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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 NTRS1995

SXI prototype mirror mount

The purpose of this contract was to provide optomechanical engineering and fabrication support to the Solar X-ray Imager (SXI) program in the areas of mirror, optical bench and camera assemblies of the telescope. The Center for Applied Optics (CAO) worked closely with the Optics and S&E technical staff of MSFC to develop and investigate the most viable and economical options for the design and fabrication of a number of parts for the various telescope assemblies. All the tasks under this delivery order have been successfully completed within budget and schedule. A number of development hardware parts have been designed and fabricated jointly by MSFC and UAH for the engineering model of SXI. The major parts include a nickel electroformed mirror and a mirror mount, plating and coating of the ceramic spacers, and gold plating of the contact rings and fingers for the camera assembly. An aluminum model of the high accuracy sun sensor (HASS) was also designed and fabricated. A number of fiber optic tapers for the camera assembly were also coated with indium tin oxide and phosphor for testing and evaluation by MSFC. A large number of the SXI optical bench parts were also redesigned and simplified for a prototype telescope. These parts include the forward and rear support flanges, front aperture plate, the graphite epoxy optical bench and a test fixture for the prototype telescope. More than fifty (50) drawings were generated for various components of the prototype telescope. Some of these parts were subsequently fabricated at UAH machine shop or at MSFC or by the outside contractors. UAH also provide technical support to MSFC staff for a number of preliminary and critical design reviews. These design reviews included PDR and CDR for the mirror assembly by United Technologies Optical Systems (UTOS), and the program quarterly reviews, and SXI PDR and CDR. UAH staff also regularly attended the monthly status reviews, and made a significant number of suggestions to improve the design, assembly and alignment of the telescope. Finally, a high level assembly and alignment plan for the entire telescope was prepared by UAH. This plan addresses the sequence of assembly, the required assembly and alignment tolerances, and the methods to verify the alignment at each step during the assembly process. This assembly and alignment plan will be used to assemble and integrate the engineering model (EM) of the telescope. Later on, based on this plan more detailed assembly and alignment procedures will be developed for the lower-level assemblies of SXI.

Source record↗
NASA NTRS1984

Thermal barrier coating life prediction model development

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology that has both performance and durability benefits. In order to achieve these benefits, however, the TBC system must be reliable. Prediction of the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry is examined. The plasma sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron beam-physical vapor depositon (EB-PVD) process by Temescal.

Strangman, T. E.↗
NASA NTRS1978

Laserfax

The photo shows an Associated Press technician receiving a photograph prepared by means of a high speed, high resolution facsimile system known as Laserfax, so called because it employs a laser beam to scan the photo being sent. Laser scanning data is converted to electrical signals and transmitted to news bureaus within the Associated Press network via microwave radio or telephone lines. At the other end, another laser sweeps reconverted imagery onto a special, light-sensitive, dry silver paper. The paper is then heat processed to reproduce the photograph. Manufactured by Harris Electronics Systems Inc., Melbourne, Florida, Laserfax incorporates NASA thermal control coating technology developed by Jet Propulsion Laboratory for use on spacecraft antennas; the coatings block absorption of solar radiation which would interfere with the antenna's proper operation. Harris Electronics Systems, originally Radiation, Inc., reused the NASA technology in development of Laserfax. A NASA technical support package provided information about the thermal properties that could be expected of various coatings for the facsimile system's paper rollers; this information served as a design base for the infrared heat source used in developing the photo. Although relatively new, Laserfax is in extensive service. It is manufactured in several models. One of them is the type used by the Associated Press, its news bureaus and affiliated newspapers, radio and television stations. Other models have been sold in large numbers to law enforcement agencies for transmitting high quality fingerprints and identification photos. Laserfax is also in service with the National Weather Service, which converts satellite imagery to weather photographs and relays them to local weather stations, television stations, newspapers and airlines.

