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NASA NTRS2021

An Investigation of the Grain Size and Adhesion Strength of High-Speed Impact Ice

Ice accumulation on aircraft from supercooled water droplets (impact icing) can increase drag and decrease lift, leading to a decrease in fuel efficiency and a potential for unsafe situations. Anti-icing materials and coatings are of high interest to prevent aircraft icing. Because no anti-icing material suitable for in-flight situations has been realized, icing models aim to predict the accumulation and shape of the ice to understand its effects. In both cases, understanding the physical mechanism behind ice adhesion and shedding is necessary. A recent literature review has shown that the apparent ice adhesion strength to any specific material varies over several orders of magnitude across studies and test methods. One of the reasons for this high variance is likely to be the varying microstructure of the ice used for different studies. Although the microstructure of impact ice has been studied in the past, those conditions were not relevant to that of in-flight aircraft icing. The microstructure of the ice formed will determine both its bulk and surface properties, yet it has been overlooked in the ice adhesion community. Here, we use optical microscopy to study the non-uniform ice crystal grain size in impact ice accreted in NASA Glenn Research Center’s Icing Research Tunnel at various icing conditions. Similar to other environmental conditions studied in the literature, we show an increase in grain size at larger distances from the growth interface; however, the data shows substantially larger grains than what was expected from the prior literature. Ice accrued at lower temperatures has a smaller grain size at all distances from the growth interface. No change in grain size was noticed when varying only the wind speed. A correlational analysis shows that smaller grain sizes at the growth interface corresponded to an increase in the apparent ice adhesion strength when the adhesive failure was interfacial, but not when the failure was cohesive. These results may explain the overall trend in the literature of increasing apparent adhesion strength with decreasing temperature. Incorporating microstructure trends for various environmental conditions in icing models may increase the certainty in predicting ice adhesion strength and shedding, and will provide a better basis for comparison between adhesive tests on ice produced in different facilities and at different storage times.

• Ice Fabric↗

NASA NTRS2014

Hydrogen-Bonding Surfaces for Ice Mitigation

Ice formation on aircraft, either on the ground or in-flight, is a major safety issue. While ground icing events occur predominantly during the winter months, in-flight icing can happen anytime during the year. The latter is more problematic since it could result in increased drag and loss of lift. Under a Phase I ARMD NARI Seedling Activity, coated aluminum surfaces possessing hydrogen-bonding groups were under investigation for mitigating ice formation. Hydroxyl and methyl terminated dimethylethoxysilanes were prepared via known chemistries and characterized by spectroscopic methods. These materials were subsequently used to coat aluminum surfaces. Surface compositions were based on pure hydroxyl and methyl terminated species as well as mixtures of the two. Coated surfaces were characterized by contact angle goniometry. Receding water contact angle data suggested several potential surfaces that may exhibit reduced ice adhesion. Qualitative icing experiments performed under representative environmental temperatures using supercooled distilled water delivered via spray coating were inconclusive. Molecular modeling studies suggested that chain mobility affected the interface between ice and the surface more than terminal group chemical composition. Chain mobility resulted from the creation of "pockets" of increased free volume for longer chains to occupy.

Smith, Joseph G., Jr.↗

DOE OSTI2023

Adhesion of impure ice on surfaces

The undesirable buildup of ice can compromise the operational safety of ships in the Arctic to high-flying airplanes, thereby having a detrimental impact on modern life in cold climates. The obstinately strong adhesion between ice and most functional surfaces makes ice removal an energetically expensive and dangerous affair. Hence, over the past few decades, substantial efforts have been directed toward the development of passive ice-shedding surfaces. Conventionally, such research on ice adhesion has almost always been based on ice solidified from pure water. However, in all practical situations, freezing water has dissolved contaminants; ice adhesion studies of which have remained elusive thus far. Here, in this work, we cast light on the fundamental role played by various impurities (salt, surfactant, and solvent) commonly found in natural water bodies on the adhesion of ice on common structural materials. We elucidate how varying freezing temperature & contaminant concentration can significantly alter the resultant ice adhesion strength making it either super-slippery or fiercely adherent. The entrapment of impurities in ice changes with the rate of freezing and ensuing adhesion strength increases as the cooling temperature decreases. We discuss the possible role played by the in situ generated solute enriched liquid layer and the nanometric water-like disordered ice layer sandwiched between ice and the substrate behind these observations. Our work provides useful insights into the elementary nature of impure water-to-ice transformation and contributes to the knowledge base of various natural phenomena and rational design of a broad spectrum of anti-icing technologies for transportation, infrastructure, and energy systems.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Energy Efficiency Improvement Approaches in Ice Related Processes

