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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Dual Material System for Polymer Large Scale Additive Manufacturing

Big Area Additive Manufacturing (BAAM) technology allows for manufacturing of large-scale objects with a potential to reduce energy embedded in products, reduce or eliminate energy necessary for transportation of goods along with reducing the lead time and cost in some cases. Over the last few years, Oak Ridge National Laboratory (ORNL) has been focusing on large-scale printing of single material systems, typically un-reinforced or short fiber reinforced polymers, in order to address needs in stiffness-limited applications. This paper describes the development of a multi-material large-scale AM system through a collaboration with Cincinnati Inc. and Performance Feed Screw Inc. Modifications to the Big Area Additive Manufacturing (BAAM) system includes a new extruder design to accommodate a dual feed system, an expanded two-dryer system with a capacity of 273 kg/dryer, and a system that is capable of mixing pelletized materials up to 60Kg/hr. This article highlights the advantages and limitations of the multi-material system as well as potential applications.

Smith, Tyler↗
NASA NTRS2011

Terahertz Computed Tomography of NASA Thermal Protection System Materials

A terahertz axial computed tomography system has been developed that uses time domain measurements in order to form cross-sectional image slices and three-dimensional volume renderings of terahertz-transparent materials. The system can inspect samples as large as 0.0283 cubic meters (1 cubic foot) with no safety concerns as for x-ray computed tomography. In this study, the system is evaluated for its ability to detect and characterize flat bottom holes, drilled holes, and embedded voids in foam materials utilized as thermal protection on the external fuel tanks for the Space Shuttle. X-ray micro-computed tomography was also performed on the samples to compare against the terahertz computed tomography results and better define embedded voids. Limits of detectability based on depth and size for the samples used in this study are loosely defined. Image sharpness and morphology characterization ability for terahertz computed tomography are qualitatively described.

Roth, D. J.↗
NASA NTRS2019

Micro-scale Artificial Weave Generation Capabilities for Thermal Protection System Material Modeling

Thermal Protection System (TPS) modeling requires accurate representation and prediction of the thermomechanical behavior of ablative materials. State-of-the-art TPS materials such as Phenolic Impregnated Carbon Ablator (PICA) have a proven flight record and demonstrate exceptional capabilities for handling extreme aerothermal heating conditions. The constant push for lightweight materials that are flexible in their design and performance, and hence allow for a wide range of mission profiles, has led NASA over the past years to develop its Heatshield for Extreme Entry Environment Technology (HEEET). HEEET is based primarily on a dual layer woven carbon fiber architecture and the technology has successfully been tested in arc-jet facilities. These recent developments have sparked interest in the accurate micro-scale modeling of composite weave architectures, to predict the structural response of macro-scale heatshields upon atmospheric entry. This effort can be extended to incorporate in-depth failure mechanics analyses as a result of local thermal gradients or high-velocity particle impact.

Visser, Sander J.↗
NASA NTRSDate not supplied

Multiscale Modeling of Fracture Strength in Fibrous Thermal Protection System Materials

This work presents a multiscale modeling approach to predict the fracture strength of fibrous Thermal Protection System (TPS) materials. The model assumes that system failure is initiated at the joints between individual fibers. We investigated three distinct TPS compositions: amorphous silica, alumina and aluminosilicate fibers. Molecular dynamics (MD) simulations were employed to determine the fracture strength values of these fiber joints for both material systems. These fracture strength values were then integrated into simulations of 3D randomly populated fiber structures, where tensile load transfer occurs through the fiber joints. These microscale properties are upscaled through a renormalization approach [1] to predict macroscale tensile strength of 3D random fiber networks, accounting for joint-dominated failure and effective load-bearing area. The study concludes by demonstrating the resulting strength variation as a function of material composition, fiber density, and morphology. We also show validation of results by comparing them against explicit fiber finite element (FE) modeling [2] where fiber joint fracture is represented by cohesive elements.

