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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
NASA NTRS1977

Evaluation of coated columbium alloy heat shields for space shuttle thermal protection system application

A three-phase program to develop and demonstrate the feasibility of a metallic heat shield suitable for use on Space Shuttle Orbiter class vehicles at operating surface temperatures of up to 1590 K (2400 F) is summarized. An orderly progression of configuration studies, material screening tests, and subscale structural tests was performed. Scale-up feasibility was demonstrated in the final phase when a sizable nine-panel array was fabricated and successfully tested. The full-scale tests included cyclic testing at reduced air pressure to 1590 K (2400 F) and up to 158 dB overall sound pressure level. The selected structural configuration and design techniques succesfully eliminated thermal induced failures. The thermal/structural performance of the system was repeatedly demonstrated. Practical and effective field repair methods for coated columbium alloys were demonstrated. Major uncertainties of accessibility, refurbishability, and durability were eliminated.

Black, W. E.↗
NASA NTRS1977

The preparation of calcium superoxide at subambient temperatures and pressures

The effects of disproportionations at lower temperatures and also of a range of reaction chamber pressures on the preparation of calcium superoxide, Ca(O2)2, from calcium peroxide diperoxyhydrate were studied. About 60% purity of product was obtained by a disproportionation procedure. The significance of features of this procedure for a prospective scale-up of the mass prepared in a single experiment is considered. The optimum pressure for product purity was determined, and the use of a molecular sieve desiccant is described.

Ballou, E. V.↗
NASA NTRS1978

Closed cycle electric discharge laser design investigation

Closed cycle CO2 and CO electric discharge lasers were studied. An analytical investigation assessed scale-up parameters and design features for CO2, closed cycle, continuous wave, unstable resonator, electric discharge lasing systems operating in space and airborne environments. A space based CO system was also examined. The program objectives were the conceptual designs of six CO2 systems and one CO system. Three airborne CO2 designs, with one, five, and ten megawatt outputs, were produced. These designs were based upon five minute run times. Three space based CO2 designs, with the same output levels, were also produced, but based upon one year run times. In addition, a conceptual design for a one megawatt space based CO laser system was also produced. These designs include the flow loop, compressor, and heat exchanger, as well as the laser cavity itself. The designs resulted in a laser loop weight for the space based five megawatt system that is within the space shuttle capacity. For the one megawatt systems, the estimated weight of the entire system including laser loop, solar power generator, and heat radiator is less than the shuttle capacity.

Baily, P. K.↗
NASA NTRS1978

ECAS Phase I fuel cell results

This paper summarizes and discusses the fuel cell system results of Phase I of the Energy Conversion Alternatives Study (ECAS). Ten advanced electric powerplant systems for central-station baseload generation using coal were studied by NASA in ECAS. Three types of low-temperature fuel cells (solid polymer electrolyte, SPE, aqueous alkaline, and phosphoric acid) and two types of high-temperature fuel cells (molten carbonate, MC, and zirconia solid electrolyte, SE) were studied. The results indicate that (1) overall efficiency increases with fuel cell temperature, and (2) scale-up in powerplant size can produce a significant reduction in cost of electricity (COE) only when it is accompanied by utilization of waste fuel cell heat through a steam bottoming cycle and/or integration with a gasifier. For low-temperature fuel cell systems, the use of hydrogen results in the highest efficiency and lowest COE. In spite of higher efficiencies, because of higher fuel cell replacement costs integrated SE systems have higher projected COEs than do integrated MC systems. Present data indicate that life can be projected to over 30,000 hr for MC fuel cells, but data are not yet sufficient for similarly projecting SE fuel cell life expectancy.

Warshay, M.↗
NASA NTRS1979

Novel duplex vapor-electrochemical method for silicon solar cells

Optimization studies were carried out for the SiF4-Na reaction with solid Na feed. The goals of the study were the consistent production of high purity reaction products and the gathering of relevant information needed to scale-up the reactor. Parameters studied include: (1) effect of surface to volume ratio of Na slices on the extent of reaction; (2) effect of Na surface oxidation on the extent of reaction; (3) effect of external heating on the extent of SiF4-Na reaction; (4) effect of Na slice addition rate on extent of the reaction; and (5) SiF4-Na reaction - high pressure experiments. An investigation was also made of the possible role played by NaF as a fluxing agent during the separation of silicon by melting of the reaction product (Si + NaF) mixture. Since silicon can be produced by the thermite reaction between Na2SiF6 and Na, studies were initiated to gather information on parameters which control the efficiency of the thermite reaction.

