrate. Mass spectrometry measurements showed a YSZ coating composition, in mol%, of ZrO{sub 2}-4.4 Y{sub 2}O{sub 3}-1.4 Nd{sub 2}O{sub 3}-1.3 Yb{sub 2}O{sub 3}. The amount of Yb{sup 3+} and Nd{sup 3+} ions in the final coating was {approx}50% of that added to the starting suspension. Wide-angle X-ray diffraction revealed a cubic ZrO{sub 2} phase, consistent with the incorporation of more stabilizer into the zirconia crystal structure. The total porosity in the coatings was {approx}35-36%, with a bulk density of 3.94 g/cm{sup 3}. Small-angle X-ray scattering measured an apparent void specific surface area of {approx}2.68 m{sup 2}/cm{sup 3} for the alloyed coating and {approx}3.19 m{sup 2}/cm{sup 3} for the baseline coating. Thermal conductivity (k{sub th}) of the alloyed coating was {approx}0.8 W/m/K at 800 C, as compared with {approx}1.5 W/m/K at 800 C for the YSZ-only baseline coating. After 50 h at 1200 C, k{sub th} increased to {approx}1.1 W/m/K at 800 C for the alloyed samples, with an associated decrease in the apparent void specific surface area to {approx}1.55 m{sup 2}/cm{sup 3}.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Chemical and structural analyses of subsurface crevices formed during spontaneous deposition of cerium-based conversion coatings

Subsurface crevices formed during the deposition of cerium-based conversion coatings were analyzed in cross-section to assess the effect of deposition and post-treatment on the structure and chemistry of phases present. An Al-O containing phase, believed to be amorphous Al(OH){sub 3}, was formed in crevices during coating deposition. Analysis by energy dispersive X-ray spectroscopy revealed the presence of up to 1.6 at.% chlorine within the Al-O phase, which was likely a product of soluble chlorides that were present in the coating solution. Cerium was not detected within crevices. After post-treatment in an 85 deg. C aqueous phosphate solution, the chloride concentration was reduced to {<=} 0.30 at.% and electron diffraction of the Al-O phase produced ring patterns, indicating it had crystallized. Some diffraction patterns could be indexed to gibbsite (Al(OH){sub 3}), but others are believed to be a combination of hydrated aluminum hydroxides and/or oxides. Aluminum phosphate was not identified. Separately from its effect on cerium-based conversion coatings, phosphate post-treatment improved the corrosion resistance of Al 2024-T3 substrates by acting to crystallize Al(OH){sub 3} present on interior surfaces of crevices and by reducing the chloride concentration in this phase. - Highlights: {yields} Analysis of subsurface crevices formed during deposition of Ce-based conversion coatings. {yields} Phosphate post-treatment improved corrosion protection in salt spray testing. {yields} Post-treatment affected the composition and structure of regions within crevices. {yields} Crystallized Al(OH){sub 3} within crevices acted as a more effective barrier to chloride ions.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Fluorohydrogenate Cluster Ions in the Gas Phase: Electrospray Ionization Mass Spectrometry of the [1-Ethyl-3-methylimidazolium+][F(HF)2.3–] Ionic Liquid

Electrospray ionization of the fluorohydrogenate ionic liquid [1-ethyl-3-methylimidazolium][F(HF)2.3] ionic liquid was conducted to understand the nature of the anionic species as they exist in the gas phase. Abundant fluorohydrogenate clusters were produced; however, the dominant anion in the clusters was [FHF-], and not the fluoride-bound HF dimers or trimers that are seen in solution. Density functional theory (DFT) calculations suggest that HF molecules are bound to the clusters by about 30 kcal/mol. The DFT-calculated structures of the [FHF-]-bearing clusters show that the favored interactions of the anions are with the methynic and acetylenic hydrogen atoms on the imidazolium cation, forming planar structures similar to those observed in the solid state. A second series of abundant negative ions was also formed that contained [SiF5-] together with the imidazolium cation and the fluorohydrogenate anions that originate from reaction of the spray solution with silicate surfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Thermoelectric properties of in-situ plasma spray synthesized sub-stoichiometry TiO 2-x