Jaehyun Cho↗
DOE OSTI2021

Interfacial thermal transport in spin caloritronic material systems

Interfaces often govern the thermal performance of nanoscale devices and nanostructured materials. As a result, accurate knowledge of thermal interface conductance is necessary to model the temperature response of nanoscale devices or nanostructured materials to heating. Here, we report the thermal boundary conductance between metals and insulators that are commonly used in spin-caloritronic experiments. We use time-domain thermoreflectance to measure the interface conductance between metals such as Au, Pt, Ta, Cu, and Al with garnet and oxide substrates, e.g., NiO, yttrium iron garnet (YIG), thulium iron garnet (TmIG), Cr 2 O 3 , and sapphire. We find that, at room temperature, the interface conductance in these types of material systems range from 50 to 300 MW m –2 K –1 . Furthermore, we also measure the interface conductance between Pt and YIG at temperatures between 80 and 350 K. At room temperature, the interface conductance of Pt/YIG is 170 MW m –2 K –1 and the Kapitza length is ~40 nm. A Kapitza length of 40 nm means that, in the presence of a steady-state heat current, the temperature drop at the Pt/YIG interface is equal to the temperature drop across a 40-nm-thick layer of YIG. At 80 K, the interface conductance of Pt/YIG is 60 MW m –2 K –1 , corresponding to a Kapitza length of ~300 nm.

36 MATERIALS SCIENCE↗
NASA NTRS1993

The implications of the LDEF results on Space Station Freedom power system materials

Results and implications of Long Duration Exposure Facility (LDEF) exposure of materials relevant to the Space Station Freedom (SSF) power system materials are presented. Atomic oxygen interactions with potential synergistic UV effects on silicone materials on LDEF were shown to result in the deposition of a dark contaminant film on adjoining surfaces. Silicones associated with solar array construction have the potential for causing reduced solar illumination of the solar cells if such silicone molecular fragments are found to be surface mobile. Results of LDEF atomic oxygen protective coatings on polyimide Kapton indicated acceptable durability to the synergistic effects of atomic oxygen, UV, thermal cycling, and micrometeoroid or debris impact. Results of combined atomic oxygen, UV radiation, thermal cycling, and micrometeoroid and debris impacts on LDEF high emittance radiator coatings indicate long term emittance and absorptance durability of Z 93 (zinc oxide pigment in a potassium silicate binder) coatings which have been selected for SSF radiator surfaces.

Banks, Bruce A.↗
NASA NTRS1982

Recent advances in carbon-carbon materials systems

Carbon-carbon materials and new oxidation resistant coating developments are discussed. Potential areas of application are highlighted. A short bibliography of selected references is included that describe carbon-carbon materials and related technology in detail.

Donald R. Rummler↗
NASA NTRS2010

Flexible Material Systems Testing

An experimental program has been undertaken to better characterize the stress-strain characteristics of flexible material systems to support a NASA ground test program for inflatable decelerator material technology. A goal of the current study is to investigate experimental methods for the characterization of coated woven material stiffness. This type of experimental mechanics data would eventually be used to define the material inputs of fluid-structure interaction simulation models. The test methodologies chosen for this stress-strain characterization are presented along with the experimental results.

Lin, John K.↗
NASA NTRS1981

Microscopy and microstructure of Shuttle thermal protection system materials

Examples of the contribution of microstructural analysis to the development of the Space Shuttle tile insulation system are presented, with photographic examples of the scanning electron microscope (SEM) investigations. After the basic thermal protection system materials had been selected, it was neccessary to analyze the mechanical responses of the combined materials; which included: (1) the polymer strain isolation pad (SIP), (2) the room temperature-vulcanizing silicone rubber bond, (RTV), and (3) rigid ceramic fiber reusable surface insulation (RSI). Microstructural analysis was used to provide information on deformation and fracture mechanisms, load transfer mechanisms, and structural alterations occurring before final failure. Both quantitative and qualitative information was obtained in the open, three-dimensional fibrous structures of the ceramic tiles by means of novel techniques of encapsulation and dissolution.

Newquist, C. W.↗
NASA NTRS1998

Launch and Propulsion Systems Materials and Process Development for Rocket Engine Components: Turbomachinery

This presentation identifies the key materials with the highest payoff to advance the state-of-the-art in materials for turbomachinery. Current show stoppers for advancing the state of the art in materials and processes were identified. Technical issues associated with incorporating key materials into new systems are discussed. Opportunities, where they exist, are identified to overcome these technical challenges.

