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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Oxide Dispersion Strengthened Ferritic Steel Wire Feedstock Development for Larger Format Additive Manufacturing (CRADA Final Report)

This CRADA project funded through DOE’s INFUSE program sought to demonstrate the viability of fabricating large, complex parts from oxide dispersion strengthened (ODS) steel with advanced manufacturing. Exhibiting excellent radiation tolerance and high mechanical performance at elevated temperatures, ODS steel is a promising structural material candidate for near-plasma components in fusion energy systems. Its use, however, has been limited by a lack of manufacturability. This project sought to produce ODS steel wire through a solid-state shear assisted extrusion process and then demonstrate that the wire can undergo controlled local melting while being welded with the final part sufficiently retaining the beneficial properties of ODS steel. This would allow the use of wire-arc additive manufacturing (WAAM) to manufacture large-scale ODS parts, even though ODS is currently only available as a powder. WAAM is a promising technique for producing components like the replaceable ARC vacuum vessel in CFS’ fusion reactor design. Meanwhile, this project will also expand PNNL’s capability in producing custom wire feedstock with friction extrusion, enabling downstream large-scale manufacturing with WAAM and solid-state based additive manufacturing. The project achieved its goals of developing tooling and fixturing to produce ODS wire at smaller diameters than previous projects. Several small lengths of wire of 1.5 mm and 2.5 mm diameter in the range of 2.5-30 mm long were produced at tool temperatures that are known to cause ODS particle coarsening (~1200 °C). Fixtures and tooling for longer (>1 m) wires were developed but further process development is needed reduce tool temperature during extrusions and to increase wire length needed for WAAM testing and development.

36 MATERIALS SCIENCE↗
NASA NTRS2003

Space Environment Factors Affecting the Performance of International Space Station Materials: The First Two Years of Flight Operations

In this paper, the natural and induced space environment factors affecting materials performance on ISS are described in some detail. The emphasis will be on ISS flight experience and the more significant design and development issues of the last two years. The intent is to identify and document the set of space environment factors, affecting materials, that are producing the largest impacts on the ISS flight hardware verification and acceptance process and on ISS flight operations. Orbital inclination (S1.6 ) and altitude (nominal3S0 km to 400 km altitude) determine the set of natural environment factors affecting the functional life of materials and subsystems on ISS. ISS operates in the F2 region of Earth's ionosphere in well-defined fluxes of atomic oxygen, other ionospheric plasma species, and solar UV, VUV, and x-ray radiation, as well as galactic cosmic rays, trapped radiation, and solar cosmic rays (1,2). The high latitude orbital environment also exposes external surfaces to significantly less well-defined or predictable fluxes of higher energy trapped electrons and auroral electrons (3 ,4). The micrometeoroid and orbital debris environment is an important determinant of spacecraft design and operations in any orbital inclination. Environment factors induced by ISS flight operations include ram-wake effects, magnetic induction voltages arising from flight through Earth's magnetic field, hypergolic thruster plume impingement from proximity operations of visiting vehicles, materials outgassing, venting and dumping of fluids, ISS thruster operations, as well as specific electrical power system interactions with the ionospheric plasma (S-7). ISS must fly in a very limited number of approved flight attitudes leading to location specific environmental exposures and extreme local thermal environments (8). ISS is a large vehicle and produces a deep wake structure from which both ionospheric plasma and neutrals (atomic oxygen) are largely excluded (9-11). At high latitude, the ISS wake may produce a spacecraft charging environment similar to that experienced by the DMSP and Freja satellites (800 to 100 km altitude polar orbits), especially during geo-magnetic disturbances (12-14). ISS is also subject to magnetic induction voltages (VxB L) on conducting structure, a result of high velocity flight through Earth's magnetic field. The magnitude of the magnetic induction voltage varies with location on ISS, as well as the relative orientation of the vehicle velocity vector and planetary magnetic field vector, leading to maximum induction voltages at high latitude (15). The space environment factors, natural and induced, that have had the largest impact on pre-launch ISS flight hardware verification and flight operations during the first two years of ISS flight operations are listed below and grouped according to the physical and chemical processes driving their interaction with ISS materials.

