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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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NASA NTRS1977

Mercury embrittlement of Cu-Al alloys under cyclic loading

The effect of mercury on the room temperature, high cycle fatigue properties of three alloys: Cu-5.5 pct Al, Cu-7.3 pct Al, and Cu-6.3 pct Al-2.5 pct Fe has been determined. Severe embrittlement under cyclic loading in mercury is associated with rapid crack propagation in the presence of the liquid metal. A pronounced grain size effect is noted under mercury, while fatigue properties in air are insensitive to grain size. The fatigue results are discussed in relation to theories of adsorption-induced liquid metal embrittlement.

Regan, T. M.↗

NASA NTRS2003

Flow Visualization of Low Prandtl Number Fluids using Electrochemical Measurements

It is well established that residual flows exist in contained liquid metal processes. In 1-g processing, buoyancy forces often drive these flows and their magnitudes can be substantial. It is also known that residual flows can exist during microgravity processing, and although greatly reduced in magnitude, they can influence the properties of the processed materials. Unfortunately, there are very few techniques to visualize flows in opaque, high temperature liquid metals, and those available are not easily adapted to flight investigation. In this study, a novel technique is developed that uses liquid tin as the model fluid and solid-state electrochemical cells constructed from Yttria-Stabilized Zirconia (YSZ) to establish and measure dissolved oxygen boundary conditions. The melt serves as a common electrode for each of the electrochemical cells in this design, while independent reference electrodes are maintained at the outside surfaces of the electrolyte. By constructing isolated electrochemical cells at various locations along the container walls, oxygen is introduced or extracted by imposing a known electrical potential or passing a given current between the melt and the reference electrode. This programmed titration then establishes a known oxygen concentration boundary condition at the selected electrolyte-melt interface. Using the other cells, the concentration of oxygen at the electrolyte-melt interface is also monitored by measuring the open-circuit potentials developed between the melt and reference electrodes. Thus the electrochemical cells serve to both establish boundary conditions for the passive tracer and sense its path. Rayleigh-Benard convection was used to validate the electrochemical approach to flow visualization. Thus, a numerical characterization of the second critical Rayleigh numbers in liquid tin was conducted for a variety of Cartesian aspect ratios. The extremely low Prandtl number of tin represents the lowest value studied numerically. Additionally, flow field oscillations are visualized and the effect of tilt on convecting systems is quantified. Experimental studies of the effect of convection in liquid tin are presented. Three geometries are studied: (1) double electrochemical cell with vertical concentration gradients; (2) double cell with horizontal concentration gradients; and (3) multiple cells with vertical temperature gradients. The first critical Rayleigh number transition is detected with geometry (1) and it is concluded that current measurements are not as affected by convection as EMF measurements. The system is compared with numerical simulations in geometry (2), and oscillating convection is detected with geometry (3).

Crunkleton, D.↗

NASA NTRS2014

Method for Making a Fuel Cell

The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which an electrolyte layer is supported between porous electrodes. The porous electrodes may be made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze-drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that, subsequent to sintering, is made into either an anode or a cathode. The electrode scaffold comprising the anode includes a layer of liquid metal. The pores of the electrode scaffolds gradually increase in diameter as the layer extends away from the electrolyte layer. As a result of this diameter increase, any forces that would tend to pull the liquid metal away from the electrolyte are reduced while maintaining a diffusion path for the fuel. Advantageously, the fuel cell of the invention may utilize a hydrocarbon fuel without pre-processing to remove sulfur.

Cable, Thomas L.↗

NASA NTRS1989

V, Cr, and Mn in the earth, moon, EPB, and SPB and the origin of the moon - Experimental studies

The abundances of V, Cr, and Mn inferred for the mantles of the earth and moon decrease in that order and are similar in both mantles (but distinct from those in the mantles of the Eucrite Parent Body and Shergottite Parent Body), suggesting a common origin for the mantles of the earth and the moon. This hypothesis was investigated on the basis of a comparison between the depletions of V, Cr, and Mn in the mantles of the earth and the moon, and the metal/silicate partition coefficients of these elements at 1260 C and 1 bar pressure among a S-bearing metallic liquid, a silicate melt, and a FeNi alloy. It was found that the earth and the moon depletions of V, Cr, and Mn are not correlated with metal/silicate partition coefficients; the V and Cr partitioned into S-rich metallic liquids under reducing conditions more strongly than Mn, consistent with the relative volatilities of these elements. This indicates that the depletion patterns of these elements in the mantles of the earth and moon cannot be attributed primarily to terrestrial core formation.