Source record↗
NASA NTRS1985

Process and design considerations for high-efficiency solar cells

This paper shows that oxide surface passivation coupled with optimum multilayer anti-reflective coating can provide approx. 3% (absolute) improvement in solar cell efficiency. Use of single-layer AR coating, without passivation, gives cell efficiencies in the range of 15 to 15.5% on high-quality, 4 ohm-cm as well as 0.1 to 0.2 ohm-cm float-zone silicon. Oxide surface passivation alone raises the cell efficiency to or = 17%. An optimum double-layer AR coating on oxide-passivated cells provides an additional approx. 5 to 10% improvement over a single-layer AR-coated cell, resulting in cell efficiencies in excess of 18%. Experimentally observed improvements are supported by model calculations and an approach to or = 20% efficient cells is discussed.

Rohati, A.↗
NASA NTRS2002

Cyclic Oxidation Modeling Program Rewritten for MS Windows

Turbine superalloy components are subject to high-temperature oxidation during operation. Protection is often conferred by coatings designed to form slow-growing, adherent oxide scales. Degradation by oxidation is exacerbated by the thermal cycling encountered during normal aircraft operations. Cooling has been identified as the major contributor to stresses in the oxidation scales, and it may often cause some oxide scale spallation with a proportional loss of protective behavior. Overall oxidation resistance is, thus, studied by the weight change behavior of alloy coupons during high-temperature cyclic oxidation in furnace or burner rig tests. The various characteristics of this behavior are crucial in understanding the performance of alloys at high temperatures. This new modeling effort helps in the understanding of the major factors involved in the cyclic oxidation process. Weight change behavior in cyclic oxidation is typified by an initial parabolic weight gain response curve that eventually exhibits a maximum, then transitions into a linear rate of weight loss due to spalling. The overall shape and magnitude of the curve are determined by the parabolic growth rate, kp, the cycle duration, the type of oxide scale, and the regular, repetitive spalling process. This entire process was modeled by a computer program called the Cyclic Oxidation Spalling Program (COSP) previously developed at the NASA Glenn Research Center. Thus, by supplying appropriate oxidation input parameters, one can determine the best fit to the actual data. These parameters describe real behavior and can be used to compare alloys and project cyclic oxidation behavior for longer times or under different cycle frequencies.

Smialek, James L.↗
DOE OSTI2021

Spot the difference: hydrogen adsorption and dissociation on unsupported platinum and platinum-coated transition metal carbides

Hydrogenation reactions are involved in several processes in heterogeneous catalysis. Platinum is the best-known catalyst; however, there are limitations to its practical use. Therefore, it is necessary to explore alternative materials and transition metal carbides (TMCs) have emerged as potential candidates. We explore the possibility of using cheap TMCs as supports for a Pt monolayer, aiming to reduce the amount of the noble metal in the catalyst without a significant loss of its activity towards H 2 dissociation. Hence, analyzing H 2 dissociation from a fundamental point of view is a necessary step towards a further practical catalyst. By means of periodic DFT calculations, we analyze H 2 adsorption and dissociation on Pt/β-Mo 2 C and Pt/α-WC surfaces, as a function of hydrogen surface coverage ( Θ H ), resembling a more realistic model of a catalyst. H 2 dissociation rates were analyzed as a function of the reaction temperature. Overall, the results show that Pt/C-WC and Pt/Mo-Mo 2 C have a Pt-like behavior for H 2 dissociation at Θ H > 1/2 ML. At a particular temperature of 298 K, Pt/C-WC and Pt/Mo-Mo2C have low energy barriers for H 2 * → 2H* (0.13 and 0.11 eV, respectively), close to the value of Pt (0.06 eV). For the highest coverage, i.e. Θ H = 1, Pt/C-WC has a lower activation energy and a higher reaction rate than Pt. Finally, the H 2 dissociation rate is higher in Pt/Mo-Mo 2 C than in Pt when increasing the temperature above 298 K. Our results put Pt/C-WC and Pt/Mo-Mo 2 C under the spotlight as potential catalysts for H 2 dissociation, with a similar performance to Pt, paving the way for further experimental and/or theoretical studies, addressing the capability of Pt/TMC as practical catalysts in hydrogenation reactions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Constraining Black Carbon Aging in Global Models to Reflect Timescales for Internal Mixing