Koontz, Steven L.↗
DOE OSTI2021

Plasma-catalyst modeling for materials selection: challenges and opportunities in nitrogen oxidation

Reliable kinetic models are essential to rationalize observations and to guide the selection of appropriate plasma-catalyst combinations. Kinetic models coupling plasma- and heterogeneous-catalytic-chemistries, however, are primitive. Here, we combine reduced plasma chemistries and density functional theory parameterized surface reactions to model NO formation from N2 oxidation, an alternative nitrogen fixation process. We first show plasma excited species can enhance turnover frequencies of both Pt and Au. The enhancing potential is a function of plasma species and their densities. We then compare NO production between plasma/Pt and plasma/Au with an integral reactor model and explore the dependence of NO production as a function of plasma conditions, reactor configurations and chemical compositions. Plasma/Pt generates more NO than plasma/Au under most thermal and plasma parametric conditions. Plasma/Au outperforms plasma/Pt under high plasma excitations at low temperatures. Furthermore, these results highlight that selection of plasma-catalyst combinations should consider the properties of plasmas, materials and the coupling of the two.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Densification and Immobilization of AgI-Containing Iodine Waste Forms Using Spark Plasma Sintering

Here in this study, porous Ag-xerogel (Ag-Xero), Ag-faujasite (Ag-FAU) zeolite, and Ag-mordenite (Ag-MOR) zeolite sorbents were loaded with iodine gas [I 2 (g)] under saturated conditions at 150 °C for 24 h, followed by densification and consolidation into monolithic waste forms using spark plasma sintering (SPS). For Ag-Xero materials, SPS pellets were made with as-loaded samples, while others were made with preheated (PH; 500 °C for 2 h) samples to help with densification. SPS processing was conducted at 50 MPa under different temperatures (T = 200–800 °C) for different times (t = 0.5–30 min), where eleven AgI-Xero samples, five AgI-FAU, and two AgI-MOR separate samples were produced. The primary goal was to look for the optimum processing parameters for each material to yield pellets with high iodine retentions, high densities, and low porosities while preventing AgI decomposition. The Ag-Xero showed the highest iodine loadings (qe = 470 mg g –1 ) compared to Ag-FAU (qe = 368 mg g –1 ) and Ag-MOR (qe = 108 mg g –1 ). Measured iodine concentrations were the highest in AgI-Xero pellets without PH, followed by AgI-Xero with PH, AgI-FAU, and then AgI-MOR. Silver utilization (I/Ag on a mol % basis) values were in the order of AgI-MOR ≈ AgI-Xero (no PH) > AgI-Xero (PH) > AgI-FAU. Chemical durabilities of SPS-densified AgI-Xero (PH) pellets were very favorable, with lower releases than SPS pellets made from AgI-Xero samples without PH. These results show promise for iodine waste form production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Overview of the COMPASS results *

COMPASS addressed several physical processes that may explain the behaviour of important phenomena. This paper presents results related to the main fields of COMPASS research obtained in the recent two years, including studies of turbulence, L–H transition, plasma material interaction, runaway electron, and disruption physics: Tomographic reconstruction of the edge/SOL turbulence observed by a fast visible camera allowed to visualize turbulent structures without perturbing the plasma. Dependence of the power threshold on the X-point height was studied and related role of radial electric field in the edge/SOL plasma was identified. The effect of high-field-side error fields on the L–H transition was investigated in order to assess the influence of the central solenoid misalignment and the possibility to compensate these error fields by low-field-side coils. Results of fast measurements of electron temperature during ELMs show the ELM peak values at the divertor are around 80% of the initial temperature at the pedestal. Liquid metals were used for the first time as plasma facing material in ELMy H-mode in the tokamak divertor. Good power handling capability was observed for heat fluxes up to 12 MW m –2 and no direct droplet ejection was observed. Partial detachment regime was achieved by impurity seeding in the divertor. The evolution of the heat flux footprint at the outer target was studied. Runaway electrons were studied using new unique systems—impact calorimetry, carbon pellet injection technique, wide variety of magnetic perturbations. Radial feedback control was imposed on the beam. Forces during plasma disruptions were monitored by a number of new diagnostics for vacuum vessel (VV) motion in order to contribute to the scaling laws of sideways disruption forces for ITER. Current flows towards the divertor tiles, incl. possible short-circuiting through PFCs, were investigated during the VDE experiments. The results support ATEC model and improve understanding of disruption loads.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2008