Cannon, James L.↗
NASA NTRSDate not supplied

Thermal Conductivity of 3D Woven Composite Thermal Protection System Materials via Multiscale Recursive Micromechanics

Multiscale micromechanics predictions have been made for the effective thermal conductivities and local thermal fields for a novel 3D woven composite thermal protection system material. The Multiscale Recursive Micromechanics approach, which enables micromechanics models to call other micromechanics models (or themselves recursively) to consider finer and finer length scales, has been employed. The multiscale model uses a recently developed version of the High-Fidelity Generalized Method of Cells micromechanics theory at each of three length scales. Results focus on the impact of the microstructural geometry representation at each length scale on the material’s effective thermal conductivity, along with the local thermal flux and temperature fields induced in the microstructures.

Composites↗
NASA NTRS2021

Thermal Conductivity of 3D Woven Composite Thermal Protection System Materials via Multiscale Recursive Micromechanics

Multiscale micromechanics predictions have been made for the effective thermal conductivities and local thermal fields for a novel 3D woven composite thermal protection system material. The Multiscale Recursive Micromechanics approach, which enables micromechanics models to call other micromechanics models (or themselves recursively) to consider finer and finer length scales, has been employed. The multiscale model uses a recently developed version of the High-Fidelity Generalized Method of Cells micromechanics theory at each of three length scales. Results focus on the impact of the microstructural geometry representation at each length scale on the material’s effective thermal conductivity, along with the local thermal flux and temperature fields induced in the microstructures.

composite↗
NASA NTRS2011

Development of a Sheathed Miniature Aerothermal Reentry Thermocouple for Thermal Protection System Materials

The Sheathed Miniature Aerothermal Reentry Thermocouple is a micro-miniature thermocouple for high temperature measurement in extreme environments. It is available for use in Thermal Protection System materials for ground testing and flight. This paper discusses the heritage, and design of the instrument. Experimental and analytical methods used to verify its performance and limitations are described.

Reentry↗
NASA NTRS2010

Three-Body Abrasion Testing Using Lunar Dust Simulants to Evaluate Surface System Materials

Numerous unexpected operational issues relating to the abrasive nature of lunar dust, such as scratched visors and spacesuit pressure seal leaks, were encountered during the Apollo missions. To avoid reoccurrence of these unexpected detrimental equipment problems on future missions to the Moon, a series of two- and three-body abrasion tests were developed and conducted in order to begin rigorously characterizing the effect of lunar dust abrasiveness on candidate surface system materials. Two-body scratch tests were initially performed to examine fundamental interactions of a single particle on a flat surface. These simple and robust tests were used to establish standardized measurement techniques for quantifying controlled volumetric wear. Subsequent efforts described in the paper involved three-body abrasion testing designed to be more representative of actual lunar interactions. For these tests, a new tribotester was developed to expose samples to a variety of industrial abrasives and lunar simulants. The work discussed in this paper describes the three-body hardware setup consisting of a rotating rubber wheel that applies a load on a specimen as a loose abrasive is fed into the system. The test methodology is based on ASTM International (ASTM) B611, except it does not mix water with the abrasive. All tests were run under identical conditions. Abraded material specimens included poly(methyl methacrylate) (PMMA), hardened 1045 steel, 6061-T6 aluminum (Al) and 1018 steel. Abrasives included lunar mare simulant JSC- 1A-F (nominal size distribution), sieved JSC-1A-F (<25 m particle diameter), lunar highland simulant NU-LHT-2M, alumina (average diameter of 50 m used per ASTM G76), and silica (50/70 mesh used per ASTM G65). The measured mass loss from each specimen was converted using standard densities to determine total wear volume in cm3. Abrasion was dominated by the alumina and the simulants were only similar to the silica (i.e., sand) on the softer materials of aluminum and PMMA. The nominal JSC- 1A-F consistently showed more abrasion wear than the sieved version of the simulant. The lunar dust displayed abrasivity to all of the test materials, which are likely to be used in lunar landing equipment. Based on this test experience and pilot results obtained, recommendations are made for systematic abrasion testing of candidate materials intended for use in lunar exploration systems and in other environments with similar dust challenges.