The radiative effects of black carbon depend critically on its atmospheric lifetime, which is controlled by the rate at which freshly emitted combustion particles become internally mixed with other aerosol components. Global aerosol models strive to represent this process, but the timescale for aerosol mixing is not easily constrained using observations. In this study, we apply a timescale parameterization derived from particle‐resolved simulations to quantify, in a global aerosol model, the timescale for internal mixing. We show that, while highly variable, the average timescale for internal mixing is approximately 3 hr, which is much shorter than the 24‐hr aging timescale traditionally applied in bulk aerosol models. We then use the mixing timescale to constrain the aging criterion in the Modal Aerosol Module. Our analysis reveals that, to best reflect timescales for internal mixing, modal models should assume that particles transition from the hydrophobic (fresh) to the hydrophilic (aged) class once they accumulate a coating thickness equal to four monolayers of sulfuric acid, as opposed to the model's current aging criterion of eight monolayers. We show that, in remote regions like the Arctic and Antarctic, predictions of black carbon loading and its seasonal variation are particularly sensitive to the model representation of aging. By constraining aging in global models to reflect mixing timescales simulated by the particle‐resolved model, we eliminate one of the free parameters governing black carbon's long‐range transport and spatiotemporal distribution.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2017

Experimental Verification of Buffet Calculation Procedure Using Unsteady Pressure-Sensitive Paint

Typically, a limited number of dynamic pressure sensors is employed to determine the unsteady aerodynamic forces on large, slender aerospace structures. This paper describes a robust calculation procedure based on frequency-specific correlation lengths and validation from an experiment conducted on a flat panel coated with fast response pressure-sensitive paint. The first part of the paper describes the procedure used to analyze the pressure sensitive paint images and a calibration method using dynamic pressure transducers. Excellent comparison in spectra, coherence, and phase, measured via pressure-sensitive paint and dynamic pressure sensors, validates the pressure-sensitive paint data. The second part of the paper describes the buffet validation process, the first step of which was to use pressure histories from all pixels to determine the true force fluctuations. In the next step, only a selected number of pixels was chosen as virtual sensors, and a correlation-length-based buffet calculation procedure was applied to determine modeled force fluctuations. By progressively decreasing the number of virtual sensors, it was observed that the present calculation procedure was able to make a close estimate of the true unsteady forces only from eight sensors. It is believed that the present work provides the first validation of a buffet calculation procedure.

Buffet↗
NASA NTRS1985

Processing of Complex Compound Semiconductors in Space

The purpose of this first year ground based research effort was to develop growth and characterization facilities for bulk single crystals of compound semiconductor alloys. As a system of 2-6 alloy crystal growth, C sub x Mn sub (1-x)Te was chosen since it has a relatively narrow solidus-liquidus separation serving as a suitable first model for zone melting and solution growth. Also, it allows, in principle, perfect lattice matching to Cd sub x Hg sub(1-x)Te that needs to be studied as a model for the investigation of heteroepitaxial growth from Te-solutions. A vertical zone melting furnace was built and used in the synthesis of Cd sub x Mn sub(1-x)Te from the elements and crystal growth in carbon coated fused silica crucibles of Bridgman growth geometry. Photoluminescence spectra of the crystals reveal band to band recombination at energies that agree with the reported literature data. In addition, deep luminescence is present at energies corresponding to proportional shifts from the 1.4 eV deep emission observed for bulk single crystals of CdTe.