A detailed survey of ice mold and evaporator metal surfaces, physical structures, operational conditions, materials of construction, design of different equipment was reviewed and analyzed. A reliable test methodology was developed to measure the ice adhesion strength of different materials and geometries identified. The developed test setup was successfully employed in measuring the ice adhesion strength on both tubular and planar substrate geometries of metals including copper, aluminum, stainless steel. Application of advanced polymer materials in lowering the adhesion strength of ice was confirmed where the measured strength was lowered by 50-70% depending on the material and geometry. Additionally, utilization of induced ultrasonic vibration in further lowering the ice harvesting energy was confirmed on multiple materials and geometries. Durability of the coating enhancement was also confirmed in a thermal cycling test under realistic operating conditions.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Generic icing effects on forward flight performance of a model helicopter rotor

An experimental program using a commercially available model helicopter has been conducted in the TAMU 7 ft x 10 ft Subsonic Wind Tunnel to investigate main rotor performance degradation due to generic ice adhesion. Base and iced performance data were gathered as functions of fuselage incidence, blade collective pitch, main rotor rotational velocity, and freestream velocity. The experimental values have shown that, in general, the presence of generic ice introduces decrements in performance caused by leading edge separation regions and increased surface roughness. In addition to the expected changes in aerodynamic forces caused by variations in test Reynolds number, forward flight data seemed to be influenced by changes in freestream and rotational velocity. The dependence of the data upon such velocity variations was apparently enhanced by increases in blade chord.

Tinetti, Ana F.↗

DOE OSTI2024

Energy Efficiency Improvement Approaches in Ice Related Processes

Application and development of energy efficient techniques to separate ice from different surfaces and substrates is of significant value in the context of building equipment performance. A hybrid approach to help dislocate the ice layer using advanced materials and ultrasonic vibration to lower ice adhesion strength was investigated. Application of advanced polymer materials in lowering the adhesion strength of ice was confirmed where the measured strength was lowered by 50-70% depending on the material and geometry. Additionally, utilization of induced ultrasonic vibration in further lowering the ice harvesting energy was confirmed on multiple materials and geometries. Durability of the coating enhancement was also confirmed in a thermal cycling test under realistic operating conditions. Integration of these technical approaches was implemented and validated in commercial ice makers showing energy consumption reduction by ~ 15% to 30% depending on the technical enhancement.

Cheekatamarla, Praveen↗

NASA NTRSDate not supplied

NASA Icing Overview 2023

This presentation summarizes NASA icing research for an invited talk to be presented on June 22, 2023, at the SAE International Conference on Icing of Aircraft, Engines, and Structures. The presentation describes the NASA icing portfolio including facilities and computational tools. In addition, high-level summaries of NASA’s current icing research activities are provided. This includes: (1) Transonic Truss Brace Wing, (2) High Lift Common Research Model, (3) Advanced Air Mobility, (4) Characterization of Low Ice Adhesion Materials, (5) High Ice Water Content Flight Research, (6) Simulated Inter-compressor Duct Research Model, (7) Efficient Quiet Integrated Propulsor. Finally, the presentation summarizes collaboration and partnership opportunities with NASA.

Icing↗

DOE OSTI2021

When SLIPS meets TIPS: An endogenous lubricant-infused surface by taking the diluent as the lubricant

Slippery lubricant-infused porous surfaces (SLIPSs) hold great promise in fields requiring adhesion resistance such as self-cleaning, anti-fouling, anti-icing, and anti-scaling. However, their road to practical application is still blocked by the complicated fabrication process and the restricted coating area. To address these challenges, we propose a new concept of endogenous SLIPS in which the porous structure grows from the solution coating of polypropylene/caprylyl methicone undergoing a thermally induced phase separation (TIPS) process. Caprylyl methicone serves as the diluent during TIPS as well as the lubricant in the SLIPS so that the coating can be fabricated in one step and unrestrictedly. Furthermore, the dissolution and phase separation mechanisms have been revealed by molecular dynamic simulation and in situ microscopic observation. Such SLIPSs exhibits impressive sliding property even for sticky and viscous liquids and exhibit extremely low ice adhesion in anti-icing tests.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRSDate not supplied