Nanis, L.↗
NASA NTRS1978

Development, fabrication and test of a high purity silica heat shield

A highly reflective hyperpure ( 25 ppm ion impurities) slip cast fused silica heat shield material developed for planetary entry probes was successfully scaled up. Process development activities for slip casting large parts included green strength improvements, casting slip preparation, aggregate casting, strength, reflectance, and subscale fabrication. Successful fabrication of a one-half scale Saturn probe (shape and size) heat shield was accomplished while maintaining the silica high purity and reflectance through the scale-up process. However, stress analysis of this original aggregate slip cast material indicated a small margin of safety (MS. = +4%) using a factor of safety of 1.25. An alternate hyperpure material formulation to increase the strength and toughness for a greater safety margin was evaluated. The alternate material incorporates short hyperpure silica fibers into the casting slip. The best formulation evaluated has a 50% by weight fiber addition resulting in an 80% increase in flexural strength and a 170% increase in toughness over the original aggregate slip cast materials with comparable reflectance.

Rusert, E. L.↗
NASA NTRS1979

High temperature polymer research at NASA Langley

Toughness properties of existing and modified resins were investigated for adhesive and matrix resin applications. Crosslinking systems, scale-up and screening, and the stability and processability of matrix resins were also investigated.

St.clair, T. L.↗
NASA NTRS1979

Graphite/polyimide state-of-the-art panel discussion

Assessment of current graphite/polyimide composite technology is presented. Work in reducing material variability, developing a broader design data base and scale-up details are seen as requirements for future research efforts.

Kushner, M.↗
NASA NTRS1978

Simulated null-gravity environments as applied to electrophoretic separations of biological species

The scale-up of electrophoretic separations to provide preparative quantities of materials has been hampered by gravity induced convection and sedimentation. The separation of biologically important species may be significantly enhanced by electrophoretic space processing. Simple demonstrations on past space flights have proven some principles. Several techniques have been evolved to study electrophoretic separations where the effects of gravity have been nullified or significantly reduced. These techniques employ mechanical design, density gradients and computer modeling. Utilization of these techniques for ground based studies will yield clues as to which biological species can be considered prime candidates for electrophoretic processing in zero-G.

Giannovario, J. A.↗
NASA NTRS1979

Regenerative CO2 removal for PLSS application

Various concepts for the design of the nonelectrochemical absorber were defined and evaluated. A preliminary design based on the use of hollow fiber membranes was developed. Small scale bench testing demonstrated the carbon dioxide removal capability and provided design data for scale-up to the one person level. A full scale conceptual design of the absorbent regeneration hardware using six electrochemical cells was also completed. The design was supported by single cell testing and showed that a full scale regeneration system, operating continuously over 24 hours, can regenerate the absorbent from one extravehicular activity mission. The single cell regeneration hardware was operated for over 800 hours.

Heppner, D. B.↗
NASA NTRS1979

Manufacturing methods of a composite cell case for a Ni-Cd battery

Basic manufacturing method refinements for using graphite epoxy material for a nickel cadmium battery cell case were performed to demonstrate production feasibility. The various facets of production scale-up, i.e., process and tooling development, together with material and process control, were integrated into a comprehensive manufacturing process that assures production reproducibility and product uniformity. Test results substantiate that a battery cell case produced from graphite epoxy pre-impregnated material, utilizing the internal pressure bag fabrication method, is feasible.