Drake, Michael J.↗

NASA NTRS1976

Energy Conversion Alternatives Study (ECAS), Westinghouse phase 1. Volume 2: Materials considerations

Extensive studies are presented which were carried out on materials behavior in nine advanced energy conversion systems employing coal and coal-derived fuels. The areas of materials behavior receiving particular attention in this regard are: (1) fireside corrosion and erosion in boiler and heat exchanger materials, (2) oxidation and hot corrosion of gas turbine materials, (3) liquid metal corrosion and mass transport, (4) high temperature steam corrosion, (5) compatability of materials with coal slag and MHD seed, (6) reaction of materials with impure helium, (7) allowable stresses for boiler and heat exchanger materials, (8) environmental effects on mechanical properties, and (9) liquid metal purity control and instrumentation. Such information was then utilized in recommending materials for use in the critical components of the power systems, and at the same time to identify materials problem areas and to evaluate qualitatively the difficulty of solving those problems. Specific materials recommendations for critical components of the nine advanced systems under study are contained in summary tables.

Thomas, D. E.↗

NASA NTRS1993

Thermal spray forming of refractory sample ampoule cartridges for single crystal growth space furnaces

A thermal spray process is being used to build up refractory metals and ceramics into a containment cartridge for high temperature, single crystal semiconductor growth experiments. This process uses high energy plasma inside a low pressure (100-200 torr) inert environment to apply layers of material onto a removable mandrel. A variety of materials are being characterized and evaluated against a demanding set of requirements, including high service temperature (1700 C), oxidation resistance, and resistance to liquid metal attack. Techniques to spray form refractory metals (tungsten, molybdenum, niobium, tantalum) and ceramics (alumina, boron nitride) are being developed in the Plasma Spray Cell at Marshall Space Flight Center. These plasma spray formed materials have been evaluated for mechanical properties, density, microstructure, and resistance to liquid metal attack. Forming techniques and the resultant mechanical and metallurgical properties will be presented.

Zimmerman, Frank↗

NASA NTRS1993

Thermal spray forming of refractory sample ampoule cartridges for single crystal growth space furnaces

Zimmerman, Frank↗

NASA NTRS2010

Design of a Mechanical NaK Pump for Fission Space Power Systems

Alkali liquid metal cooled fission reactor concepts are under development for mid-range spaceflight power requirements. One such concept utilizes a sodium-potassium eutectic (NaK) as the primary loop working fluid. Traditionally, linear induction pumps have been used to provide the required flow and head conditions for liquid metal systems but can be limited in performance. This paper details the design, build, and check-out test of a mechanical NaK pump. The pump was designed to meet reactor cooling requirements using commercially available components modified for high temperature NaK service.

Mireles, Omar R.↗

NASA NTRS2005

Electromagnetic Pumps for Conductive-Propellant Feed Systems

Prototype electromagnetic pumps for use with lithium and bismuth propellants were constructed and tested. Such pumps may be used to pressurize future electric propulsion liquid metal feed systems, with the primary advantages being the compactness and simplicity versus alternative pressurization technologies. Design details for two different pumps are described: the first was designed to withstand (highly corrosive) lithium propellant, and t he second was designed to tolerate the high temperature required to pump liquid bismuth. Both qualitative and quantitative test results are presented. Open-loop tests demonstrated the capability of each device to electromagnetically pump its design propellant (lithium or bismuth). A second set of tests accurately quantified the pump pressure developed as a function of current. These experiments, which utilized a more easily handled material (gallium), demonstrated continuously-adjustable pump pressure levels ranging from 0-100 Torr for corresponding input current levels of 0-75 A. While the analysis and testing in this study specifically targeted lithium and bismuth propellants, the underlying design principles should be useful in implementing liquid metal pumps in any conductive-propellant feed system.

Markusic, Thomas E.↗

NASA NTRS1998

Temperature Dependence of Diffusivities in Liquid Elements (LMD)

This research was to advance the understanding of diffusion mechanisms in liquid metals and alloys through accurate diffusivity measurements over a wide range of temperatures, including the proximity of the materials melting points. Specifically, it was driven towards developing a methodology (and subsequent flight hardware) to enable several diffusion coefficient measurements (i.e., at several different temperatures) to be performed using a single sample. The Liquid Metal Diffusion (LMD) was funded as a Flight Definition Project in February 1993 in response to NRA 91-OSSA-20 (Microgravity Science and Applications Division). The Science Concept Review for LAID was held during April 1994. In January 1995 we were informed that we had failed this review and the project was change to ground-based activities only. A new proposal was submitted for the next NRA addressing the panels concerns. As part of NASA's Risk Mitigation program, a scaled-down version of the hardware was funded in July of 1995 for a flight opportunity utilizing experiment on the Microgravity Isolation Mount. This experiment was to determine the self-diffusivity of indium at 185 C. The LMD was transferred to the Mir Space Station in STS-81 and returned on STS-84 (January - May 1997). Three, out of five, self-diffusion data sets were returned. A description of this experiment/hardware is included below. This summary is only intended to give the reader an overview of the results obtained for the tasks outlined in the original proposal. Research that was not published is explained in more detail. At the end of this report is a list of refereed publications and invited talks that were given as a result of this work. The reader is directed to these for further details. Attachment: Real-time diffusivity measurements in liquids at several temperatures with one sample, On the insensitivity of liquid diffusivity measurements to deviations from 1D transport, and Numerical simulations of the convective contamination of diffusivity measurements in liquids.

