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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Thermochemistry of Calcium-Magnesium-Aluminum-Silicate (CMAS) and Components of Advanced Thermal and Environmental Barrier Coating Systems

There is increasing interest in the degradation mechanism studies of thermal and environmental barrier coatings (TEBCs) of gas turbines by molten CaO-MgO-Al(exp. 2)O(exp. 3)-SiO(exp. 2) CMAS). CMAS minerals are usually referred as silicon-containing sand dust and volcano ash materials that are carried by the intake air into gas turbines, e.g. in aircraft engines, and their deposits often react at high temperatures (greater than 1200 degrees C) with the engine turbine coating systems and components. The high temperature reactions causes degradation and accelerated failure of the static and rotating components of the turbine engines. We discuss some results of the reactions between the CMAS and Rare-Earth (RE = Y, Yb, Dy, Gd, Nd and Sm) - oxide stabilized ZrO(exp. 2) or HfO(exp. 2) systems, and the stability of the resulting oxides and silicates. Plasma sprayed hollow tube samples (outside diameter = 4.7 mm, wall thickness = 0.76 mm and = 26 mm height) were half filled with CMAS powder, wrapped and sealed with platinum foil, and heat treated at 1310 degrees C for 5h. Samples were characterized by differential scanning calorimetry (DSC), X-ray diffraction, and cross-section electron microscopy analysis and energy dispersive X-ray spectroscopy. It was found that CMAS penetrated the samples at the grain boundaries and dissolved the TEBC materials to form silicate phases containing the rare-earth elements. Furthermore, it was found that apatite crystalline phases were formed in the samples with total rare-earth content higher than 12 mol% in the reaction zone for the ZrO(exp. 2) system. In general, samples with the nominal compositions (30YSZ), HfO(exp. 2)-7Dy(exp. 2)O(exp. 2) and ZrO(exp. 2)-9.5Y(exp. 2)O(exp. 3)-2.25Gd(exp. 2)O(exp. 3)-2.25Yb(exp. 2)O(exp. 3) exhibited lower reactivity or more resistance to CMAS than the other coating compositions of this work.

degradation↗
NASA NTRS2019

Mechanical Tensile Testing of Hiperco 50A at Cryogenic Temperature

Hiperco 50A is a highly desired material for use in cryogenic applications, specifically for adiabatic demagnetization refrigerators (ADRs) due to its magnetic field shielding capabilities. Although the alloy has good strength, there is a concern with the material's brittle behavior which is believed to worsen at low temperature based on previous tests. The testing described here investigates the mechanical properties of Hiperco 50A at cryogenic temperature through mechanical tensile testing to failure and evaluation of the failed coupons. The methods and techniques used to determine the elongation, yield strength, ultimate tensile strength, and break strength of the material as well as the results will be presented here.

material properties↗
NASA NTRS1990

Combustion interaction with radiation-cooled chambers

Over 15 hours of thruster operation at temperatures between 1916 and 2246 C without failure or erosion has been demonstrated using iridium-coated rhenium chamber materials with nitrogen tetroxide/monomethylhydrazine propellants operating over a mixture ratio range of 1.60-2.05. Research is now under way to provide a basic understanding of the mechanisms which make high-temperature operation possible and to extend the capability to a wider range of conditions, including other propellant combinations and chamber materials. Techniques have been demonstrated for studying surface fracture phenomena. These include surface Raman and Auger for study of oxide formation, surface Raman and X-ray diffraction to determine the oxide phase, Auger to study oxide stoichiometry, and sputter Auger to study interdiffusion of alloy species.

Rosenberg, S. D.↗
DOE OSTI2022

Quantifying Thermal Output of Energetic Materials (LDRD Final Report)

We present the results of an LDRD project, funded by the Nuclear Deterrence IA, to develop capabilities for quantitative assessment of pyrotechnic thermal output. The thermal battery igniter is used as an exemplar system. Experimental methodologies for thermal output evaluation are demonstrated here, which can help designers and engineers better specify pyrotechnic components , provide thermal output guidelines for new formulations, and generate new metrics for assessing component performance and margin given a known failure condition. A heat-transfer analysis confirms that the dominant mode of energy transfer from the pyrotechnic output plume to the heat pellet is conduction via deposition of hot titanium particles. A simple lumped-parameter model of titanium particle heat transfer and a detailed multi-phase model of deposition heat transfer are discussed. Pyrotechnic function, as defined by "go/no-go" standoff testing of a heat pellet, is correlated with experimentally measured igniter plume temperature, titanium metal particle temperature, and energy deposition. Three high-speed thermal diagnostics were developed for this task. A three-color imaging pyrometer, acquiring 100k images per second on three color channels, is deployed for measurement of titanium particle temperatures. Complimentary measurements of the overall igniter plume emission ("color") temperature were conducted using a transmission-grating spectrograph in line-imaging mode. Heat flux and energy deposition to a cold wall at the heat-pellet location were estimated using an eroding thermocouple probe, with a frequency response of ~5 kHz. Ultimate "go/no-go" function in the igniter/heat-pellet system was correlated with quantitative thermal metrics, in particular surface energy deposition and plume color temperature. Titanium metal-particle and plume color temperatures both experience an upper bound approximated by the 3245-K boiling point of TiO 2 . Average metal-particle temperatures remained nearly constant for all standoff distances at T = 2850 K, ± 300 K, while plume color temperature and heat flux decay with standoff—suggesting that heat-pellet failure results from a drop in metal-particle flux and not particle temperature. At 50% likelihood of heat-pellet failure, peak time-resolved plume color temperatures drop well below TiO 2 boiling to ~2000 - 2200 K, near the TiO 2 melting point. Estimates of peak heat flux decline from up to 1 GW/m 2 for near-field standoffs to below 320 MW/m 2 at 50% failure likelihood.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Fission fragment assisted reactor concept for space propulsion: Foil reactor

