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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 NTRS2002

High Temperature Composite Heat Exchangers

High temperature composite heat exchangers are an enabling technology for a number of aeropropulsion applications. They offer the potential for mass reductions of greater than fifty percent over traditional metallics designs and enable vehicle and engine designs. Since they offer the ability to operate at significantly higher operating temperatures, they facilitate operation at reduced coolant flows and make possible temporary uncooled operation in temperature regimes, such as experienced during vehicle reentry, where traditional heat exchangers require coolant flow. This reduction in coolant requirements can translate into enhanced range or system payload. A brief review of the approaches and challengers to exploiting this important technology are presented, along with a status of recent government-funded projects.

Eckel, Andrew J.↗
NASA NTRS2002

HfB2-SiC Materials for Sharp Leading Edges

Future reentry vehicles will need better maneuverability to improve safety and performance. Vehicles with sharp leading edges, as opposed to the blunt nose and leading edges on the current space shuttle, can provide improved lift-to-drag and thus improved maneuverability. Materials capable of operating at temperatures in excess of 2000 C are required. Ultrahigh temperature ceramics (UHTCs) are one class of material being investigated for this application. These materials are diborides of hafnium or zirconium with a second phase of sic. The benefits of using these materials will be discussed as developments in the processing of HfB2/SiC.

Johnson, Sylvia M.↗
NASA NTRS2003

2002 NASA Seal/Secondary Air System Workshop

The 2002 NASA Seal/Secondary Air System Workshop covered the following topics: (i) Overview of NASA s perspective of aeronautics and space technology for the 21st century; (ii) Overview of the NASA-sponsored Ultra-Efficient Engine Technology (UEET), Turbine-Based Combined-Cycle (TBCC), and Revolutionary Turbine Accelator (RTA) programs; (iii) Overview of NASA Glenn's seal program aimed at developing advanced seals for NASA's turbomachinery, space propulsion, and reentry vehicle needs; (iv) Reviews of sealing concepts, test results, experimental facilities, and numerical predictions; and (v) Reviews of material development programs relevant to advanced seals development. The NASA UEET and TBCC/RTA program overviews illustrated for the reader the importance of advanced technologies, including seals, in meeting future turbine engine system efficiency and emission goals. For example, the NASA UEET program goals include an 8- to 15-percent reduction in fuel burn, a 15-percent reduction in CO2, a 70-percent reduction in NOx, CO, and unburned hydrocarbons, and a 30-dB noise reduction relative to program baselines. The workshop also covered several programs NASA is funding to investigate advanced reusable space vehicle technologies (X-38) and advanced space ram/scramjet propulsion systems. Seal challenges posed by these advanced systems include high-temperature operation, resiliency at the operating temperature to accommodate sidewall flexing, and durability to last many missions.

Steinetz, Bruce M.↗
NASA NTRS1961

Heat-Transfer Measurements on the Apexes of Two 60 deg Sweptback Delta Wings (Panel Semiapex Angle of 30 deg) Having 0 deg and 45 deg Dihedral at a Mach Number of 4.95

An experimental investigation was conducted to evaluate the heat-transfer rates at the apex of two 60 degree sweptback delta wings (panel semi-apex angle of 30 degrees) having cylindrical leading edges and 0 degrees and 45 degree positive dihedral. The models tested might correspond to the first several feet of a hypersonic reentry vehicle. The tests were conducted at a Mach number of 4.95 and a stagnation temperature of 400 F. nominal test-section unit Reynolds numbers varied from 2 x 10(exp 6) to 12 x 10(exp 6) per foot. The results of the investigation indicated that the laminar heat-transfer distributions (ratio of local to stagnation-line heating rate) about the models normal to the leading edges were in close agreement with two-dimensional blunt-body theory. The three-dimensional stagnation point heat-transfer rate on the 0 degree dihedral model was in excellent agreement with theory and the stagnation-line heat transfer on the straight portion of the leading edge of both models approached a constant level 12 percent above the theoretical stagnation-line level on an isolated swept infinite cylinder. When the heating rates on the 45 degree dihedral model (planform sweep of 69.3 degree) were compared with those on the 0 degree dihedral model (planform sweep of 60 degrees) at equal angles of attack and equal lifts greater than zero, the stagnation-line heating rates on the 45 degrees dihedral model were, in general, considerably lower as a result of the difference in effective sweeps of the leading edges. On the wing panels inboard from the stagnation lines, the differences in heating were very small. The stagnation-line heat-transfer variation with angle of attack, the shift in stagnation-line location, and the reduction in stagnation-line heat transfer resulting from the increase in effective sweep when positive dihedral is incorporated into a constant-panel 0 degree dihedral wing, all agreed with the results of a theoretical study made of highly swept delta wings with large positive dihedral.