Banish, R. Michael↗

NASA NTRS1990

Rare-gas liquids - Equation of state and reduced-pressure, reduced-bulk-modulus, and reduced-sound-velocity functions

This paper is concerned with verification of the applicability of the Vinet et al. (1987) universal equation of state to the liquid phase of the rare-gas elements under pressure. As previously observed in solids and liquids metals, to a good approximation, in the absence of phase transitions, plots of the logarithms of the reduced pressure function, of the reduced sound velocity, and of the reduced bulk modulus, are all linear functions of 1 - X over the entire experimental pressure range. The results obtained on the rare-gas liquids are comparable in accuracy to those obtained in previous work on solids and liquid metals.

Schlosser, Herbert↗

NASA NTRS1992

Heat pipe and surface mass transfer cooling of hypersonic vehicle structures

The problem of determining the feasibility of cooling hypersonic vehicle leading-edge structures exposed to severe aerodynamic surface heating using heat pipe and mass transfer cooling techniques is addressed. A description is presented of a numerical finite-difference-based hypersonic leading-edge cooling model incorporating poststartup liquid metal heat pipe cooling with surface transpiration and film cooling to predict the transient structural temperature distributions and maximum surface temperatures of hypersonic vehicle leading edge. An application of this model to the transient cooling of a typical aerospace plane wing leading-edge section. The results of this application indicated that liquid metal heat pipe cooling alone is insufficient to maintain surface temperatures below an assumed maximum level of 1800 K for about one-third of a typical aerospace plane ascent trajectory through the earth's atmosphere.

Colwell, Gene T.↗

NASA NTRS2006

Stainless Steel NaK Circuit Integration and Fill Submission

The Early Flight Fission Test Facilities (EFF-TF) team has been tasked by the Marshall Space Flight Center Nuclear Systems Office to design, fabricate, and test an actively pumped alkali metal flow circuit. The system, which was originally designed to hold a eutectic mixture of sodium potassium (NaK), was redesigned to hold lithium; but due to a shift in focus, it is once again being prepared for use with NaK. Changes made to the actively pumped, high temperature loop include the replacement of the expansion reservoir, addition of remotely operated valves, and modification of the support table. Basic circuit components include: reactor segment, NaK to gas heat exchanger, electromagnetic (EM) liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and a spill reservoir. A 37-pin partial-array core (pin and flow path dimensions are the same as those in a full design) was selected for fabrication and test. This document summarizes the integration and fill of the pumped liquid metal NaK flow circuit.

Garber, Anne E.↗

NASA NTRS1997

Fundamentals of Mold Free Casting: Experimental and Computational Studies

Researchers are developing the technology of 'Ballistic Particle Manufacturing' (BPM) in which individual drops are precisely layered onto a substrate, and the drops are deposited so as to prevent splatting. These individual drops will ultimately be combined to form a net-shape, three-dimensional object. Our understanding of controlled drop deposition as applied to BPM is far from complete. Process parameters include the size and temperature of the liquid metal drop, its impact velocity and trajectory, and the condition and temperature of the substrate. Quantitative knowledge of the fluid mechanics and heat transfer of drop deposition and solidification are necessary to fully optimize the manufacturing process and to control the material microstructure of the final part. The object of this study is to examine the dynamics of liquid metal drops as they impinge upon a solid surface and solidify under conditions consistent with BPM (i.e. conditions which produce non-splatting drops). A program of both numerical simulations and experiments will be conducted. Questions this study will address include the following: How do the deformation and solidification of the drop depend on the properties of the fluid drop and the solid substrate? How does the presence of previously deposited drops affect the impingement and solidification process? How does the impingement of the new drop affect already deposited material? How does the cooling rate and solidification of the drops influence the material microstructure?

Tryggvason, Gretar↗

NASA NTRS2006

Design, Fabrication and Integration of a NaK-Cooled Circuit

The Early Flight Fission Test Facilities (EFF-TF) team has been tasked by the NASA Marshall Space Flight Center Nuclear Systems Office to design, fabricate, and test an actively pumped alkali metal flow circuit. The system, which was originally designed for use with a eutectic mixture of sodium potassium (NaK), was redesigned to for use with lithium. Due to a shi$ in focus, it is once again being prepared for use with NaK. Changes made to the actively pumped, high temperature circuit include the replacement of the expansion reservoir, addition of remotely operated valves, and modification of the support table. Basic circuit components include: reactor segment, NaK to gas heat exchanger, electromagnetic (EM) liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and a spill reservoir. A 37-pin partial-array core (pin and flow path dimensions are the same as those in a fill design) was selected for fabrication and test. This paper summarizes the integration and preparations for the fill of the pumped liquid metal NaK flow circuit.