Extraction of Thermal Performance Values from Samples in the Lunar Dust Adhesion Bell Jar

A simulation chamber has been developed to test the performance of thermal control surfaces under dusty lunar conditions. The lunar dust adhesion bell jar (LDAB) is a diffusion pumped vacuum chamber (10(exp -8) Torr) built to test material samples less than about 7 cm in diameter. The LDAB has the following lunar dust simulant processing capabilities: heating and cooling while stirring in order to degas and remove adsorbed water; RF air-plasma for activating the dust and for organic contaminant removal; RF H/He-plasma to simulate solar wind; dust sieving system for controlling particle sizes; and a controlled means of introducing the activated dust to the samples under study. The LDAB is also fitted with an in situ Xe arc lamp solar simulator, and a cold box that can reach 30 K. Samples of thermal control surfaces (2.5 cm diameter) are introduced into the chamber for calorimetric evaluation using thermocouple instrumentation. The object of this paper is to present a thermal model of the samples under test conditions and to outline the procedure to extract the absorptance, emittance, and thermal efficiency from the pristine and sub-monolayer dust covered samples.

Gaier, James R.↗
NASA NTRS2008

Extraction of Thermal Performance Values from Samples in the Lunar Dust Adhesion Bell Jar

A simulation chamber has been developed to test the performance of thermal control surfaces under dusty lunar conditions. The lunar dust adhesion bell jar (LDAB) is a diffusion pumped vacuum chamber (10-8 Torr) built to test material samples less than about 7 cm in diameter. The LDAB has the following lunar dust stimulant processing capabilities: heating and cooling while stirring in order to degas and remove absorbed water; RF air-plasma for activating the dust and for organic contaminant removal; RF H/He-plasma to simulate solar wind; dust sieving system for controlling particle sizes; and a controlled means of introducing the activated dust to the samples under study. The LDAB is also fitted with an in situ Xe arc lamp solar simulator, and a cold box that can reach 30 K. Samples of thermal control surfaces (2.5 cm diameter) are introduced into the chamber for calorimetric evaluation using thermocouple instrumentation. The object of this paper is to present a thermal model of the samples under test conditions, and to outline the procedure to extract the absorptance, emittance, and thermal efficiency from the pristine and sub-monolayer dust covered samples

Gaier, James R.↗
NASA NTRS2010

Extraction of Thermal Performance Values from Samples in the Lunar Dust Adhesion Bell Jar

A simulation chamber has been developed to test the performance of thermal control surfaces under dusty lunar conditions. The lunar dust adhesion bell jar (LDAB) is a diffusion pumped vacuum chamber (10(exp -8) Torr) built to test material samples less than about 7 cm in diameter. The LDAB has the following lunar dust simulant processing capabilities: heating and cooling while stirring in order to degas and remove adsorbed water; RF air-plasma for activating the dust and for organic contaminant removal; RF H/He-plasma to simulate solar wind; dust sieving system for controlling particle sizes; and a controlled means of introducing the activated dust to the samples under study. The LDAB is also fitted with an in situ Xe arc lamp solar simulator, and a cold box that can reach 30 K. Samples of thermal control surfaces (2.5 cm diameter) are introduced into the chamber for calorimetric evaluation using thermocouple instrumentation. The object of this paper is to present a thermal model of the samples under test conditions and to outline the procedure to extract the absorptance, emittance, and thermal efficiency from the pristine and sub-monolayer dust covered samples.