The Measurement of Shear Strain in Impact Ice Using a Modified Lap Joint Test and Digital Image Correlation

The results of ice adhesion testing efforts are typically quantified using the maximum shear stress sustained at the interface before the ice detaches from the underlying substrate. While this singular value can be useful for understanding the role icing wind tunnel conditions and substrate surface properties have on the strength of the ice-substrate interface, it does not capture the mechanical behavior of the ice during an experiment. To better understand the deformation of the ice sample and ice-substrate interface during testing, digital image correlation was applied to the lap-joint shear test methodology utilized at NASA Glenn Research Center. Preparation of the sample surface for digital image correlation, initial parsing of the correlation data, and the time synchronization of data from multiple sources are discussed. Using the directional components of deformation measured via digital image correlation, a novel approach to calculating the interfacial shear strain is presented. Results from analyzing several impact ice samples consistently reveals a non-linear response in the ice during mechanical loading which occurs prior to sample delamination, a behavior not observable in the force and displacement data gathered from the testing apparatus. Both the full and small angle forms of the engineering shear strain are evaluated, with the full shear strain form providing considerably lower noise levels. The transition of sample response from near the interface to the bulk behavior of the ice under shear loading is discussed with results from several samples being presented.

Ice adhesion↗

NASA NTRSDate not supplied

The Measurement of Shear Strain in Impact Ice Using a Modified Lap Joint Test and Digital Image Correlation

: Ice Adhesion, Digital Image Correlation, Experim↗

NASA NTRS2018

Polymer-Filled Metal Foams for Contamination Resistant Aircraft Leading Edges

Adhesion of contaminants has been identified as a ubiquitous issue for aeronautic exterior surfaces. Organic coatings have been demonstrated to enable reduction in insect residue adhesion as well as a reduction in ice adhesion strength. These approaches however, have yet to demonstrate sufficient durability to enable application to commercial aircraft wing leading edges. High durability materials have been developed in parallel to these efforts; contaminant adhesion issues are not addressed. This work describes a first attempt to identify a solution to the seemingly competing issues of contaminant adhesion and durability. A co-continuous network of organic and metallic domains may provide greater durability, while still enabling the changes in surface-contaminant interactions that have been realized. To that end, unique properties have been achieved through fabrication of composite metal foam materials. Likewise, extensive research has been dedicated toward development of polymeric coatings for mitigation of insect residue adhesion.This work describes initial results from infusion of a low surface free energy epoxy resin into a composite metal foam substrate for the purpose of generating a durable contaminant adhesion-resistant material.

Robbins, Samuel J.↗

NASA NTRSDate not supplied

NASA Icing Research Update 2024

This presentation summarizes NASA’s current icing research portfolio for an invited talk on August 1, 2024, at the AIAA Aviation Forum and Exposition. The presentation overviews NASA facilities, computational tools, and latest research. This research is categorized as application focused research, atmospheric characterization, and fundamental research / capability improvement. The application focused research includes (1) the Transonic Truss Brace Wing, (2) High Lift Common Research Model, (3) Advanced Air Mobility, and (4) Efficient Quiet Integrated Propulsor. The atmospheric characterization work includes High Ice Water Content Flight Research, while the fundamental research / capability improvement area includes (1) the Simulated Inter-compressor Duct Research Model, (2) Characterization of Low Ice Adhesion Materials, (3) Collection Efficiency Measurements, (4) Impedance Based Ice/ Water Sensor, (5) Tomography for Cloud Uniformity in the Icing Research Tunnel, and (6) Supercooled Large Drop Research. Finally, the presentation summarizes collaboration and partnership opportunities with NASA.

Icing↗

NASA NTRSDate not supplied

NASA Icing Update – May 2024

This presentation provides a status update on select NASA icing research activities for the SAE AC-9C Icing Technical Committee Meeting on May 6, 2024. The updates include the following topics: (1) Propulsion Systems Lab (PSL), (2) Adaptive Icing Tunnel (AIT), (3) Ice Adhesion / Deformed Skin Adhesion Test, (4) GlennICE, (5) Efficient Quiet Integrated Propulsor, (6) Icing Research Tunnel (IRT) CFD Characterization, and (7) Supercooled Large Droplet (SLD) Research.