Bachmann, K.↗
DOE OSTI2024

Fuel Performance Modeling Plan to Support the Advance Gas Reactor Program

This report documents the current status of the fuel performance modeling initiative to support the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program in the development of tristructural-isotropic-coated fuel particles. It includes a brief summary of the codes that have been developed to support tristructural isotropic modeling along with a summary of the behavior of fuel particles during irradiation and the modeling used to capture these effects. In addition, this report identifies further modeling and material property needs for further development based on experience from previously performed AGR experiments. In general, the remaining activities to support fuel performance modeling for the AGR program include continued AGR experiment support for AGR-3/4 and AGR-5/6/7 as well as modeling improvements identified throughout the course of the program. These modeling improvements can be summarized as thermomechanical particle behavior and fission product transport. Additional modeling needs may be identified while processing the data collected during the AGR post-irradiation examination campaign and may lead to further improvements that are not included in this report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1986

Micromechanisms of thermomechanical fatigue: A comparison with isothermal fatigue

Thermomechanical Fatigue (TMF) experiments were conducted on Mar-M 200, B-1900, and PWA-1480 (single crystals) over temperature ranges representative of gas turbine airfoil environments. The results were examined from both a phenomenological basis and a micromechanical basis. Depending on constituents present in the superalloy system, certain micromechanisms dominated the crack initiation process and significantly influenced the TMF lives as well as sensitivity of the material to the type TMF cycle imposed. For instance, high temperature cracking around grain boundary carbides in Mar-M 200 resulted in short in-phase TMF lives compared to either out-of-phase or isothermal lives. In single crystal PWA-1480, the type of coating applied was seen to be the controlling factor in determining sensitivity to the type of TMF cycle imposed. Micromechanisms of deformation were observed over the temperature range of interest to the TMF cycles, and provided some insight as to the differences between TMF damage mechanisms and isothermal damage mechanisms. Finally, the applicability of various life prediction models to TMF results was reviewed. Current life prediction models based on isothermal data must be modified before being generally applied to TMF.

Bill, R. C.↗
NASA NTRS1994

High-temperature behavior of advanced spacecraft TPS

The objective of this work has been to develop more efficient, lighter weight, and higher temperature thermal protection systems (TPS) for future reentry space vehicles. The research carried out during this funding period involved the design, analysis, testing, fabrication, and characterization of thermal protection materials to be used on future hypersonic vehicles. This work is important for the prediction of material performance at high temperature and aids in the design of thermal protection systems for a number of programs including programs such as the National Aerospace Plane (NASP), Pegasus and Pegasus/SWERVE, the Comet Rendezvous and Flyby Vehicle (CRAF), and the Mars mission entry vehicles. Research has been performed in two main areas including development and testing of thermal protection systems (TPS) and computational research. A variety of TPS materials and coatings have been developed during this funding period. Ceramic coatings were developed for flexible insulations as well as for low density ceramic insulators. Chemical vapor deposition processes were established for the fabrication of ceramic matrix composites. Experimental testing and characterization of these materials has been carried out in the NASA Ames Research Center Thermophysics Facilities and in the Ames time-of-flight mass spectrometer facility. By means of computation, we have been better able to understand the flow structure and properties of the TPS components and to estimate the aerothermal heating, stress, ablation rate, thermal response, and shape change on the surfaces of TPS. In addition, work for the computational surface thermochemistry project has included modification of existing computer codes and creating new codes to model material response and shape change on atmospheric entry vehicles in a variety of environments (e.g., earth and Mars atmospheres).

Pallix, Joan↗
NASA NTRS2021

Pluto’s Sputnik Planitia: Composition of geological units from infrared spectroscopy