The concept is to fabricate a reactor using thin films or foils of uranium, uranium oxide and then to coat them on substrates. These coatings would be made so thin as to allow the escaping fission fragments to directly heat a hydrogen propellant. The idea was studied of direct gas heating and direct gas pumping in a nuclear pumped laser program. Fission fragments were used to pump lasers. In this concept two substrates are placed opposite each other. The internal faces are coated with thin foil of uranium oxide. A few of the advantages of this technology are listed. In general, however, it is felt that if one look at all solid core nuclear thermal rockets or nuclear thermal propulsion methods, one is going to find that they all pretty much look the same. It is felt that this reactor has higher potential reliability. It has low structural operating temperatures, very short burn times, with graceful failure modes, and it has reduced potential for energetic accidents. Going to a design like this would take the NTP community part way to some of the very advanced engine designs, such as the gas core reactor, but with reduced risk because of the much lower temperatures.

Wright, Steven A.↗
NASA NTRS2002

Tensile Strength of Carbon Nanotubes Under Realistic Temperature and Strain Rate

Strain rate and temperature dependence of the tensile strength of single-wall carbon nanotubes has been investigated with molecular dynamics simulations. The tensile failure or yield strain is found to be strongly dependent on the temperature and strain rate. A transition state theory based predictive model is developed for the tensile failure of nanotubes. Based on the parameters fitted from high-strain rate and temperature dependent molecular dynamics simulations, the model predicts that a defect free micrometer long single-wall nanotube at 300 K, stretched with a strain rate of 1%/hour, fails at about 9 plus or minus 1% tensile strain. This is in good agreement with recent experimental findings.

Wei, Chen-Yu↗
DOE OSTI2026

A simple wire-coil resistive heater for high temperature radial x-ray diffraction in a diamond anvil cell

Diamond anvil cells are commonly used at synchrotron x-ray diffraction beamlines to study structural and thermoelastic properties of materials at high pressures. In a radial geometry, where the x-ray probe is oriented perpendicular to the axis of force, the deformation and strength of materials can be measured in situ. Because the anelastic and failure properties of materials depend strongly on temperature, many applications would benefit from the ability to measure high pressure radial diffraction in elevated and accurately controlled thermal environments. Previous work to introduce high temperature to radial diamond anvil cells has been largely limited to laser heating, with relatively scant efforts to resistively heat the sample. Here, we report a relatively straightforward adaptation of a simple wire coil heater, with in situ high-temperature radial diffraction performed on tungsten carbide up to 573 K at beamline 12.2.2 of the Advanced Light Source. In conclusion, the results demonstrate that the differential stress supported by WC decreases with increasing temperature: the differential stress on the basal (001) and pyramidal (101) planes decreased 6.6% and 5.5%, respectively, while the (100) plane only saw a 2.7% decrease, in agreement with previous studies.

Diamond anvil cells↗
DOE OSTI2025

Carbon Fiber Oxidation in 4D

The oxidation of carbon fibers at high temperatures is the primary degradation process in the thermal protection system of many hypersonic flight vehicles. Predicting the rate and the extent of oxidation is critical to ensure a safe and effective design. An oversized thermal protection system adds unnecessary mass, while an under-designed one risks system failure and mission loss. Resolving high-temperature material degradation due to oxidation has been a long-standing challenge in designing for re-entry flight environments. Using time-resolved in situ X-ray microtomography, the oxidation of carbon fibers at high temperatures is directly imaged, resolving the two limiting degradation regimes: diffusion- and reaction-limited. The ability to resolve material degradation in time at the sub-micron scale sheds light on the ablation phenomenon and enables predictions of material constitutive properties evolving in time, with profound implications on the ability to model the aerothermal response of heat shield materials in hostile environments.

