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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 37 records · Page 2

Advanced fabrication techniques for cooled engine structures

An improved design for regeneratively cooled engine structures was identified. This design uses photochemically machined (PCM) coolant passages. It permits the braze joint to be placed in a relatively cool area, remote from the critical hot face sheet. The geometry of the passages at the face sheet also minimizes stress concentration and, therefore, enhances the low cycle fatigue performance. The two most promising alloys identified for this application are Inconel 617 and Nickel 201. Inconel 617 was selected because it has excellent creep rupture properties, while Nickel 201 was selected because of its predicted good performance under low cycle fatigue loading. The fabrication of the PCM coolant passages in both Inconel 617 and Nickel 201 was successfully developed. During fabrication of Inconel 617, undesirable characteristics were observed in the braze joints. A development program to resolve this condition was undertaken and led to definition of an isothermal solidification process for joining Inconel 617 panels. This process produced joints which approach parent metal strength and homogeneity.

Buchmann, O. A.↗

Thermo-oxidative stability of graphite fiber/PMR-15 polyimide composites at 350 deg C

A series of graphite fiber/PMR-15 polyimide composites were subjected to isothermal aging at 350 C in flowing air (100 cc/min and 1000 cc/min) over a 520 hr time period. The graphite fibers were analyzed by ISS/SIMS techniques before composite fabrication. Fibers exposed at the surface of the composite due to the isothermal aging process were also analyzed by the ISS/SIMS method. Component and composite weight less studies were also conducted for similarly exposed materials. Optical micrograph investigations of composites to follow the progress of the thermo-oxidative process were also conducted. Flexural and interlaminar shear strengths of the imaged and aged composites were measured. The relationship of component and composite properties as they relate to the thermo-oxidative behavior of the materials was discussed.

Scola, D. A.↗

Non-Isothermal Experimental Study of the Constrained Vapor Bubble Thermosyphon

Experimental and theoretical techniques to study non-isothermal transport processes in the constrained vapor bubble thermosyphon (CVBT) were developed using a pentane/quartz system. The transport processes can be evaluated by measuring the liquid film profile, which gives the pressure field, and the temperature field. The axial variation in the capillary pressure was measured using an image-analyzing interferometer that is based on computer-enhanced video microscopy of the naturally occurring interference fringes. Thermoelectric coolers were used to control the temperature level in the condensation region and, therefore, the length of the approximately 'adiabatic' surface region which is a function of the temperature difference between the CVBT surface and the surroundings. High values for the axial thermal conductance in the 'adiabatic' surface region were demonstrated under certain conditions.

Karthikeyan, Muthu↗

Adsorption Thermodynamics for Process Simulation

Adsorption has rapidly evolved in recent decades and is an established separation technology extensively practiced in gas separation industries and others. However, rigorous thermodynamic modeling of multicomponent adsorption equilibrium remains elusive, and industrial practitioners rely heavily on expensive and time-consuming trial-and-error pilot studies to develop adsorption units. Here, this article highlights the need for rigorous adsorption thermodynamic models and the limitations and deficiencies of existing models such as the extended Langmuir isotherm, dual-process Langmuir isotherm, and adsorbed solution theory. It further presents a series of recent advances in the generalization of the classical Langmuir isotherm of single-component adsorption by deriving an activity coefficient model to account for the adsorbed phase adsorbate–adsorbent interactions, substituting adsorbed phase adsorbate and vacant site concentrations with activities, and extending to multicomponent competitive adsorption equilibrium, both monolayer and multilayer. Requiring a minimum set of physically meaningful model parameters, the generalized Langmuir isotherm for monolayer adsorption and the generalized Brunauer–Emmett–Teller isotherm for multilayer adsorption address various thermodynamic modeling challenges including adsorbent surface heterogeneity, isosteric enthalpies of adsorption, BET surface areas, adsorbed phase nonideality, adsorption azeotrope formation, and multilayer adsorption. Also discussed is the importance of quality adsorption data that cover sufficient temperature, pressure, and composition ranges for reliable determination of the model parameters to support adsorption process simulation, design, and optimization.