The thermoelectric properties of sub-stoichiometric TiO 2-x deposits produced by cascaded-plasma spray process are investigated from room-temperature to 750 K. Sub-stoichiometric TiO 2-x deposits are formed through in-situ reaction of the TiO 1.9 within the high temperature plasma flame and manipulated through introduction of varying amounts of hydrogen in the plasma. Although the TiO 2-x particles experience reduction within plasma, it can also re-oxidize through interaction with the surrounding ambient atmosphere, resulting in a complex interplay between process conditions and stoichiometry. The deposits predominantly contain rutile phase with presence of Magneli phases especially under significantly reducing plasma conditions. The resultant deposits show sensitivity to thermoelectric properties and under certain optimal conditions repeatedly show Seebeck coefficients reaching values of -230 μV K -1 at temperatures of 750 K while providing an electrical conductivity of 5.48 × 10 3 S m -1 , relatively low thermal conductivity in the range of 1.5 to 2 W m -1 K -1 resulting in power factor of 2.9 μW cm -1 K -2 . The resultant maximum thermoelectric figure of merit value reached 0.132 under these optimal conditions. Lastly, the results point to a potential pathway for a large-scale fabrication of low-cost oxide based thermoelectric with potential applicability at moderate to high temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Aerosol Deposition: Room Temperature Solid-State Deposition of Ceramics

The ability to integrate ceramics with other materials has been limited by the high temperature s (>800C) associated with ceramic processing. A novel process, known as aerosol deposition (AD), capable of preparing ceramic films at room temperature (RT) has been the subject of recent interest in the thermal spray and microelectronics communities. In this process, ceramic particles are accelerated using pressurized gas, impacted on a substrate and form a dense film under vacuum. This revolutionary process eliminates high temperature processing, enabling new coatings and microelectronic device integration as a back end of line process, in which ceramics can be deposited on metals, plastics, and glasses . Future impact s of this technology on Sandia's mission could include improved ceramic integration, miniaturized magnetic circulators in radar applications, new RF communication products, modification of commercial - off - the - shelf electronics, fabrication of conformal capacitors, thin batteries, glass - to - metal seals, and transparent electronics. Currently, optimization for RT solid - state deposition of ceramics is achieved empirically and fundamental mechanisms for ceramic particle - particle bonding are not well understood. Obtaining this knowledge will allow process - microstructure - property relation ship realization and will enable a differentiating ceramic integration capability. This LDRD leveraged Sandias existing equipment and capabilities in simulation, experimentation, and materials characterization to discover the fundamental mechanisms for ceramic particle deformation, particle - substrate bonding, and particle - particle bonding in RT consolidated films. RT deformation of individual Al 2 O 3 particles was examined computationally and experimentally as a model system for understanding the complex dynamics associated with in vacuo RT deposition conditions associated with AD. Subsequently, particle - substrate bonding and particle - particle bonding in AD Al 2 O 3 consolidated films were examined computationally and experimentally. Fundamental mechanisms behind the AD process were proposed.

36 MATERIALS SCIENCE↗
NASA NTRS1973

Method of making pressure tight seal for super alloy

A procedure for forming a pressure tight seal along two edges of super alloy sheets is presented. The procedure consists of flame spraying a powdered aluminum-nickel composition on the joint. The use of frozen carbon dioxide and carbon dioxide gas to maintain a low temperature environment during the flame spraying is described.

Little, R. E.↗
NASA NTRS1987

Simultaneous radio and white light observations of the 1984 June 27 coronal mass ejection event

Two-dimensional images of radio bursts in the 25-50-MHz frequency range obtained with the SMM Coronagraph/Polarimeter and Mauna Loa K-coronameter during a coronal mass ejection event on June 27, 1984 are discussed. The present event is shown to be spatially and temporally associated with precursors in the form of meter-decameter type III bursts, soft X-ray emission, and a H-alpha flare spray. The results suggest gyrosychrotron emission from a plasmoid containing a magnetic field of about 2.5 G and nonthermal electrons with a number density of about 100,000/cu cm and energy of greater than about 350 keV.

Gopalswamy, N.↗
NASA NTRS2014

Methods of Making Z-Shielding

Methods of building Z-graded radiation shielding and covers. In one aspect, the method includes: providing a substrate surface having about medium Z-grade; plasma spraying a first metal having higher Z-grade than the substrate surface; and infusing a polymer layer to form a laminate. In another aspect, the method includes electro/electroless plating a first metal having higher Z-grade than the substrate surface. In other aspects, the methods include improving an existing electronics enclosure to build a Z-graded radiation shield by applying a temperature controller to at least part of the enclosure and affixing at least one layer of a first metal having higher Z-grade from the enclosure.

Thomsen, III, Donald Laurence↗
NASA NTRS2018

Methods of Making Z-Shielding

Disclosed are methods of building Z-graded radiation shielding and covers. In one aspect. the method includes: providing a substrate surface having about medium Z-grade; plasma spraying a first metal having higher Z-grade than the substrate surface; and infusing a polymer layer to form a laminate. In another aspect, the method includes electro/electroless plating a first metal having higher Z-grade than the substrate surface. In other aspects, the invention provides methods of improving an existing electronics enclosure to build a Z-graded radiation shield by applying a temperature controller to at least part of the enclosure and affixing at least one layer of a first metal having higher Z-grade than the enclosure.