Gaier, James R.↗
NASA NTRS1991

Oxygen production processes on the Moon: An overview

The production of oxygen on the Moon utilizing indigenous material is paramount to a successful lunar colonization. Several processes were put forth to accomplish this. The lunar liquid oxygen (LLOX) generation schemes which have received the most study to date are those involving: (1) the reduction of ilmenite (FeTiO3) by H2, C, CO, CH4, CO-Cl2 plasma; (2) magma electrolysis, both unadulterated and fluoride-fluxed, and (3) several others, including carbo-chlorination, HF acid leaching, fluorine extraction, magma oxidation, and vapor pyrolysis. The H2 reduction of ilmenite and magma electrolysis processes have received the most study to date. At this stage of development, they both appear feasible schemes with various pros and cons. However, all processes should be addressed at least at the onset of the considerations. It is ultimatley the energy requirements of the entire process, including the acquisition of feedstock, which will determine the mode of oxygen productions. There is an obvious need for considerably more experimentation and study. Some of these requisite studies are in progress, and several of the most studied and feasible processes for winning oxygen from lunar materials are reviewed.

Taylor, Lawrence A.↗
NASA NTRS2022

Design of Hypervelocity Flow Generator (HFG) and Its Diagnostics

Ground facilities for hypersonic research are a key element for successful development of aerodynamically proven hypervelocity vehicles. Design concepts and diagnostics of a hypervelocity flow generator (HFG) were made as a test platform for hypersonic/hypervelocity spacecraft models at the NASA Langley Research Center. The HFG is a hypersonic flow field generator using optically heated gas which is blown into an 80 cu m vacuum chamber. The vacuum chamber is kept at a stable vacuum pressure with a combination of three large vacuum pumps, while the HFG is in the test mode. The HFG provides a relatively small test section with approximately a 20 cm window. This facility was designed to generate 2.45 km/sec of flow speed, and potentially generate a continuous flow with the nozzle and vacuum system. The window in test section provides a direct view of the shock wave around a model in order to measure temperature, pressure, and density profile within the shock layer. One of the key test goals under this project is to understand why the emission spectra from the standing shockwave plasma predicted by Lora-Loran codes are significantly different from the measured emission spectra from the Flight Investigation Reentry Environment (FIRE II) Flight. The correct estimate of the thermal loading on the leading edge of hypersonic vehicles greatly affects the aerodynamic design, the material selection for the vehicle, and the cooling requirement and can be obtained by the precise modeling of emission spectra from shockwave plasma. However, the estimation of thermal loading is not an easy task due to complex non-equilibrium radiative process within high temperature shock layers that still falls into a category of cold plasma. Direct flight experiments are the most desirable, but not a cost-effective approach. Analysis by computational fluid dynamics (CFD) offers many test flexibilities. However, the CFD codes must be fully tested and validated with experimental data before the codes are effectively used for practical design. Large discrepancies between experiments and codes appear in hypersonic/hypervelocity flow regimes at high altitudes of 60 km ~ 90 km. This HFG facility offers some important parameters for CFD code validation, such as collision cross-sections, relaxation times, reaction rate coefficients and transportation coefficients. The HFG test facility is based on the ejection flow of high temperature gas heated over to 3500 K through a nozzle. The tungsten gas chamber of the HFG is heated up to a desired temperature by a 60 kW optical power beam source. This system consists of an optical power source, a thermal chamber, an expansion nozzle, a test section, and an 80 cu m vacuum tank. 60 kW optical input power is obtained from the 150 kW Vortek arc lamp system (by Vortek Industries, Vancouver, Canada). This optical beam is focused to heat the gas chamber within which a flow media is heated. The maximum achievable temperature of the flow medium reached approximately 3500 K or even higher but is limited by the melting point of the chamber material used. The exhaust velocity through the nozzle was determined by the stagnation temperature and the molecular weight of the working medium at the test section. To provide design parameters, a NASA Chemical Equilibrium with Application (CEA) computer program is used for the simulation of aerothermal data. This CEA program can calculate chemical equilibrium and properties of complex mixtures using shock tube parameters. For nitrogen gas at 2666 K stagnation temperature, the maximum achievable velocity at the test section is approximately 2.45 km/sec which is within the range of the thermal velocity of 8000 K shock layer. Based on the calculation through the CEA program, the design parameters of a HFG were determined and implemented for the test section that includes an expansion nozzle. The installed test section of the experimental facility can sustain a condition of a re-entry vehicle from the Space at an altitude of 60-90 km. After installation of the HFG, the system was fully tested and its operational parameters were measured. An 80 cu m vacuum chamber of HFG was set at 1 torr level to keep a stable downstream condition. The pumping time to reach the minimum vacuum pressure (~ 1 torr) at the test chamber from atmospheric pressure was approximately an hour using Kinney (MBV-14000/MB -1600/KT-300) and Stokes (Model 1772 and 412) pumps. Such a setup condition allowed a continued stable operation of the HFG experiment with flowrates through 1-, 3-, or 5-mm diameters of nozzle throat. The flow characteristics of the HFG for various operating conditions were performed using a focused Schlieren method. At 0.8 torr chamber pressure, a barrel shock was observed at the test section. With a sphere obstacle of 12 mm diameter in the flow, a bow shock (~ 2-mm thickness) was observed by a focused Schlieren visualization method.