We have compared spectroscopic data of Sputnik Planitia on Pluto, as acquired by New Horizons’ Linear Etalon Imaging Spectral Array (LEISA) instrument, to the geomorphology as mapped by White et al. (2017) using visible and panchromatic imaging acquired by the LOng-Range Reconnaissance Imager (LORRI) and the Multi-spectral Visible Imaging Camera (MVIC). We have focused on 13 of the geologic units identified by White et al. (2017), which include the plains and mountain units contained within the Sputnik basin. We divided the map of Sputnik Planitia into 15 provinces, each containing one or more geologic units, and we use LEISA to calculate the average spectra of the units inside the 15 provinces. Hapke-based modeling was then applied to the average spectra of the units to infer their surface composition, and to determine if the composition resulting from the modeling of LEISA spectra reflects the geomorphologic analyses of LORRI data, and if areas classified as being the same geologically, but which are geographically separated, share a similar composition. We investigated the spatial distribution of the most abundant ices on Pluto’s surface - CH4, N2, CO, H2O, and a non-ice component presumed to be a macromolecular carbon-rich material, termed a tholin, that imparts a positive spectral slope in the visible spectral region and a negative spectral slope longward of ~1.1 μm. Because the exact nature of the non-ice component is still debated and because the negative spectral slope of the available tholins in the near infrared does not perfectly match the Pluto data, for spectral modeling purposes we reference it generically as the negative spectral slope endmember (NSS endmember). We created maps of variations in the integrated band depth (from LEISA data) and areal mass fraction (from the modeling) of the components. The analysis of correlations between the occurrences of the endmembers in the geologic units led to the observation of an anomalous suppression of the strong CH4 absorption bands in units with compositions that are dominated by H2O ice and the NSS endmember. Exploring the mutual variation of the CH4 and N2 integrated band depths with the abundance of crystalline H2O and NSS endmember revealed that the NSS endmember is primarily responsible for the suppression of CH4 absorptions in mountainous units located along the western edge of Sputnik Planitia. Our spectroscopic analyses have provided additional insight into the geological processes that have shaped Sputnik Planitia. A general increase in volatile abundance from the north to the south of Sputnik Planitia is observed. Such an increase first observed and interpreted by Protopapa et al., 2017 and later confirmed by climate modeling (Bertrand et al., 2018) is expressed geomorphologically in the form of preferential deposition of N2 ice in the upland and mountainous regions bordering the plains of southern Sputnik Planitia. Relatively high amounts of pure CH4 are seen at the southern Tenzing Montes, which are a natural site for CH4 deposition owing to their great elevation and the lower insolation they are presently receiving. The NSS endmember correlates the existence of tholins within certain units, mostly those coating the low-latitude mountain ranges that are co-latitudinal with the tholin-covered Cthulhu Macula. The spectral analysis has also revealed compositional differences between the handful of occurrences of northern non-cellular plains and the surrounding cellular plains, all of which are located within the portion of Sputnik Planitia that is presently experiencing net sublimation of volatiles, and which do not therefore exhibit a surface layer of bright, freshly-deposited N2 ice. The compositional differences between the cellular and non-cellular plains here hint at the effectiveness of convection in entraining and trapping tholins within the body of the cellular plains, while preventing the spread of such tholins to abutting non-cellular plains.

Pluto's Sputnik Planitia↗
NASA NTRS2002

Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines require materials that can meet high temperatures while resisting the corrosive oxidation-reduction reaction of combustion known as blanching, the main cause of engine failure. A project was initiated at NASA-Marshal Space Flight Center (MSFC) to combine three existing technologies to build and demonstrate an advanced liquid rocket engine combustion chamber that would provide a 100 mission life. Technology developed in microgravity research to build cartridges for space furnaces was utilized to vacuum plasma spray (VPS) a functional gradient coating on the hot wall of the combustion liner as one continuous operation, eliminating any bondline between the coating and the liner. The coating was NiCrAlY, developed previously as durable protective coatings on space shuttle high pressure fuel turbopump (HPFTP) turbine blades. A thermal model showed that 0.03 in. NiCrAlY applied to the hot wall of the combustion liner would reduce the hot wall temperature 200 F, a 20% reduction, for longer life. Cu-8Cr-4Nb alloy, which was developed by NASA-Glenn Research Center (GRC), and which possesses excellent high temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability, was utilized as the liner material in place of NARloy-Z. The Cu-8Cr-4Nb material exhibits better mechanical properties at 650 C (1200 F) than NARloy-Z does at 538 C (1000 F). VPS formed Cu-8Cr-4Nb combustion chamber liners with a protective NiCrAlY functional gradient coating have been hot fire tested, successfully demonstrating a durable coating for the first time. Hot fire tests along with tensile and low cycle fatigue properties of the VPS formed combustion chamber liners and witness panel specimens are discussed.