Thomsen, III, Donald Laurence↗
NASA NTRS1993

Simulation of preburner sprays, volume 1

Under the present contract a study was made on the characteristics of the sprays of coaxial injectors with particular emphasis on those aspects relevant to the performance of rocket engines. The technical effort was performed primarily by Imperial College of Science and Technology and the details of this effort are contained in the accompanying technical report by Hardalupas and Whitelaw, which forms Vol. 2 of the report. The role of Scientific Research Associates was review of material, initial direction of the technical effort and review of all reports. The study considered characteristics of sprays under a variety of conditions. Control of these sprays is important as the spray details can control both rocket combustion stability and efficiency. Imperial College considered the following: first, measurement of the size and rate of spread of the sprays produced by single coaxial airblast nozzles with axial gaseous stream. The local size, velocity and flux characteristics for a wide range of gas and liquid flowrates were measured and the results were correlated with the conditions of the spray at the nozzle exit. Second, examination of the effect of the geometry of single coaxial airblast atomizers on spray characteristics. The gas and liquid tube diameters were varied over a range of values, the liquid tube recess was varied and the shape of the exit of the gaseous jet was varied from straight to converging. Third, quantification of the effect of swirl in the gaseous stream on the spray characteristics produced by single coaxial airblast nozzles. Fourth, quantification of the effect of reatomization by impingement of the spray on a flat disc positioned around 200 mm from the nozzle exit. This models spray impingement on the turbopump dome during the startup process of the preburner of the Space Shuttle Main Engine (SSME). Fifth, study of the interaction between multiple sprays without and with swirl in their gaseous stream. The spray characteristics of single nozzles were compared with that of three identical nozzles with their axis at a small distance from each other. This study simulates the sprays in the preburner of the SSME, where there are around 260 elements on the faceplate of the combustion chamber. And lastly, design an experimental facility to study the characteristics of sprays at high pressure conditions and at supercritical pressure and temperature for the gas but supercritical pressure and subcritical temperature for the liquid.

Source record↗
DOE OSTI2022

Facile synthesis and phase stability of Cu-based Na 2 Cu(SO 4 ) 2 · x H 2 O ( x = 0–2) sulfate minerals as conversion type battery electrodes

Mineral exploration forms a key approach for unveiling functional battery electrode materials. The synthetic preparation of naturally found minerals and their derivatives can aid in designing of new electrodes. Herein, saranchinaite Na 2 Cu(SO 4 ) 2 and its hydrated derivative kröhnkite Na 2 Cu(SO 4 ) 2 ·2H 2 O bisulfate minerals have been prepared using a facile spray drying route for the first time. The phase stability relation during the (de)hydration process was examined synergising in situ X-ray diffraction and thermochemical studies. Kröhnkite forms the thermodynamically stable phase as the hydration of saranchinaite to kröhnkite is highly exothermic (-51.51 ± 0.63 kJ mol -1 ). Structurally, kröhnkite offers a facile 2D pathway for Na+ ion migration resulting in 20 times higher total conductivity than saranchinaite at 60 °C. Both compounds exhibited a conversion redox mechanism for Li-ion storage with the first discharge capacity exceeding 650 mA h g -1 (at 2 mA g -1 vs. Li + /Li) upon discharge up to 0.05 V. Post-mortem analysis revealed that the presence of metallic Cu in the discharged state is responsible for high irreversibility during galvanostatic cycling. This study reaffirms the exploration of Cu-based polyanionic sulfates, which while having limited (de)insertion properties, can be harnessed for conversion-based electrode materials for batteries.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1998

Method of Forming a Composite Coating with Particle Materials that are Readily Dispersed in a Sprayable Polyimide Solution

A method for creating a composite form of coating from a sprayable solution of soluble polyimides and particle materials that are uniformly dispersed within the solution is described. The coating is formed by adding a soluble polyimide to a solvent, then stirring particle materials into the solution. The composite solution is sprayed onto a substrate and heated in an oven for a period of time in order to partially remove the solvent. The process may be repeated until the desired thickness or characteristic of the coating is obtained. The polyimide is then heated to at least 495 F, so that it is no longer soluble.