Icing↗

NASA NTRS2019

Incorporation of Functionalized Polyhedral Oligomeric Silsesquioxane Nanomaterials as Reinforcing Agents for Impact Ice Mitigating Coatings

In-flight, aircraft are exposed to a wide range of environments. One commonly exposed environment are clouds containing super-cooled water droplets. These water drop- lets exist in a metastable state below the freezing point of water, in the range of 0 to -20°C. As the vehicle impacts the droplets, latent heat is released and within milliseconds the droplets convert to ice. This process is referred to as impact icing or in-flight icing.1 Impact icing is a major concern for aircraft since it can lead to degraded aerodynamic performance and, if left un- treated, can lead to loss of the vehicle. Active approaches (i.e., pneumatic boots, heated air ducts) typically utilized in mitigating in-flight ice accretion significantly increases vehicle weight and cannot be applied to all aircraft.1-3 A passive approach based on coatings is desired, but durability issues are a concern, especially on the wing leading edge.3 Nanomaterials have been shown to afford significant improvement in coating and composite physical properties at low loading levels.4 In this study, Polyhedral Oligomeric Silsesquioxane (POSS) nanomaterials have been shown to increase coating durability. Also, with wide variety of functionalities present on the arm structure, POSS nanomaterials have been shown to readily alter coating surface chemistry to mitigate impact ice adhesion from -16 to -8°C in a simulated in-flight icing environment.

Beck, Devon M.↗

NASA NTRSDate not supplied

Designed Adhesion - Exploring the Unknown

The ability to design materials and substrates for adhesive properties is highly desirable for the aeronautics industry. This includes the ability to design substrates that have low ice adhesion to increase efficiency of the fleet, as well as the ability to design structural adhesives to improve manufacturing rate. The Designed Adhesion group was chosen during the 2023 Wicked Wild Pitch Event sponsored by CAS and is currently in the discovery phase.

Design↗

NASA NTRSDate not supplied

Idea Evolution ... What's Next?

No research project lasts forever. Even the most wildly successful programs will eventually come to an end. The challenge in that moment, when a project ends, is how to take what was learned in that project and apply it to the next research activity you undertake. Although not always possible, information and insights from a project that is underway or coming to a close can be leveraged to identify a new research direction and advance existing tangentially related activities. In this presentation, a common thread will be followed through a series of sequential research projects where lessons learned in each activity were built into the next enabling each new research project to advance further and faster. Initial research focused on lunar dust adhesion mitigation coalesced into two major contributors to adhesion interactions; which were, not surprisingly, surface chemistry and topography. This knowledge was applied to addressing insect residue adhesion mitigation on commercial aircraft leading edge surfaces. Composite epoxy coatings formulated with controlled surface chemistry and topography were evaluated and led to identification of additional relevant considerations: dynamics and surface morphology. Collectively, these considerations were applied to address impact ice adhesion mitigation where further properties were elucidated: surface mechanical properties and durability. Seeking commonality between these research endeavors led to greater understanding of each new research objective and ultimately, identification of robust, viable pathways toward meaningful results.