Bauer, J. L.↗
NASA NTRS1979

Automated array assembly, phase 2

Tasks of scaling up the tandem junction cell (TJC) from 2 cm x 2 cm to 6.2 cm and the assembly of several modules using these large area TJC's are described. The scale-up of the TJC was based on using the existing process and doing the necessary design activities to increase the cell area to an acceptably large area. The design was carried out using available device models. The design was verified and sample large area TJCs were fabricated. Mechanical and process problems occurred causing a schedule slippage that resulted in contract expiration before enough large-area TJCs were fabricated to populate the sample tandem junction modules (TJM). A TJM design was carried out in which the module interconnects served to augment the current collecting buses on the cell. No sample TJMs were assembled due to a shortage of large-area TJCs.

Carbajal, B. G.↗
NASA NTRS1979

A new furnace for high gradient directional growth

A new design furnace for high gradient solidification of in-situ composites is presented. Its essential feature is the direct addition of heat to one side of a thin, pancake-like layer of liquid, and continuous withdrawal of a solid crystal from the other side. Liquid in the thin layer is continuously replenished by solid or liquid feed, and the thinness of the layer permits a large heat throughput with a high temperature gradient without excessive metal superheat. The commercial advantages of this design are improved process efficiency in scale-up, lower melt temperatures, and control of interface morphology by adjusting heater position and temperature. The furnace was tested on Sn-Pb and Al-Cu alloys, obtaining 100C/mm gradients for 6 mm specimens of Al-31.5 % Cu alloy.

Flemings, M. C.↗
NASA NTRS1979

Manufacturing methods of a composite cell case for a Ni-Cd battery

Graphite epoxy material for a nickel cadmium battery cell case has been evaluated and determined to perform in the simulated environment of the battery. The basic manufacturing method requires refinement to demonstrate production feasibility. The various facets of production scale-up, i.e., process and tooling development together with material and process control, have been integrated into a comprehensive manufacturing process that assures production reproducibility and product uniformity. Test results substantiate that a battery cell case produced from graphite epoxy pre-impregnated material utilizing internal pressure bag fabrication method is feasible.

Bauer, J. L.↗
NASA NTRS1979

Silicon material task - Low cost solar array project /JPL/DOE/

The paper describes the silicon material task of the low-cost solar array project, which has the objective of establishing a silicon production capability equivalent to 500 mW per year at a price less than 10 dollars/kg (1975 dollars) in 1986. The task program is divided into four phases: technical feasibility, scale-up studies (the present phase), experimental process system development units, and implementation of large-scale production plants, and it involves the development of processes for two groups of materials, that is, semiconductor grade and solar cell grade. In addition, the effects of impurities on solar cell performance are being investigated. Attention is given to problem areas of the task program, such as environmental protection, material compatibility between the reacting chemicals and materials of construction of the equipment, and waste disposal.

Lutwack, R.↗
NASA NTRS1980

The preparation of calcium superoxide in a flowing gas stream and fluidized bed

Superoxides can be used as sources of chemically stored oxygen in emergency breathing apparatus. The work reported here describes the use of a low-pressure nitrogen gas sweep through the reactant bed, for temperature control and water vapor removal. For a given set of gas temperature, bed thickness, and reaction time values, the highest purity calcium superoxide, Ca(O2)2, was obtained at the highest space velocity of the nitrogen gas sweep. The purity of the product was further increased by flow conditions that resulted in the fluidization of the reactant bed. However, scale-up of the low-pressure fluidized bed process was limited to the formation of agglomerates of reactant particles, which hindered thermal control by the flowing gas stream. A radiofrequency flow discharge inside the reaction chamber prevented agglomeration, presumably by dissipation of the static charges on the fluidized particles.

Wood, P. C.↗
NASA NTRS1976

Sewage Treatment

A million gallon-a-day sewage treatment plant in Huntington Beach, CA converts solid sewage to activated carbon which then treats incoming waste water. The plant is scaled up 100 times from a mobile unit NASA installed a year ago; another 100-fold scale-up will be required if technique is employed for widespread urban sewage treatment. This unique sewage-plant employed a serendipitous outgrowth of a need to manufacture activated carbon for rocket engine insulation. The process already exceeds new Environmental Protection Agency Standards Capital costs by 25% compared with conventional secondary treatment plants.

Source record↗
NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

pragmatic method↗