Hypervelocity flow↗
NASA NTRS2006

Electrically Conductive Anodized Aluminum Surfaces

Anodized aluminum components can be treated to make them sufficiently electrically conductive to suppress discharges of static electricity. The treatment was conceived as a means of preventing static electric discharges on exterior satin-anodized aluminum (SAA) surfaces of spacecraft without adversely affecting the thermal-control/optical properties of the SAA and without need to apply electrically conductive paints, which eventually peel off in the harsh environment of outer space. The treatment can also be used to impart electrical conductivity to anodized housings of computers, medical electronic instruments, telephoneexchange equipment, and other terrestrial electronic equipment vulnerable to electrostatic discharge. The electrical resistivity of a typical anodized aluminum surface layer lies between 10(exp 11) and 10(exp 13) Omega-cm. To suppress electrostatic discharge, it is necessary to reduce the electrical resistivity significantly - preferably to < or = 10(exp 9) Omega-cm. The present treatment does this. The treatment is a direct electrodeposition process in which the outer anodized surface becomes covered and the pores in the surface filled with a transparent, electrically conductive metal oxide nanocomposite. Filling the pores with the nanocomposite reduces the transverse electrical resistivity and, in the original intended outer-space application, the exterior covering portion of the nanocomposite would afford the requisite electrical contact with the outer-space plasma. The electrical resistivity of the nanocomposite can be tailored to a value between 10(exp 7) and 10(exp 12) Omega-cm. Unlike electrically conductive paint, the nanocomposite becomes an integral part of the anodized aluminum substrate, without need for adhesive bonding material and without risk of subsequent peeling. The electrodeposition process is compatible with commercial anodizing production lines. At present, the electronics industry uses expensive, exotic, electrostaticdischarge- suppressing finishes: examples include silver impregnated anodized, black electroless nickel, black chrome, and black copper. In comparison with these competing finishes, the present nanocomposite finishes are expected to cost 50 to 20 percent less and to last longer.

Nguyen, Trung Hung↗
NASA NTRS1978

The association of nonthermal electrons with non-flaring coronal transients

A close temporal and spatial association has been found between erupting filaments/coronal transients and radio noise storm continua. The three transients studied occurred away from active regions and are members of a class not usually accompanied by chromospheric emission. The data analyzed were from the S-054 soft X-ray telescope on Skylab and from one- and two-dimensional interferometers at meter and decameter wavelengths at Nancay and Clark Lake observatories. Calculations confirmed that observed microwave radiation from the transients is due to thermal bremsstrahlung. The results are consistent with an interpretation of heating of an increased amount of coronal plasma by nonthermal, 10-100 keV electrons. Three possibilities for the source of the material are described: (1) the filament material; (2) evaporation from the chromosphere or transition region; and (3) via a long-lived reconnection process.