Adhesion Mitigation↗

DOE OSTI2026

Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology

Refrigerator technology has advanced significantly over the last couple of decades. Today’s refrigerators use only about 25% of the energy that was required to power models built in 1975. Even as they continually improve efficiency to meet standards, refrigerators have increased in size by almost 20%, added energy-consuming features such as through-the-door ice, and provide more benefits than ever before. However, a few challenges and technology gaps are preventing further improvement of the demand responsiveness and efficiency of the refrigerators. One of the major technology gaps in existing refrigerators is their outdated de-icing process. When the evaporator generates frost, an old-fashioned resistive heating element melts the ice. Most refrigerators have a timed defrost cycle, rather than an active system that could monitor the state of the frost. In these systems, not only is the precious electricity used at its least efficient form of conversion (direct conversion of electricity to heat), but also all the latent heat associated with the ice is wasted during the melting process. On top of that, the refrigerator needs to work harder to pull the temperature down after defrosting, and, last but not least, the food quality is severely impacted by the temperature swings during the defrost cycle. According to a study, the EU alone wastes 89 million tons of food in the supply chain every year. Any temperature swing during defrosting (about 6F according to Emerson for low-temperature cases) can negatively impact the shelf life of meat and other products for multiple days. All these issues can happen during the peak demand time of the electric grid. Unlike the conventional systems, the proposed novel advanced micro-vibrational deicing process uses no heat for defrosting. Instead, it uses the micro vibrations generated by a piezoelectric or vibration-generating module to mechanically break ice from the heat exchanger almost instantaneously. The project titled “Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology, performed by Ultrasonic Technology Solutions, LLC (UTS) of Knoxville, TN, in collaboration with Emerson (now Copeland), represents the final phase of a multi-year effort funded under the U.S. Department of Energy’s Building Technologies Office (BTO) BENEFIT FOA 2020. Initiated on October 1, 2021, and completed after a nine-month no-cost extension ending September 30, 2025, this project aimed to develop and validate a novel micro-vibrational mechanical defrosting system, achieving more than 25% improvement in defrosting energy efficiency over conventional baseline defrosting technologies. Over sixteen quarters, the project advanced from fundamental ice-mechanical characterization and prototype development to full-scale system integration and validation. Initial efforts established project management infrastructure and characterized ice adhesion properties, followed by the design and fabrication of early aluminum-based prototypes for resonance frequency testing. Subsequent quarters saw rapid technical progression, including the identification of optimal piezoelectric and motor-based vibration mechanisms, the demonstration of effective de-icing over 6x6-inch aluminum surfaces. The team achieved its Go/No-Go milestone by exceeding the 25% energy-efficiency improvement target—reaching up to 3,340% under optimized conditions—and later confirmed that motor-driven systems offered superior performance and energy efficiency compared to piezoelectric alternatives. Continued refinement led to the development of amplifier systems on printed circuit boards, improved control and instrumentation hardware, and integration into full-scale heat exchanger (HX) prototypes at both UTS and Copeland facilities. Multiple vibration-mounting studies and frost-growth experiments guided mechanical optimization and noise-mitigation strategies, achieving a 17.5 dB reduction in sound pressure level and verifying robust mechanical performance. Advanced analyses, including modal and harmonic simulations, established a quantitative understanding of vibrational behavior and de-icing efficiency across >1000 cm² systems. The final project phase successfully demonstrated scalable integration within reach-in and chest freezer prototypes, confirmed >25% efficiency improvements in large-area systems, and completed a comprehensive business model and scale-up strategy identifying electric defrost systems as the primary beachhead market. The culmination of this DOE-supported effort establishes micro-vibrational defrosting as a viable, high-efficiency, low-noise, and demand-flexible de-icing technology, paving the way for commercial deployment and broader application in next-generation refrigeration systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2019

Polymer Infused Composite Metal Foam as a Potential Aircraft Leading Edge Material

The leading edge of the aircraft wings must be free from three-dimensional disturbances caused by insect adhesion, ice accretion, and particle wear in order to improve flight performance, safety, and fuel efficiency of the aircraft. An innovative solution was explored in this work by infusing stainless steel composite metal foam (SS CMF) with a hydrophobic epoxy resin system. S-S CMF was made with 100% stainless steel using a powder metallurgy technique. The infused epoxy filled the macro- and microporosities, unique to SS CMF’s structure, creating a product with a density similar to that of aluminum. The contact angle, wear rate, erosion resistance, and insect adhesion of the novel infused composite metal foam were measured and compared to aluminum, epoxy and stainless steel. The infusion process was determined to fill up to 88% of the pores within the SS CMF and was found to reduce wettability and insect residue accretion. The contact angle of the infused SS CMF was 43% higher than its parent material, stainless steel, and 130% higher than aluminum. Insect residue maximum height and areal coverage were reduced by 60 and 30%, respectively, compared to aluminum. Grit blast experiments to simulate erosion resulted in a greater roughness increase for aluminum than for the parent epoxy resin or the resin-infused SS CMF. These results suggest that the durability and performance of infused SS CMF was superior compared to aluminum, which is the current leading edge material of choice. Based on the promising results under relevant wear and erosion conditions, it is concluded that the infused SS CMF can offer a potential tailored replacement to aluminum leading edge material.

Jacob C. Marx↗