Gunn, Charles R.↗
NASA NTRS1997

Isolated Roughness Induced Boundary-Layer Transition: Shuttle Orbiter Ground Tests and Flight Experience

Recent Orbiter wind tunnel data and flight data have been used to evaluate boundary-layer transition induced by discrete-roughness elements on the Orbiter windward surface. Orbiter flow field calculations have been used to compute transition parameters and disturbance parameters for correlating the results and comparing the trends. Existing transition correlations have been modified and applied to the Orbiter. These correlations provide a means to predict transition on the Orbiter given a known isolated roughness element. Furthermore, these data and data reduction methods provide information and guidance for the prediction of transition due to &screte-roughness elements on future winged reentry vehicles.

Bouslog, Stanley A.↗
NASA NTRS2004

Actively Cooled Ceramic Matrix Composite Concepts for High Heat Flux Applications

High temperature composite heat exchangers are an enabling technology for a number of aeropropulsion applications. They offer the potential for mass reductions of greater than fifty percent over traditional metallics designs and enable vehicle and engine designs. Since they offer the ability to operate at significantly higher operating temperatures, they facilitate operation at reduced coolant flows and make possible temporary uncooled operation in temperature regimes, such as experienced during vehicle reentry, where traditional heat exchangers require coolant flow. This reduction in coolant requirements can translate into enhanced range or system payload. A brief review of the approaches, challenges and test results are presented, along with a status of recent government-funded projects.

Eckel, Andrew J.↗
NASA NTRS2004

Implementation Challenges for Ceramic Matrix Composites in High Temperature Applications

Ceramic matrix composites are leading candidate materials for a number of applications in aeronautics, space, energy, electronics, nuclear, and transportation industries. In the aeronautics and space exploration systems, these materials are being considered for applications in hot sections of jet engines such as the combustor liner, nozzle components, nose cones, leading edges of reentry vehicles and space propulsion components. Applications in the energy and environmental industries include radiant heater tubes, heat exchangers, heat recuperators, gas and diesel particulate filters (DPFs), and components for land based turbines for power generation. These materials are also being considered for use in the first wall and blanket components of fusion reactors. There are a number of critical issues and challenges related to successful implementation of composite materials. Fabrication of net and complex shape components with high density and tailorable matrix properties is quite expensive, and even then various desirable properties are not achievable. In this presentation, microstructure and thermomechanical properties of composites fabricated by two techniques (chemical vapor infiltration and melt infiltration), will be presented. In addition, critical need for robust joining and assembly technologies in successful implementation of these systems will be discussed. Other implementation issues will be discussed along with advantages and benefits of using these materials for various components in high temperature applications.

Singh, Mrityunjay↗
NASA NTRS2002

Evaluation of Ultra-High Temperature Ceramics for Propulsion Application

Ultra-high temperature ceramic (UHTC) materials consisting of zirconium diboride or hafnium diboride plus silicon carbide offer a combination of properties that make them candidates for airframe leading edges on sharp-bodied reentry vehicles. These UHTC perform well in the environment for such applications, i.e. low pressure air. The purpose of this study was to examine three of these materials under conditions more representative of a propulsion environment, i.e. higher oxygen and total pressure. Results of stren$h and fracture toughness measurements, furnace oxidation, and thermal shock exposures are presented. The poor oxidation resistance of UHTCs is the predominant factor limiting their applicability to propulsion.