Webb, D. F.↗
NASA NTRS2008

Spray Forming of NiTi and NiTiPd Shape-Memory Alloys

In the work to be presented, vacuum plasma spray forming has been used as a process to deposit and consolidate prealloyed NiTi and NiTiPd powders into near net shape actuators. Testing showed that excellent shape memory behavior could be developed in the deposited materials and the investigation proved that VPS forming could be a means to directly form a wide range of shape memory alloy components. The results of DSC characterization and actual actuation test results will be presented demonstrating the behavior of a Nitinol 55 alloy and a higher transition temperature NiTiPd alloy in the form of torque tube actuators that could be used in aircraft and aerospace controls.

Mabe, James↗
NASA NTRS1985

Development of thermomechanical life prediction models for thermal barrier coatings

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology with both performance and durability benefits. The foremost TBC benefit is the reduction of heat transferred into air-cooled components. To achieve these benefits, however, the TBC system must be reliable. Mechanistic thermomechanical and thermochemical life models and statistically significant design data are therefore required for the reliable exploitation of TBC benefits on gas turbine airfoils. Garrett's NASA-HOST Program (NAS3-23945) is designed to fulfill these requirements. This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) applied oxidation resistant NiCrAlY bond coating, and an air-plasma-sprayed yttria partially stabilized zirconia insulated layer is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron beam-physical vapor deposition process by Temescal. Thermomechanical life models are being tailored to predict TBC strain tolerance in terms of materials, engine, and mission parameters. Continuum and fracture mechanics approaches and statistical methods are being evaluated to develop tensile and compressive strain functions required to drive a mission analysis capable thermomechanical life model for TBCs. Results of initial testing to calibrate these life models will be presented.

Strangman, T. E.↗
NASA NTRS2015

Spillage of Lunar Polar Crater Volatiles onto Adjacent Terrains: The Case for Dynamic Processes

We present an investigation of the release and transport of lunar polar crater volatiles onto topside regions surrounding the cold traps. The volatiles are liberated via surface energization processes associated with the harsh space environment, including solar wind plasma sputtering and impact vaporization. We find that some fraction of these volatiles can migrate from crater floors onto topside regions (those regions directly adjacent to and above the polar crater floors), and that these surrounding terrains should contain a sampling of the material originating within the crater itself. It is concluded that the nature of the volatile content on crater floors can be obtained by sampling the surface volatiles that have migrated or "spilled out" onto the adjacent terrain. This "spillage" effect could make human or robotic prospecting for crater resources significantly easier, since an assessment may not require direct entry into the very harsh polar crater environment. We also suggest that there are dynamic processes actively operating on the crater floors, and we estimate their source rates assuming dynamic equilibrium of the observed water frost and our modeled loss rates.

Vaporization↗
DOE OSTI2025

Measurement of partial vapor pressures of salt mixtures via combined horizontal transpiration and thermogravimetric analysis

A method combining thermogravimetric analysis (TGA) and horizontal transpiration with elemental analysis via inductively coupled plasma mass spectrometry or ion chromatography enabled calculation of partial pressures of individual salts in molten mixtures. TGA quantified total mass loss, while transpiration identified vapor-phase composition. Furthermore, two chloride (NaCl-MgCl 2 , NaCl-MgCl 2 + UCl 3 ) salts and one mixed halide (LiCl-LiF + Li 2 O) salt were analyzed at 750 °C and 550 °C, respectively. NaCl and MgCl 2 vapor pressures were 2.19–2.61 × 10 -4 atm and 2.47–2.48 × 10 -5 atm (dependent upon the identity of the invesitgated mixture); UCl 3 was 1.42 × 10 -7 atm. LiCl and LiF vapor pressures at 550 °C were 1.53 × 10 -6 and 6.32 × 10 -6 atm, respectively. Additionally, the TGA method was validated against values from the literature for unary LiCl and LiF.

36 MATERIALS SCIENCE↗