Kobrick, Ryan L.↗
NASA NTRS1991

Composite material systems for hydrogen management

The task of managing hydrogen entry into elevated temperature structural materials employed in turbomachinery is a critical engineering area for propulsion systems employing hydrogen or decomposable hydrocarbons as fuel. Extant structural materials, such as the Inconel series, are embrittled by the ingress of hydrogen in service, leading to a loss of endurance and general deterioration of load-bearing dependability. Although the development of hydrogen-insensitive material systems is an obvious engineering option, to date insensitive systems cannot meet the time-temperature-loading service extremes encountered. A short-term approach that is both feasible and technologically sound is the development and employment of hydrogen barrier coatings. The present project is concerned with developing, analyzing, and physically testing laminate composite hydrogen barrier systems, employing Inconel 718 as the structural material to be protected. Barrier systems will include all metallic, metallic-to-ceramic, and, eventually, metallic/ceramic composites as the lamellae. Since space propulsion implies repetitive engine firings without earth-based inspection and repair, coating durability will be closely examined, and testing regimes will include repetitive thermal cycling to simulate damage accumulation. The target accomplishments include: generation of actual hydrogen permeation data for metallic, ceramic-metallic, and hybrid metallic/ceramic composition barrier systems, practically none of which is currently extant; definition of physical damage modes imported to barrier systems due to thermal cycling, both transient temperature profiles and steady-state thermal mismatch stress states being examined as sources of damage; and computational models that incorporate general laminate schemes as described above, including manufacturing realities such as porosity, and whatever defects are introduced through service and characterized during the experimental programs.

Pangborn, R. N.↗
NASA NTRSDate not supplied

Error Sources and Mitigation Strategies for Thermocouples Integrated in Flexible Thermal Protection System Materials

• The flexible thermal protection system (FTPS) on NASA’s Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) vehicle will be instrumented with thermocouples (TCs) to measure the in-depth thermal response during entry into Earth’s atmosphere. Accurate flight temperature measurements are critical for verifying vehicle performance and reducing thermal model uncertainties. • The TC leads are routed from the measurement location to the data acquisition system within the same FTPS layer that they are monitoring the temperature. This approach eliminates the need to put holes in the FTPS layers. However, the insulated TC leads are exposed to high temperatures and large thermal gradients. • The baseline TCs were commercially available 30 AWG Type K TCs with a binder impregnated glass braid insulation. The glass braid is rated to a maximum continuous use temperature of 482°C. LOFTID’s heat pulse will be on the order of minutes and the maximum predicted temperature beneath the outermost FTPS layers is 1350°C.

R. A. Miller↗
NASA NTRS2014

Advanced Compatibility Characterization Of AF-M315E With Spacecraft Propulsion System Materials Project

All spacecraft require propulsion systems for thrust and maneuvering. Propulsion systems can be chemical, nuclear, electrical, cold gas or combinations thereof. Chemical propulsion has proven to be the most reliable technology since the deployment of launch vehicles. Performance, storability, and handling are three important aspects of liquid chemical propulsion. Bipropellant systems require a fuel and an oxidizer for propulsion, but monopropellants only require a fuel and a catalyst for propulsion and are therefore simpler and lighter. Hydrazine is the state of the art propellant for monopropellant systems, but has drawbacks because it is highly hazardous to human health, which requires extensive care in handling, complex ground ops due to safety and environmental considerations, and lengthy turnaround times for reusable spacecraft. All users of hydrazine monopropellant must contend with these issues and their associated costs. The development of a new monopropellant, intended to replace hydrazine, has been in progress for years. This project will apply advanced techniques to characterize the engineering properties of materials used in AF-M315E propulsion systems after propellant exposure. AF-M315E monopropellant has been selected HQ's Green Propellant Infusion Mission (GPIM) to replace toxic hydrazine for improved performance and reduce safety and health issues that will shorten reusable spacecraft turn-around time. In addition, this project will fundamentally strengthen JSC's core competency to evaluate, use and infuse liquid propellant systems.

McClure, Mark B.↗