Levine, Stanley R.↗
NASA NTRS2003

Ultra-High-Temperature Ceramics Evaluated for Aeropropulsion Use

Ultra-high-temperature ceramics (UHTC) are a group of materials consisting of zirconium diboride (ZrB2) or hafnium diboride (HfB2) plus silicon carbide (SiC), and in some instances, carbon (C). They offer a combination of properties that make them candidates for airframe leading edges on sharp-bodied reentry vehicles. These UHTCs perform well in the environment for such applications (i.e., air at low pressures). The purpose of this study at the NASA Glenn Research Center was to examine three of these materials under conditions more representative of a propulsion environment: that is, higher oxygen partial pressure and total pressure. Relatively long, multiple-exposure cycles were emphasized. We completed an in-house study of ZrB2 plus 20 vol% SiC (abbreviated as ZS), ZrB2 plus 14 vol% SiC and 30 vol% C (ZSC), and SCS-9a SiC fiber-reinforced ZrB2 plus 20 vol% SiC (ZSS). HfB2-based compositions were not included in the study because of their high cost. The capability of UHTC for propulsion applications must be compared with that of mature, available, and commercially used ceramics such as silicon nitride (e.g., AS-800) to put things in proper perspective. In terms of mechanical properties, UHTCs fall short in terms of strength and fracture toughness. At about 1300 C, the creep resistance of ZS appears to be superior to the creep resistance reported for AS-800. However, the stress rupture life for Si3N4 under stress and temperature conditions similar to those used in this study is measured in hundreds of hours. Because of oxidation, ZS could not achieve such lives. In terms of oxidation resistance, acceptable amounts of material recession in 1 hour to thousands of hours, depending on the specific propulsion application, are on the order of 100 to 300 mm. This converts to an acceptable range of parabolic recession rate constants kp" of approximately less than or equal to 10(exp -1) to 10(exp -2) square millimeters per hour for a 1-hr application. For a 100-hr application, an acceptable range of kp" would be less than or equal to those values divided by 100. For the more oxidation resistant ZS material, measured parabolic recession rate constants were 4.7 x 10(exp -3) millimeters per hour at 1327 C, 7.8 x 10(exp -2) square millimeters per hour at 1627 C, and 1.3 millimeters per hour at 1927 C. Thus, recession rate constants for ZS are acceptable at 1327 C for a 1-hr application, but here silicon nitride is a superior material. At 1627 C, ZS oxidation is marginal for a 1-hr application, but dimensional growth would be an issue. In a 100-hr application, ZS cannot be considered at any temperature. Our cursory examination of thermal shock, both from a theoretical and experimental viewpoint, indicated that the ZS and ZSC UHTCs are inferior to AS-800 silicon nitride. On the basis of this limited study, UHTCs are not ready to be considered as aeropropulsion materials for any applications longer than a few minutes. Current materials suffer from aggressive oxidation and moisture attack (Quynhgiao Nguyen, NASA Glenn, and Raymond C. Robinson, QSS Group, Inc., Cleveland, OH, 2002, private communication), and they are susceptible to thermal shock. For long-term propulsion applications, major improvements in environmental durability are needed. Work is in progress to improve the oxidation resistance of UHTC materials.

Levine, Stanley R.↗
NASA NTRS2005

Incorporation of a Chemical Equilibrium Equation of State into LOCI-Chem

Renewed interest in development of advanced high-speed transport, reentry vehicles and propulsion systems has led to a resurgence of research into high speed aerodynamics. As this flow regime is typically dominated by hot reacting gaseous flow, efficient models for the characteristic chemical activity are necessary for accurate and cost effective analysis and design of aerodynamic vehicles that transit this regime. The LOCI-Chem code recently developed by Ed Luke at Mississippi State University for NASA/MSFC and used by NASA/MSFC and SSC represents an important step in providing an accurate, efficient computational tool for the simulation of reacting flows through the use of finite-rate kinetics [3]. Finite rate chemistry however, requires the solution of an additional N-1 species mass conservation equations with source terms involving reaction kinetics that are not fully understood. In the equilibrium limit, where the reaction rates approach infinity, these equations become very stiff. Through the use of the assumption of local chemical equilibrium the set of governing equations is reduced back to the usual gas dynamic equations, and thus requires less computation, while still allowing for the inclusion of reacting flow phenomenology. The incorporation of a chemical equilibrium equation of state module into the LOCI-Chem code was the primary objective of the current research. The major goals of the project were: (1) the development of a chemical equilibrium composition solver, and (2) the incorporation of chemical equilibrium solver into LOCI-Chem. Due to time and resource constraints, code optimization was not considered unless it was important to the proper functioning of the code.

Cox, Carey F.↗
NASA NTRS2005

Glenn Refractory Adhesive for Bonding and Exterior Repair (GRABER) Developed for Repairing Shuttle Damage

Advanced in-space repair technologies for reinforced carbon/carbon composite (RCC) thermal protection system (TPS) structures are critically needed for the space shuttle Return To Flight (RTF) efforts. These technologies are also critical for the repair and refurbishment of thermal protection system structures of future Crew Exploration Vehicles of space exploration programs. The Glenn Refractory Adhesive for Bonding and Exterior Repair (GRABER) material developed at the NASA Glenn Research Center has demonstrated capabilities for repair of small cracks and damage in RCC leading-edge material. The concept consists of preparing an adhesive paste of desired ceramic in a polymer/phenolic resin matrix with appropriate additives, such as surfactants, and then applying the paste into the damaged or cracked area of the RCC composite components with caulking guns. The adhesive paste cures at 100 to 120 C and transforms into a high-temperature ceramic during simulated vehicle reentry testing conditions.