09 BIOMASS FUELS↗

Structure-property characterization of rheocast and VADER processed IN-100 superalloy

Two recent solidification processes have been applied in the production of IN-100 nickel-base superalloy: rheocasting and vacuum arc double electrode remelting (VADER). A detailed microstructural examination has been made of the products of these two processes; associated tensile strength and fatigue crack propagation (FCP) rate at an elevated temperature were evaluated. In rheocasting, processing variables that have been evaluated include stirring speed, isothermal stirring time and volume fraction solid during isothermal stirring. VADER processed IN-100 was purchased from Special Metals Corp., New Hartford, NY. As-cast ingots were subjected to hot isostatic pressing (HIP) and heat treatment. Both rheocasting and VADER processed materials yield fine and equiaxed spherical structures, with reduced macrosegregation in comparison to ingot materials. The rheocast structures are discussed on the basis of the Vogel-Doherty-Cantor model of dendrite arm fragmentation. The rheocast ingots evaluated were superior in yield strength to both VADER and commercially cast IN-100 alloy. Rheocast and VADER ingots may have higher crack propagation resistance than P/M processed material.

Cheng, J. J. A.↗

Crystal Microbalance Monitors Relative Humidity

Sensor monitors water evaporation in industrial drying processes. Measured adsorption isotherm for instrument essentially linear over entire range of relative humidity. Testing at each temperature setting less than half hour for full relative-humidity range, with estimated frequency response time less than 10 seconds. Used to measure relative humidity of ambient atmosphere near drying paper, food textile fabrics and pulp to optimize water-drying portion of processing cycle.

Yang, L. C.↗

Effects of temperature inversion on densification in chemical vapor infiltration

In a classical chemical vapor infiltration (CVI) process, the competing effects of chemical kinetics and reagent gas transport lead to non–uniform depositions such that outer layers of a preform densify faster leaving the core highly porous. Currently, CVI must be performed at a sufficiently low temperature to achieve good densification quality which leads to high processing time and cost. Volumetric heating of the preform, especially through microwaves, can create temperature inversion such that the core is hotter than the outer surface and potentially, overcome the challenges associated with isothermal CVI. Direct numerical simulations (DNS) of densification under various such temperature distributions indicate that microwave heating in CVI processing can lead to better (uniform) densification of porous preforms. Here the role of key parameters describing the temperature distributions on the densification behavior is investigated. Strategic temporal control of the temperature distribution shows that processing times can be reduced by almost half while maintaining a good densification quality similar to that of low–temperature isothermal processing. Inside–out densification due to the inverted temperature profile is a key distinguishing characteristic of microwave assisted CVI.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

An Overview of the Thermal Challenges of Designing Microgravity Furnaces

In the last few years, Marshall Space Flight Center has become heavily involved in a wide variety of microgravity projects that require furnaces, with hot zone temperatures ranging from 300 C to 2300 C, requirements for isothermal and gradient processing, and both semi-conductor and metal materials. On these types of projects, the thermal engineer is a key player in the design process. These furnaces present unique challenges to the thermal designer. One challenge is designing a sample containment system that achieves dual containment, yet allows a high radial heat flux. Another challenge is providing a high axial gradient but a very low radial gradient. These furnaces also present unique challenges to the thermal analyst. First, there are several orders of magnitude difference in the size of the thermal "conductors" between various parts of the model. A second challenge is providing high fidelity in the sample model, and connecting the sample with the rest of the furnace model, yet maintaining some sanity in the number of total nodes in the model. The purpose of this paper is to present an overview of the challenges involved in designing and analyzing microgravity furnaces and how some of these challenges have been overcome. The thermal analysis tools presently used to analyze microgravity furnaces and how they have been applied will be explained. Challenges for the future and a description of future analysis tools will be given.

Westra, Douglas G.↗

Dissociation and Internal Excitation of Molecular Nitrogen Due to N + N2 Collisions Using Direct Molecular Simulation

In this work we present a molecular level study of N2+N collisions, focusing on excitation of internal energy modes and non-equilibrium dissociation. The computation technique used here is the direct molecular simulation (DMS) method and the molecular interactions have been modeled using an ab−initio potential energy surface (PES) developed at NASA's Ames Research Center. We carried out vibrational excitation calculations between 5000K and 30000K and found that the characteristic vibrational excitation time for the N + N2 process was an order of magnitude lower than that predicted by the Millikan and White correlation. It is observed that during vibrational excitation the high energy tail of the vibrational energy distribution gets over populated first and the lower energy levels get populated as the system evolves. It is found that the non-equilibrium dissociation rate coefficients for the N + N2 process are larger than those for the N2 + N2 process. This is attributed to the non-equilibrium vibrational energy distributions for the N + N2 process being less depleted than that for the N2 +N2 process. For an isothermal simulation we find that the probability of dissociation goes as 1/T(sub tr) for molecules with internal energy (epsilon(sub int)) less than approximately 9.9eV, while for molecules with epsilon (sub int) greater than 9.9eV the dissociation probability was weakly dependent on translational temperature of the system. We compared non-equilibrium dissociation rate coefficients and characteristic vibrational excitation times obtained by using the ab-initio PES developed at NASA's Ames Research Center to those obtained by using an ab-initio PES developed at the University of Minnesota. Good agreement was found between the macroscopic properties and molecular level description of the system obtained by using the two PESs.