Holmes, Richard↗
NASA NTRSDate not supplied

AI-Enhanced Computational Tools for Entry Systems Modeling

To advance the understanding of complex atmospheric entry phenomena, NASA’s Entry Systems Modeling (ESM) team [1] has developed high-fidelity computational tools addressing multiscale challenges, from material microstructures to full-scale heatshield response. This abstract highlights a subset of ESM tools, focusing on AI integration to enhance workflows and predictive modeling. - PuMA [2] computes effective material properties from high-resolution micro-CT scans, supporting TPS analysis for NASA missions. - TomoSAM [3] automates 3D tomography dataset segmentation for PuMA using the Segment Anything Model, reducing manual effort and improving accuracy. - PATO [4] models porous reactive materials under extreme conditions, with advancements such as unified solvers, mechanical erosion, and TPS coatings for NASA missions. - arcjetCV [5] employs deep learning to analyze arc jet test footage, measuring recession rates, shape changes, and shock standoff distances, bridging simulations, and experiments to reveal TPS ablation behavior. - ARCHeS [6] simulates arc heater plasma flows, modeling turbulence, radiation, and electromagnetic interactions to optimize arc heater performance, validate TPS under extreme conditions, and serve as a foundation for developing digital twins of arc heater facilities. - SPARTA [7] simulates rarefied hypersonic flows and gas-surface interactions for planetary entry missions, leveraging GPU architectures for scalable and efficient aerothermal and ablation analyses. AI-driven solutions, such as deep learning segmentation, have streamlined workflows in ESM tools and still hold significant potential to further accelerate processes and enhance automation in entry systems modeling. [1] Haskins, J.B. (2023), [2] Ferguson, J.C. (2018), [3] Meurisse, J.B.E. (2018), [4] Semeraro, F. (2023), [5] Quintart, A. (2024) [6] Meurisse, J.B.E. (2022), [7] Plimpton, S.J. (2019)

Predictive Modeling↗
NASA NTRS2001

Adjustable Focus Optical Correction Lens (AFOCL)

This report describes a metrology plan that was developed for the characterization of PLZT-based devices, such as the Adjustable Focus Optical Correction Lens (AFOCL) in support of and as part of the deliverables for NASA contract NAS8-00118. The areas to be investigated include intensiometric effects (those that limit or alter the intensity of the light transmitted through the optic); interferometric effects (the phase change induced through the optic); and polarimetric effects (evaluating the differential lag between two polarization states propagating through the optic). These distinct phenomena are often coupled together in real applications consequently, there is a need to develop different standardized testing apparatus to: (1) isolate one effect from another; (2) gather information for understanding the physical effects; (3) anchor wavefront corrector modeling efforts; (4) develop the ability to decouple different effects; (5) demonstrate the suitability of PLZT technology to perform wavefront correction. The Center for Applied Optics (CAO) at the University of Alabama in Huntsville (UAH) is skilled in the characterization of transmission wavefront shaping devices using traditional interferometers available within the CAO Optical Metrology Laboratory and their Advanced Polarization Test Facility. Besides the imaging and interferometers available, the polarimetry facility has at its disposal, a Mueller Matrix Imaging Polarimeter (MMIP) which is well suited to the characterization of SLMs, polarizers, and thin film coatings within the visible and near-IR spectrums. In addition, the phase-shifting interferometry facilities at NASA-MSFC and the unique interferometers they processes are some of the most advanced available and may be of value especially for performing real-time optical performance evaluation of AFOCL test components.