Garber, Anne↗

NASA NTRS1986

Laser-powered MHD generators for space application

Magnetohydrodynamic (MHD) energy conversion systems of the pulsed laser-supported detonation (LSD) wave, plasma MHD, and liquid-metal MHD (LMMHD) types are assessed for their potential as space-based laser-to-electrical power converters. These systems offer several advantages as energy converters relative to the present chemical, nuclear, and solar devices, including high conversion efficiency, simple design, high-temperature operation, high power density, and high reliability. Of these systems, the Brayton cycle liquid-metal MHD system appears to be the most attractive. The LMMHD technology base is well established for terrestrial applications, particularly with regard to the generator, mixer, and other system components. However, further research is required to extend this technology base to space applications and to establish the technology required to couple the laser energy into the system most efficiently. Continued research on each of the three system types is recommended.

Jalufka, N. W.↗

NASA NTRS2011

Fission Surface Power Technology Development Update

Power is a critical consideration in planning exploration of the surfaces of the Moon, Mars, and places beyond. Nuclear power is an important option, especially for locations in the solar system where sunlight is limited or environmental conditions are challenging (e.g., extreme cold, dust storms). NASA and the Department of Energy are maintaining the option for fission surface power for the Moon and Mars by developing and demonstrating technology for a fission surface power system. The Fission Surface Power Systems project has focused on subscale component and subsystem demonstrations to address the feasibility of a low-risk, low-cost approach to space nuclear power for surface missions. Laboratory demonstrations of the liquid metal pump, reactor control drum drive, power conversion, heat rejection, and power management and distribution technologies have validated that the fundamental characteristics and performance of these components and subsystems are consistent with a Fission Surface Power preliminary reference concept. In addition, subscale versions of a non-nuclear reactor simulator, using electric resistance heating in place of the reactor fuel, have been built and operated with liquid metal sodium-potassium and helium/xenon gas heat transfer loops, demonstrating the viability of establishing system-level performance and characteristics of fission surface power technologies without requiring a nuclear reactor. While some component and subsystem testing will continue through 2011 and beyond, the results to date provide sufficient confidence to proceed with system level technology readiness demonstration. To demonstrate the system level readiness of fission surface power in an operationally relevant environment (the primary goal of the Fission Surface Power Systems project), a full scale, 1/4 power Technology Demonstration Unit (TDU) is under development. The TDU will consist of a non-nuclear reactor simulator, a sodium-potassium heat transfer loop, a power conversion unit with electrical controls, and a heat rejection system with a multi-panel radiator assembly. Testing is planned at the Glenn Research Center Vacuum Facility 6 starting in 2012, with vacuum and liquid-nitrogen cold walls to provide simulation of operationally relevant environments. A nominal two-year test campaign is planned including a Phase 1 reactor simulator and power conversion test followed by a Phase 2 integrated system test with radiator panel heat rejection. The testing is expected to demonstrate the readiness and availability of fission surface power as a viable power system option for NASA's exploration needs. In addition to surface power, technology development work within this project is also directly applicable to in-space fission power and propulsion systems.

Palac, Donald T.↗

NASA NTRS2005

Electromagnetic Pumps for Conductive-Propellant Feed Systems

There has been a recent, renewed interest in high-power electric thrusters for application in nuclear-electric propulsion systems. Two of the most promising thrusters utilize liquid metal propellants: the lithium-fed magnetoplasmadynamic thruster and the bismuth-fed Hall thruster. An important element of part of the maturation of these thrusters will be the development of compact, reliable conductive-propellant feed system components. In the present paper we provide design considerations and experimental calibration data for electromagnetic (EM) pumps. The role of an electromagnetic pump in a liquid metal feed system is to establish a pressure gradient between the propellant reservoir and the thruster - to establish the requisite mass flow rate. While EM pumps have previously been used to a limited extent in nuclear reactor cooling loops, they have never been implemented in electric propulsion (EP) systems. The potential benefit of using EM pumps for EP are reliability (no moving parts) and the ability to precisely meter the propellant flow rate. We have constructed and tested EM pumps that use gallium, lithium, and bismuth propellants. Design details, test results (pressure developed versus current), and material compatibility issues are reported. It is concluded that EM pumps are a viable technology for application in both laboratory and flight EP conductive-propellant feed systems.

Markusic, T. E.↗