Singh, Mrityunjay↗
NASA NTRS2005

Six-Degree-of-Freedom Trajectory Optimization Utilizing a Two-Timescale Collocation Architecture

Six-degree-of-freedom (6DOF) trajectory optimization of a reentry vehicle is solved using a two-timescale collocation methodology. This class of 6DOF trajectory problems are characterized by two distinct timescales in their governing equations, where a subset of the states have high-frequency dynamics (the rotational equations of motion) while the remaining states (the translational equations of motion) vary comparatively slowly. With conventional collocation methods, the 6DOF problem size becomes extraordinarily large and difficult to solve. Utilizing the two-timescale collocation architecture, the problem size is reduced significantly. The converged solution shows a realistic landing profile and captures the appropriate high-frequency rotational dynamics. A large reduction in the overall problem size (by 55%) is attained with the two-timescale architecture as compared to the conventional single-timescale collocation method. Consequently, optimum 6DOF trajectory problems can now be solved efficiently using collocation, which was not previously possible for a system with two distinct timescales in the governing states.

Desai, Prasun N.↗
NASA NTRS2005

A Numerical Study of Resistivity and Hall Effects for a Compressible MHD Model

The effect of resistive, Hall, and viscous terms on the flow structure compared with compressible ideal MHD is studied numerically for a one-fluid non-ideal MHD model. The goal of the present study is to shed some light on the emerging area of non-ideal MHD modeling and simulation. Numerical experiments are performed on a hypersonic blunt body flow with future application to plasma aerodynamics flow control in reentry vehicles. Numerical experiments are also performed on a magnetized time-developing mixing layer with possible application to magnetic/turbulence mixing.

Yee, H. C.↗
NASA NTRS2005

2004 NASA Seal/Secondary Air System Workshop, Volume 1

The 2004 NASA Seal/Secondary Air System workshop covered the following topics: (1) Overview of NASA s new Exploration Initiative program aimed at exploring the Moon, Mars, and beyond; (2) Overview of the NASA-sponsored Ultra-Efficient Engine Technology (UEET) program; (3) Overview of NASA Glenn s seal program aimed at developing advanced seals for NASA s turbomachinery, space, and reentry vehicle needs; (4) Reviews of NASA prime contractor and university advanced sealing concepts including tip clearance control, test results, experimental facilities, and numerical predictions; and (5) Reviews of material development programs relevant to advanced seals development. The NASA UEET overview illustrated for the reader the importance of advanced technologies, including seals, in meeting future turbine engine system efficiency and emission goals. For example, the NASA UEET program goals include an 8- to 15-percent reduction in fuel burn, a 15-percent reduction in CO2, a 70-percent reduction in NOx, CO, and unburned hydrocarbons, and a 30-dB noise reduction relative to program baselines. The workshop also covered several programs NASA is funding to develop technologies for the Exploration Initiative and advanced reusable space vehicle technologies. NASA plans on developing an advanced docking and berthing system that would permit any vehicle to dock to any on-orbit station or vehicle, as part of NASA s new Exploration Initiative. Plans to develop the necessary mechanism and androgynous seal technologies were reviewed. Seal challenges posed by reusable re-entry space vehicles include high-temperature operation, resiliency at temperature to accommodate gap changes during operation, and durability to meet mission requirements.

Source record↗
NASA NTRS2006

Integrated Thermal Protection Systems and Heat Resistant Structures

In the early stages of NASA's Exploration Initiative, Snecma Propulsion Solide was funded under the Exploration Systems Research & Technology program to develop a CMC heatshield, a deployable decelerator, and an ablative heat shield for reentry vehicles. Due to changes within NASA's Exploration Initiative, this task was cancelled in early FY06. This paper will give an overview of the work that was accomplished prior to cancellation. The Snecma team consisted of MT Aerospace, Germany, and Materials Research & Design (MR&D), NASA Langley, NASA Dryden, and NASA Ames in the United States. An Apollo-type capsule was chosen as the reference vehicle for the work. NASA Langley generated the trajectory and aerothermal loads. Snecma and MT Aerospace began the design of a ceramic aft heatshield (CAS) utilizing C/SiC panels as the capsule heatshield. MR&D led the design of a C/SiC deployable decelerator, NASA Ames led the characterization of several ablators, NASA Dryden led the development of a heath management system and the high temperature structures testing, and NASA Langley led the insulation characterization. Though the task was pre-maturely cancelled, a significant quantity of work was accomplished.