Peters, Bruce R.↗
NASA NTRS2006

Impact Damage and Strain Rate Effects for Toughened Epoxy Composite Structures

Structural integrity of composite systems under dynamic impact loading is investigated herein. The GENOA virtual testing software environment is used to implement the effects of dynamic loading on fracture progression and damage tolerance. Combinations of graphite and glass fibers with a toughened epoxy matrix are investigated. The effect of a ceramic coating for the absorption of impact energy is also included. Impact and post impact simulations include verification and prediction of (1) Load and Impact Energy, (2) Impact Damage Size, (3) Maximum Impact Peak Load, (4) Residual Strength, (5) Maximum Displacement, (6) Contribution of Failure Modes to Failure Mechanisms, (7) Prediction of Impact Load Versus Time, and (8) Damage, and Fracture Pattern. A computer model is utilized for the assessment of structural response, progressive fracture, and defect/damage tolerance characteristics. Results show the damage progression sequence and the changes in the structural response characteristics due to dynamic impact. The fundamental premise of computational simulation is that the complete evaluation of composite fracture requires an assessment of ply and subply level damage/fracture processes as the structure is subjected to loads. Simulation results for the graphite/epoxy composite were compared with the impact and tension failure test data, correlation and verification was obtained that included: (1) impact energy, (2) damage size, (3) maximum impact peak load, (4) residual strength, (5) maximum displacement, and (6) failure mechanisms of the composite structure.

Chamis, Christos C.↗
DOE OSTI2024

Bench-Scale Development of a Novel Direct Air Capture Technology Using High-Capacity Structured Sorbents

The work performed under this project has resulted into development of a DAC technology utilizing a structured sorbent to capture CO 2 from ambient air with a key innovation of direct Joule heating of the sorbent for CO 2 desorption. A working SMA, fully integrated with an electrically resistive heating layer, high surface area support, and high CO 2 capacity sorbent coated onto a commercial ceramic monolithic substrate, was successfully developed and demonstrated over >200 adsorption-desorption cycles in a high-fidelity bench test unit directly using ambient air. A cordierite-based monolith was selected as a substrate owing to its high surface area, low bulk density, low heat capacity, and commercial availability. Reaction kinetics study conducted during this project led to development of a promoter for the base Na 2 CO 3 sorbent that could be incorporated into the sorbent to enhance to achieve higher CO 2 adsorption/desorption rates, greater working capacity, and reduced regeneration temperature. An accelerated aging study was conducted in a TGA to determine sorbent stability and no degradation in the sorbent performance was observed even after 250 adsorption-desorption cycles. An electrically resistive heating layer was developed with tunable electrical properties. The heating layer was coated onto the selected cordierite substrate. Aging studies performed showed the electrical properties and heating performance was stable after 500 heating and cooling cycles. The collective findings on the selected cordierite substrate, robust heating layer, promoter and sorbent selection were used to synthesize a full, 6”x6” SMA for bench-scale testing. The bench-scale DAC system was constructed to test full size SMAs using real ambient air for adsorption and joule heating for regeneration. After completing shakedown and commissioning of the 1 kg/day of CO 2 capacity DAC bench unit, an extended operation was performed to complete over 230 cycles with the full size SMA. This testing showed no observable degradation in sorbent performance. A detailed process model, TEA and LCA were developed for a conceptual 100,000 TPY CO 2 removal DAC facility. The LCA results show the net CO 2 e emissions from the DAC system are highly dependent on the electricity source. All other factors, including SMA manufacturing, materials for facility enclosure, etc., are minor cost contributors compared to the energy consumption required for CO 2 removal. With the successful development and validation of the SMA for the sustained performance for CO 2 removal from ambient air with joule heated regeneration in this project, a fully integrated 1 TPY bench-scale DAC system is currently in development with the support of DOE/FECM (DE-FE0032243). The project objective is to demonstrate the engineering design of the DAC system to produce a continuous, high purity CO 2 stream from ambient air. This project will address and validate key engineering features of the DAC system including the gas sealing mechanism and panels, enclosure and air contactor design, and automation sequence to achieve continuous CO 2 production.

42 ENGINEERING↗