ablation↗
DOE OSTI2021

Performance of Embedded Sensors in 3D Printed SiC

This report summarizes recent advances in embedding sensors in 3D printed silicon carbide (SiC) ceramic components under the Transformational Challenge Reactor (TCR) program. The additive manufacturing technologies developed under this program will enable fabrication of complex structures with embedded fuels and sensors. The sensors will be capable of characterizing fuel performance using spatially distributed measurements at the most strategic locations that would be otherwise inaccessible using conventional manufacturing techniques. While previous programmatic updates describe initial concepts for embedding sensors, materials selection, and initial characterization of the embedded sensors, the technology requires further demonstration, and quality-significant procedures must be established before the embedding technology is ready for adoption by industry. To this end, this report describes the most effective techniques that have been used to embed functional sensors in 3D printed components using a combination of binder-jet additive manufacturing and chemical vapor infiltration (CVI). A detailed procedure describes each step in the process and is available upon request. Molybdenum (Mo)-sheathed thermocouples have been successfully embedded in complex SiC components, and temperatures were monitored in situ during the embedding process. Post-embedding measurements showed no significant hysteresis, and characterization of the interface revealed qualitatively strong bonding around the entire perimeter of the sensor sheath. Distributed fiber-optic temperature sensors were able to briefly measure temperature profiles during CVI, but they ultimately failed prior to completion of the CVI run. The failure appears to be related to the fiber coating at temperatures close to 1,000°C. Future work will focus on irradiation testing of embedded thermocouples and other sheathed electrical sensors, as well as the identification of fiber-optic sensor coatings that can survive CVI.

42 ENGINEERING↗
NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt.% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF/HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damages at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, were observed especially for the combined LCF/HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗
NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF-HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damage at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, was observed especially for the combined LCF-HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗
DOE OSTI2024

Design Methods, Tools, and Data for Ceramic Solar Receivers

This report presents the development of tools and methods for evaluating the reliability and performance of ceramic materials in high temperature solar receivers. As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat requirements, current high temperature metallic materials face challenges in maintaining structural integrity. This report explores advanced ceramics as a promising alternative, given their superior high temperature strength and lower thermal expansion, compared to metals. To address the need for effective ceramic receiver design tools, this report integrates statistical failure models of ceramics into the existing srlife tool: an open-source software package designed to estimate the life of high temperature CSP components. These failure models account for the inherent variability and flaw distribution in ceramics, as well as the impact of subcritical crack growth under high temperature cyclic loads. The report also presents experimental data collected for a commercially available ceramic material, SiC, and details the process of estimating reliability model parameters from these data. A comparative design analysis is then performed between ceramic (SiC) and metallic (current nickel-based superalloys A740H and A282) receiver. This comparison demonstrates that SiC receivers can achieve service life exceeding 30 years under high incident heat flux conditions, compared to just a few years for metallic receivers.

14 SOLAR ENERGY↗
NASA NTRS2001

Evaluation of Data Retention Characteristics for Ferroelectric Random Access Memories (FRAMs)

Data retention and fatigue characteristics of 64 Kb lead zirconate titanate (PZT)-based Ferroelectric Random Access Memories (FRAMs) microcircuits manufactured by Ramtron were examined over temperature range from -85 C to +310 C for ceramic packaged parts and from -85 C to +175 C for plastic parts, during retention periods up to several thousand hours. Intrinsic failures, which were caused by a thermal degradation of the ferroelectric cells, occurred in ceramic parts after tens or hundreds hours of aging at temperatures above 200 C. The activation energy of the retention test failures was 1.05 eV and the extrapolated mean-time-to-failure (MTTF) at room temperature was estimated to be more than 280 years. Multiple write-read cycling (up to 3x10(exp 7)) during the fatigue testing of plastic and ceramic parts did not result in any parametric or functional failures. However, operational currents linearly decreased with the logarithm of number of cycles thus indicating fatigue process in PZT films. Plastic parts, that had more recent date code as compared to ceramic parts, appeared to be using die with improved process technology and showed significantly smaller changes in operational currents and data access times.

