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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
DOE OSTI2020

Modeling the corrosion of steel casing and the damage of well cement in a borehole system

This work presents the effect of chloride-induced corrosion in an underground borehole system, specifically considering the steel casing and further damage to the surrounding cement. In the past four decades, oil well cement has been successfully used for underground construction. However, high concentrations of chloride ions gradually degrade the functionality and durability of well cement. Gasses and liquids can leak from deterioration caused by chloride ions, and thus motivate this study. The chemo-mechanical coupling diffusion model and a classical fracture mechanics model are applied. The model is validated with OPC concrete corrosion data from literature, and then applied to well cement using experimentally obtained material property data. The time when crack initiation, peak pressure, and complete fracture is reached in the model of the cement sheath provides a quantification of the expected service life of the borehole system.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Graphite fluoride fibers and their applications in the space industry

Characterization and potential space applications of graphite fluoride fibers from commercially available graphitized carbon fibers are presented. Graphite fluoride fibers with fluorine to carbon ratios of 0.65 and 0.68 were found to have electrical resistivity values of 10(exp 4) and 10(exp 11) Ohms-cm, respectively, and thermal conductivity values of 24 and 5 W/m-K, respectively. At this fluorine content range, the fibers have tensile strength of 0.25 + or - 0.10 GPa (36 + or - 14 ksi), Young's modulus of 170 + or - 30 GPa (25 + or - 5 Msi). The coefficient of thermal expansion value of a sample with fluorine to carbon ratio of 0.61 was found to be 7 ppm/C. These properties change and approach the graphite value as the fluorine content approach 0. Electrically insulative graphite fluoride fiber is at least five times more thermally conductive than fiberglass. Therefore, it can be used as a heat sinking printed circuit board material for low temperature, long life power electronics in spacecraft. Also, partially fluorinated fiber with tailor-made physical properties to meet the requirements of certain engineering design can be produced. For example, a partially fluorinated fiber could have a predetermined CTE value in -1.5 to 7 ppm/C range and would be suitable for use in solar concentrators in solar dynamic power systems. It could also have a predetermined electrical resistivity value suitable for use as a low observable material. Experimental data indicate that slightly fluorinated graphite fibers are more durable in the atomic oxygen environment than pristine graphite. Therefore, fluorination of graphite used in the construction of spacecraft that would be exposed to the low Earth orbit atomic oxygen may protect defect sites in atomic oxygen protective coatings and therefore decrease the rate of degradation of graphite.

Hung, Ching-Chen↗
NASA NTRS2000

The Effect of Boron on the Low Cycle Fatigue Behavior of Disk Alloy KM4

The durability of powder metallurgy nickel base superalloys employed as compressor and turbine disks is often limited by low cycle fatigue (LCF) crack initiation and crack growth from highly stressed surface locations (corners, holes, etc.). Crack growth induced by dwells at high stresses during aerospace engine operation can be particularly severe. Supersolvus solution heat treatments can be used to produce coarse grain sizes approaching ASTM 6 for improved resistance to dwell fatigue crack growth. However, the coarse grain sizes reduce yield strength, which can lower LCF initiation life. These high temperature heat treatments also can encourage pores to form. In the advanced General Electric disk superalloy KM4, such pores can initiate fatigue cracks that limit LCF initiation life. Hot isostatic pressing (HIP) during the supersolvus solution heat treatment has been shown to improve LCF initiation life in KM4, as the HIP pressure minimizes formation of the pores. Reduction of boron levels in KM4 has also been shown to increase LCF initiation life after a conventional supersolvus heat treatment, again possibly due to effects on the formation tendencies of these pores. However, the effects of reduced boron levels on microstructure, pore characteristics, and LCF failure modes in KM4 still need to be fully quantified. The objective of this study was to determine the effect of boron level on the microstructure, porosity, LCF behavior, and failure modes of supersolvus heat treated KM4.

Gabb, Timothy↗
NASA NTRS1983

Some Comments on Longevity by a Technologist

The durability of flywheels was investigated. Since only composite flywheels possess the potential for system energy densities in the range of 20 to 40 W hr/kg, and they are not yet at a level of maturity where a comfortable data base exists, the longevity aspects of the yet to be developed devices is still a speculation. The general methodologies that have been used in some of the more established technology areas to establish some degree of credibility in the ability to predict the upper limits of expected useful life based on the current limiting decay mechanism are outlined.

Thaller, L. H.↗
NASA NTRS1979

Durability of foam insulation for LH2 fuel tanks of future subsonic transports

Organic foams were tested to determine their suitability for insulating liquid hydrogen tanks of subsonic aircraft. The specimens, including nonreinforced foams and foams with chopped glass reinforcements, flame retardants, and vapor barriers, were scaled to simulate stress conditions in large tanks. The tests were conducted within aluminum tank compartments filled with liquid hydrogen and the boil-off rate was used as the criterion of thermal performance. It was found that while all insulations deteriorated with increased cycles, two nonreinforced polyurethane foams showed no structural deterioration after 4200 thermal cycles (equivalent to 15 years of airline service). It was also found that fiberglass reinforcement and flame retardants impaired thermal performance and reduced useful life of the foams. Vapor barriers enhanced structural integrity without any deterioration in thermal properties.