Grover, Maninder S.↗

Predicting Multicomponent Aqueous Phase Adsorption Equilibria of Organic Acids Using the Generalized Brunauer–Emmett–Teller Isotherm Model

Here, to support process development of adsorptive separation of organic acids, this work presents a thermodynamic modeling methodology to predict multicomponent aqueous phase organic acid adsorption equilibria from single-component adsorption isotherms using the generalized Brunauer–Emmett–Teller isotherm model (gBET). With the organic acid fugacities rigorously accounting for the aqueous phase organic acid solution chemistry and solution nonideality, gBET precisely represents the single-component adsorption isotherms and accurately predicts the binary and ternary mixed-acid adsorption equilibria for the ranges of initial pH (∼3–7), acid concentration (100–400 mmol/L), and temperature (298.15–328.15 K) with less than 10% average absolute relative deviation. In addition, gBET with pH-independent parameters provides insights into the underlying adsorption phenomena, including the adsorbate loadings and compositions in the monolayer and subsequent layers under varying initial pH, temperature, concentration, and composition. The gBET model predictions outperform the predictions from the overloading model and the Ideal Dilute Solution Theory.

09 BIOMASS FUELS↗

Enhanced Boiling on Micro-Configured Composite Surfaces Under Microgravity Conditions

In order to accommodate the growing thermal management needs of future space platforms, several two-phase active thermal control systems (ATCSs) have evolved and were included in the designs of space stations. Compared to the pumped single-phase liquid loops used in the conventional Space Transportation System and Spacelab, ATCSs offer significant benefits that may be realized by adopting a two-phase fluid-loop system. Alternately, dynamic power systems (DPSs), based on the Rankine cycle, seem inevitably to be required to supply the electrical power requirements of expanding space activities. Boiling heat transfer is one of the key technologies for both ATCSs and DPSs. Nucleate boiling near critical heat flux (CHF) can transport very large thermal loads with much smaller device size and much lower pumping power. However, boiling performance deteriorates in a reduced gravity environment and operation in the CHF regime is precarious because any slight overload will cause the heat transfer to suddenly move to the film boiling regime, which in turn, will result in burnout of the heat transfer surfaces. New materials, such as micro-configured metal-graphite composites, can provide a solution for boiling enhancement. It has been shown experimentally that this type of material manifests outstanding boiling heat transfer performance and their CHF is also extended to higher values. Due to the high thermal conductivity of graphite fiber (up to 1,200 W/m-K in the fiber direction), the composite surfaces are non-isothermal during the boiling process. The composite surfaces are believed to have a much wider safe operating region (a more uniform boiling curve in the CHF regime) because non-isothermal surfaces have been found to be less sensitive to variations of wall superheat in the CHF regime. The thermocapillary forces formed by the temperature difference between the fiber tips and the metal matrix play a more important role than the buoyancy in the bubble detachment, for the bubble detachment manifests itself by a necking process which should not be weakened by reduced gravity. In addition, the composite surfaces introduce no extra pressure drop, no fouling and do not impose significant primary or maintenance costs. All of these suggest that this type of composite is an ideal material for the challenge of accounting for both reliability and economy of the relevant components applied in the ATCSs, the DPSs and other devices in future space missions. The aim of the proposed work is to experimentally investigate high nucleate pool boiling performance on a micro-configured metal-graphite composite surface and to determine the mechanisms of the nucleate boiling heat transfer both experimentally and theoretically. Freon-113 and water will be used as the test liquids to investigate wettability effects on boiling characteristics. The Cu-Gr and Al-Gr composites with various volume fractions of graphite fibers will be tested to obtain the heat transfer characteristic data in the nucleate boiling region and in the CHF regime. In the experiments, the bubble emission and coalescence processes will be recorded by a video camera with a magnifying borescope probe immersed in the working fluid. The temperature profile in the thermal boundary layer on the composite surfaces will be measured by a group of micro thermocouples consisting of four ultra fine micro thermocouples. This instrument was developed and successfully used to measure the temperature profile of evaporating liquid thin layers by the proposers in a study performed at the NASA/Lewis Research Center. A two tier model to explain the nucleate boiling process and the performance enhancement on the composite surfaces has been suggested by the authors. According to the model, the thicknesses of the microlayer and the macrolayer underneath the bubbles and mushrooms, can be estimated by the geometry of the composite surface. The experimental results will be compared to the predictions from the model, and in turn, to revise and improve it.