Pichon, Thierry↗
NASA NTRS2006

2005 NASA Seal/Secondary Air System Workshop, Volume 1

The 2005 NASA Seal/Secondary Air System workshop covered the following topics: (i) Overview of NASA s new Exploration Initiative program aimed at exploring the Moon, Mars, and beyond; (ii) Overview of the NASA-sponsored Propulsion 21 Project; (iii) Overview of NASA Glenn s seal project aimed at developing advanced seals for NASA s turbomachinery, space, and reentry vehicle needs; (iv) Reviews of NASA prime contractor, vendor, and university advanced sealing concepts including tip clearance control, test results, experimental facilities, and numerical predictions; and (v) Reviews of material development programs relevant to advanced seals development. Turbine engine studies have shown that reducing high-pressure turbine (HPT) blade tip clearances will reduce fuel burn, lower emissions, retain exhaust gas temperature margin, and increase range. Several organizations presented development efforts aimed at developing faster clearance control systems and associated technology to meet future engine needs. The workshop also covered several programs NASA is funding to develop technologies for the Exploration Initiative and advanced reusable space vehicle technologies. NASA plans on developing an advanced docking and berthing system that would permit any vehicle to dock to any on-orbit station or vehicle. Seal technical challenges (including space environments, temperature variation, and seal-on-seal operation) as well as plans to develop the necessary "androgynous" seal technologies were reviewed. Researchers also reviewed tests completed for the shuttle main landing gear door seals.

Steinetz, Bruce M.↗
NASA NTRS2007

Fluorescence Visualization of Hypersonic Flow over Rapid Prototype Wind-Tunnel Models

Reentry models for use in hypersonic wind tunnel tests were fabricated using a stereolithography apparatus. These models were produced in one day or less, which is a significant time savings compared to the manufacture of ceramic or metal models. The models were tested in the NASA Langley Research Center 31-Inch Mach 10 Air Tunnel. Most of the models did not survive repeated tests in the tunnel, and several failure modes of the models were identified. Planar laser-induced fluorescence (PLIF) of nitric oxide (NO) was used to visualize the flowfields in the wakes of these models. Pure NO was either seeded through tubes plumbed into the model or via a tube attached to the strut holding the model, which provided localized addition of NO into the model s wake through a porous metal cylinder attached to the end of the tube. Models included several 2-inch diameter Inflatable Reentry Vehicle Experiment (IRVE) models and 5-inch diameter Crew Exploration Vehicle (CEV) models. Various configurations were studied including different sting placements relative to the models, different model orientations and attachment angles, and different NO seeding methods. The angle of attack of the models was also varied and the location of the laser sheet was scanned to provide three-dimensional flowfield information. Virtual Diagnostics Interface technology, developed at NASA Langley, was used to visualize the data sets in post processing. The use of calibration "dotcards" was investigated to correct for camera perspective and lens distortions in the PLIF images. Lessons learned and recommendations for future experiments are discussed.

Alderfer, D. W.↗
NASA NTRS2005

Advanced Ceramic Matrix Composites (CMCs) for High Temperature Applications

Advanced ceramic matrix composites (CMCs) are enabling materials for a number of demanding applications in aerospace, energy, and nuclear industries. In the aerospace systems, these materials are being considered for applications in hot sections of jet engines such as the combustor liner, vanes, nozzle components, nose cones, leading edges of reentry vehicles, and space propulsion components. Applications in the energy and environmental industries include radiant heater tubes, heat exchangers, heat recuperators, gas and diesel particulate filters, and components for land based turbines for power generation. These materials are also being considered for use in the first wall and blanket components of fusion reactors. In the last few years, a number of CMC components have been developed and successfully tested for various aerospace and ground based applications. However, a number of challenges still remain slowing the wide scale implementation of these materials. They include robust fabrication and manufacturing, assembly and integration, coatings, property modeling and life prediction, design codes and databases, repair and refurbishment, and cost. Fabrication of net and complex shape components with high density and tailorable matrix properties is quite expensive, and even then various desirable properties are not achievable. In this presentation, a number of examples of successful CMC component development and testing will be provided. In addition, critical need for robust manufacturing, joining and assembly technologies in successful implementation of these systems will be discussed.

Singh, M.↗