Sharma, Ashok K.↗
DOE OSTI2023

AGR-5/6/7 Thermal Model with Non-uniform Gas Gaps

Fuel compact temperatures are a crucial factor in assessing irradiation performance of the Tristructural isotropic fuel particles. In the absence of direct measurement, fuel compact temperatures were calculated using a three-dimensional finite element thermal model, which is subject to simulation uncertainty. The most dominant factor in uncertainty of calculated fuel temperature is the gas gap uncertainty due to the nub-to-shell clearance because of fabrication error. A revision to the thermal model was made to examine the most probable offset position for four different dates of interest. The offset position options varied in magnitude and azimuthal direction of offset of the holder top and bottom position. The best-fit offset of the holder is estimated based on the minimum root mean square error of residuals for all operational thermocouples (TCs). From these results, the following conclusions were made: 1) During earlier cycles (162A – 164A) when numerous TCs were still operational, the best-fit offset distance varied in range [0.002 – 0.0035 in.] for both the top and bottom holder while offset azimuthal direction varied widely, especially for the holder bottom. 2) Holder offset led to slightly lower Capsule 1 average temperature, but wider temperature variation (lower minimum and higher peak fuel temperatures). 3) The maximum offset of 0.006 in. to the northwest direction for both the top and bottom holder yielded a much higher temperature than the original peak fuel temperature, which increased from 1422 to 1557 ? (or 135 ? increase). This could be one of the reasons for massive particle failure near the end of Cycle 165A. 4) Even though, the highest temperature at the TC-1-7 tip reached slightly higher than 1000?, the temperature along the TC wire reached as high as 1335? assuming a holder offset of 0.006 in. to the northwest. Consequently, at this temperature nickel from this TC wire could cause particle failures in Capsule 1.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2007

Fracture Strength of Single-Crystal Silicon Carbide Microspecimens at Room and Elevated Temperature

Three shapes of tensile specimens were tested--curved with a very low stress concentration factor and straight with either a circular hole or an elliptical hole. The nominal thickness was 125 micron with a net section 100 micron wide; the overall length of these microspecimens was 3.1 mm. They were fabricated by an improved version of deep reactive ion etching, which produced specimens with smooth sidewalls and cross-sections having a slightly trapezoidal shape that was exaggerated inside the holes. The novel test setup used a vertical load train extending into a resistance furnace. The specimens had wedge-shaped ends which fit into ceramic grips. The fixed grip was mounted on a ceramic post, and the movable grip was connected to a load cell and actuator outside the furnace with a ceramic-encased nichrome wire. The same arrangement was used for tests at 24 and at 1000 C. The strengths of the curved specimens for two batches of material (made with slightly different processes) were 0.66+/-0.12 GPa and 0.45+/-0.20 GPa respectively at 24 C with identical values at 1000 C. The fracture strengths of the circular-hole and elliptical-hole specimens (computed from the stress concentration factors and measured loads at failure) were approximately 1.2 GPa with slight decreases at the higher temperature. Fractographic examinations showed failures initiating on the surface--primarily at corners. Weibull predictions of fracture strengths for the hole specimens based on the properties of the curved specimens were reasonably effective for the circular holes, but not for the elliptical holes.

Nemeth, Noel N.↗
NASA NTRS2018

Modeling of Time-Dependent Strength Degradation of SiC/SiC Ceramic Matrix Composites via MAC/GMC Computer Code

Silicon carbide fiber reinforced silicon carbide (SiC/SiC) ceramic matrix composites (CMCs) display time-dependent strength degradation at intermediate temperatures (600 to 900 degrees Centigrade). This is generally believed to be an oxidation induced phenomenon. The understanding of the effect of temperature with environment (oxidation) is key towards development of SiC/SiC CMCs with a reliable load carrying capacity. Various theories have been proposed to explain the strength degradation. One suggests that the boron nitride (BN) coating deposited on the fibers oxidizes causing fusion of fibers. Another theory proposes that the SiC fibers are oxidized forming a silica scale leading to premature fiber failure. A more recent theory suggests that SiC fiber strength is intrinsically time-dependent due to slow crack growth of flaws in the fibers. An empirical model, termed as a "fiber classic model," which is based on a standard slow crack growth type power-law, has been implemented within NASA's micromechanics-based MAC/GMC computer code as a user routine. Model parameters for this "classic model" were calibrated from stress-rupture data of Hi-Nicalon (TM) monofilaments using the maximum likelihood estimation (MLE) technique. This new capability in the MAC/GMC computer code was then used to predict the stress-rupture behavior of Hi-Nicalon (TM) tows as well as 2-D SiC/SiC composites reinforced with Hi-Nicalon (TM) fibers. Results demonstrate that the MAC/GMC with this new capability successfully predicts the time-to-failure vs. applied stress within the intermediate temperature range at various scales as well as laminated composites in an oxidizing environment.

Environmental degradation↗
NASA NTRS1984

Environmental influences on transverse failure of graphite/epoxy composites

In the present experimental investigation of environmental influence on the transverse tensile properties of various batches of graphite/epoxy composites, specimens fabricated from Thornel 300 graphite fibers in either 5280 or 934 epoxy resin matrices were exposed to different temperature and moisture conditions and then tested to failure. While batch-to-batch differences in environmental response were noted, 74 C testing was found to universally lower transverse tensile strengths measured during 24 C tests. Neither thermal cycling nor spiking produced significant changes in strength; wet conditions, however, decreased strength in all cases.

Clements, L. L.↗