Zhang, Nengli↗

Effect of Composition Variation on Isothermal Rapid Curing Resins for Aerospace Applications

To meet the projected demand for single-aisle composite aircraft in 2040, the production rate of these aircraft will need to increase by four to six times what is currently achievable. A composite manufacturing process with the potential to enable the targeted rates is isothermal resin infusion where infusion and cure occur at the same temperature. However, presently there is not an accepted aerospace-grade resin that can support this isothermal infusion process and maintain acceptable resin properties. Therefore, resin development initiatives have designed anionic catalyzed epoxy systems capable of isothermal infusion and rapid cure at a temperature below 100 ˚C in one hour. High-performance aerospace properties are achieved after undergoing a freestanding post-cure. The resins facilitate faster, energy efficient production cycles by reducing the time and temperature required for cure and eliminating temperature ramps typically required of materials used in the aerospace industry. This work discusses several of the developed resin systems and the impact of varying composition on rheological, thermal, and mechanical properties. Carbon fiber composites were fabricated for one composition by resin transfer molding to demonstrate the potential of these isothermal, rapid cure systems for meeting industry needs.

resin transfer molding↗

Experimental and Theoretical Thermokinetic Analysis of the Na 3 VO 4 –CO 2 Reaction System under Different Physicochemical Conditions

Sodium vanadate (Na 3 VO 4 ) was synthesized, structural and microstructurally characterized as well as tested as possible carbon dioxide (CO 2 ) captor through thermodynamic calculations in addition to thermogravimetric dynamic and isothermal analyses. Ceramic structural characterization evidenced the formation of the Na 3 VO 4 crystal phase, while microstructural features evidenced dense agglomerates with a poor specific surface area, although synthesis temperature (600 °C) was not as high as that for other sodium ceramics. Na 3 VO 4 was investigated for the CO 2 capture process through dynamic and isothermal experiments, in the presence or absence of oxygen. All these experiments showed that Na 3 VO 4 possesses interesting CO 2 capture properties in a specific temperature range (520 and 600 °C). Isothermal products characterization allowed to elucidate the reaction pathway, implying the Na 4 V 2 O 7 formation, as possible reactive intermediate. In fact, reaction path evolution was supported with theoretical thermodynamic data. Moreover, the kinetic analysis, performed using the Avrami-Erofeev mathematical model and subsequent thermodynamic data obtention, probed the positive influence of the temperature, in both CO 2 superficial and bulk chemical sorption processes, while oxygen addition did not enhance the superficial process. Additionally, as it would be expected, kinetics were enhanced as a function of the CO 2 concentration.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

CMPO-Functionalized Silica Sorbents for pH-Tunable Separation and Enrichment of Rare-Earth Elements from Environmental Matrices

Rare-earth elements (REEs) are crucial in many applications, yet mutual separation is challenging due to their similar chemical behavior. Octylphenyl- N,N-diisobutyl carbamoyl methyl phosphine oxide (CMPO) is an organophosphorus ligand originally developed for extracting actinides and lanthanides from spent nuclear fuel. Here, we report a pH-tunable CMPOfunctionalized silica sorbent for selective REE separation from complex aqueous matrices. A CMPO-associated silica gel sorbent was synthesized and characterized by Brunauer−Emmett−Teller (BET) surface area, scanning electron microscopy, and X-ray photoelectron spectroscopy to confirm the surface functionalization and binding behavior. Sorbent performance was evaluated by using a synthetic 46- element solution and a real phosphate rock fertilizer leachate. Notably, REEs were successfully eluted with ultrapure water, demonstrating reversible desorption controlled by pH adjustment. Packed-bed column studies increased the REE mass fraction from 3.6% to 64% (20-fold enrichment), with up to 30-fold enrichment of neodymium. The adsorption process follows the Langmuir isotherm behavior and follows pseudo-second-order kinetics. The uptake capacity of 1 μmol of REEs per 4.2 μmol of CMPO supports the formation of a predominantly 4:1 ligand:rare earth element(III) pseudocomplex. These results demonstrate CMPO-functionalized silica as a selective, water-elutable, and low-chemical-input platform for sustainable REE recovery from environmental and industrial sources.

chelating ligands↗