Tran, Sang Q.↗
NASA NTRS2008

Fabricating Large-Area Sheets of Single-Layer Graphene by CVD

This innovation consists of a set of methodologies for preparing large area (greater than 1 cm(exp 2)) domains of single-atomic-layer graphite, also called graphene, in single (two-dimensional) crystal form. To fabricate a single graphene layer using chemical vapor deposition (CVD), the process begins with an atomically flat surface of an appropriate substrate and an appropriate precursor molecule containing carbon atoms attached to substituent atoms or groups. These molecules will be brought into contact with the substrate surface by being flowed over, or sprayed onto, the substrate, under CVD conditions of low pressure and elevated temperature. Upon contact with the surface, the precursor molecules will decompose. The substituent groups detach from the carbon atoms and form gas-phase species, leaving the unfunctionalized carbon atoms attached to the substrate surface. These carbon atoms will diffuse upon this surface and encounter and bond to other carbon atoms. If conditions are chosen carefully, the surface carbon atoms will arrange to form the lowest energy single-layer structure available, which is the graphene lattice that is sought. Another method for creating the graphene lattice includes metal-catalyzed CVD, in which the decomposition of the precursor molecules is initiated by the catalytic action of a catalytic metal upon the substrate surface. Another type of metal-catalyzed CVD has the entire substrate composed of catalytic metal, or other material, either as a bulk crystal or as a think layer of catalyst deposited upon another surface. In this case, the precursor molecules decompose directly upon contact with the substrate, releasing their atoms and forming the graphene sheet. Atomic layer deposition (ALD) can also be used. In this method, a substrate surface at low temperature is covered with exactly one monolayer of precursor molecules (which may be of more than one type). This is heated up so that the precursor molecules decompose and form one monolayer of the target material.

Bronikowski, Michael↗
DOE OSTI2019

Assessment of impinged flame structure in high-pressure direct diesel injection

Spray impingement often occurs during cold-start in direct-injection diesel engines, affecting the subsequent combustion process by altering the local flow condition. This work has investigated the impinged flame structure by examining local expansion distance and planar curvature of the boundary in details. The experiments were carried out in a constant volume combustion chamber. The injection pressure and ambient density were varied from 120 to 180 MPa and 14.8 to 30.0 kg/m 3 under non-vaporizing conditions, respectively. For reacting conditions, the injection pressure and ambient density were fixed at 150 MPa and 22.8 kg/m 3 but with different ambient temperatures from 800 to 1000 K. Unlike orthogonal spray impingement, the profile of expansion distance along the radial direction at the 60° impinging angle is non-uniform but the profile is comparable between the non-vaporizing and reacting conditions under the same injection pressure and ambient density. With the help of Intensity-aXial-Time method, the most intensive soot luminosity region and Mie scattering intensity region are identified and the region has been found to be along the impinged spray axial direction. Outmost boundary of an impinged flame is found to have wrinkles attributed to air entrainment. The temporal level of flame wrinkles is higher in reacting conditions than in non-vaporizing conditions. The scatter distribution of the boundary curvature and near-field soot formation illustrates an inverted “S” shape correlation with time. High flame luminosity is found to be formed in concave regions while less soot is formed in convex regions. This inverted S-shape is a new finding of the state relationship at the solid–liquid–gas impinged flame propagation. Finally, heat flux measurement through the plate is examined.

Engineering↗
DOE OSTI2014

Turbine airfoil to shroud attachment method

Bi-casting a platform (50) onto an end portion (42) of a turbine airfoil (31) after forming a coating of a fugitive material (56) on the end portion. After bi-casting the platform, the coating is dissolved and removed to relieve differential thermal shrinkage stress between the airfoil and platform. The thickness of the coating is varied around the end portion in proportion to varying amounts of local differential process shrinkage. The coating may be sprayed (76A, 76B) onto the end portion in opposite directions parallel to a chord line (41) of the airfoil or parallel to a mid-platform length (80) of the platform to form respective layers tapering in thickness from the leading (32) and trailing (34) edges along the suction side (36) of the airfoil.

17 WIND ENERGY↗
NASA NTRS1931

The N.A.C.A. Apparatus for Studying the Formation and Combustion of Fuel Sprays and the Results from Preliminary Tests

Described here is an apparatus for studying the formation and combustion of fuel sprays under conditions closely simulating those in a high speed compression-ignition engine. The apparatus consists of a single-cylinder modified test engine, a fuel injection system so designed that a single charge of fuel can be injected into the combustion chamber, an electric driving motor, and a high-speed photographic apparatus. The cylinder head of the engine has a vertical disk form of combustion chamber whose sides are glass windows. When the fuel is injected into the combustion chamber, motion pictures at the rate of 2000 per second are taken of the spray formation by means of spark discharges. When combustion takes place, the light of combustion is recorded on the same photographic film as the spray photographs. Included here are the results of some tests to determine the effect of air temperature, air flow, and nozzle design on the spray formation. The results show that the compression temperature has little effect on the penetration of the fuel spray, but does not affect the dispersion, that air velocities of about 300 feet per second are necessary to destroy the core of the spray, and that the effect of air flow on the spray is controlled to a certain extent by the design of the injection nozzle. The results on the combustion of the spray show that when ignition does not take place until after spray cut-off, the ignition may start almost simultaneously throughout the combustion chamber or at different points throughout the chamber. When ignition takes place before spray cut-off, the combustion starts around the edge of the spray and then spreads throughout the chamber.

Rothrock, A M↗