Sharpe, E. L.↗
DOE OSTI2020

Beyond the Polysulfide Shuttle and Lithium Dendrite Formation: Addressing the Sluggish Sulfur Redox Kinetics for Practical High‐Energy Li‐S Batteries

Abstract Electrolyte modulation simultaneously suppresses polysulfide the shuttle effect and lithium dendrite formation of lithium–sulfur (Li‐S) batteries. However, the sluggish S redox kinetics, especially under high S loading and lean electrolyte operation, has been ignored, which dramatically limits the cycle life and energy density of practical Li‐S pouch cells. Herein, we demonstrate that a rational combination of selenium doping, core–shell hollow host structure, and fluorinated ether electrolytes enables ultrastable Li stripping/plating and essentially no polysulfide shuttle as well as fast redox kinetics. Thus, high areal capacity (>4 mAh cm −2 ) with excellent cycle stability and Coulombic efficiency were both demonstrated in Li metal anode and thick S cathode (4.5 mg cm −2 ) with a low electrolyte/sulfur ratio (10 μL mg −1 ). This research further demonstrates a durable Li‐Se/S pouch cell with high specific capacity, validating the potential practical applications.

Zhao, Chen↗
NASA NTRS2006

HSR Overview

The leading Aeronautics program within NASA is the High Speed Research Program (HSR). The HSR program's highest priorities are high pay-off technologies for airframe and propulsion systems required for a high speed civil transport (HSCT). These priorities have been developed collaboratively with NASA, FAA and the US Industry (Boeing-McDonnell Douglas, Pratt & Whitney and General Electric). Phase one of the HSR program started on 1990, and concentrated on the environmental challenges of minimizing NOx and noise. The first program goal is to reduce the NOx emission index to less than 5 (Concord NOx index is 20 and is unacceptable), in order to have little impact on the earth's ozone layer. The second goal is to reduce noise levels to FAR Stage 3 (or better), comparable to those of subsonic aircraft (far below the Concorde noise levels that require exemptions form less stringent standards). This requirement greatly impacts the nozzle design increasing its length and complexity and poses unique sealing challenges. Phase two started in 1993 and initiated work on the technologies required for an economical HSCT. Materials technologies under development include a ceramic-matrix-composite combustion liner, lightweight materials for the nozzle, as well long-life turbomachinery disk and blade alloys. Other required materials are being developed under the DOD-IHPTET program, where there is close cooperation. Economic goals translate into the development of technologies for tri-class service, 5000 nautical mile range aircraft with a ticket price no more than 20% over the subsonic ticket price. The potential market could be as large as 1500 aircraft, according to a Boeing study. Technology alone will not enable this airplane, yet without enabling technologies "on the shelf", it will not occur. The HSCT engine will be the largest engine ever built and operate at maximum conditions for long periods of time posing a number of challenges. The HSR engine mission requires that rotating equipment stay at take-off condition temperatures for hours not minutes per flight. Hence rotating equipment and seals must operate for many thousands of hours at extreme temperatures. It is anticipated that the nozzle will be 12 feet long and roughly 4 ft. by 5 ft. in cross-section with a nominal airflow of 800 lbs/sec. The complex function of the nozzle (including an ejector for noise attenuation) combined with long life place new demands on nozzle seal design. Three inlet configurations are under consideration with attendant sealing challenges, as will be illustrated herein. Four of these engines are required to propel a 5000 nautical mile class vehicle which demand that component reliability be at the highest possible level. In response, an HSR seals session was implemented as a part of the 1997-Seals and Secondary Flow Workshop. Overview presentations were given for each of the following areas: inlet, turbomachinery, combustor and nozzle. The HSCT seal issues center on durability and efficiency of rotating equipment seals (including brush seals), structural seals (including rope seals and other advanced concepts), and high-speed bearing and sump seals. Tighter clearances, propulsion system size and thermal requirements represent extremes that challenge the component designers. This document provides an initial step toward defining HSR seal needs. The overview for HSR seal designs includes, defining seal objectives, summarizing sealing and materials requirements, presenting relevant seal cross-sections, and identifying technology needs for the HSR office.

Hendricks, R. C.↗
NASA NTRS1993

Characterization and durability testing of plasma-sprayed zirconia-yttria and hafnia-yttria thermal barrier coatings. Part 1: Effect of spray parameters on the performance of several lots of partially stabilized zirconia-yttria powder

Initial experiments conducted on thermal barrier coatings prepared in the newly upgraded research plasma spray facility and the burner rig test facilities are discussed. Part 1 discusses experiments which establish the spray parameters for three baseline zirconia-yttria coatings. The quality of five similar coating lots was judged primarily by their response to burner rig exposure supplemented by data from other sources such as specimen characterizations and thermal diffusivity measurements. After allowing for burner rig variability, although there appears to be an optimum density (i.e., optimum microstructure) for maximum burner rig life, the distribution tends to be rather broad about the maximum. In Part 2, new hafnia-yttria-based coatings were evaluated against both baseline and alternate zirconia-yttria coatings. The hafnia-yttria coatings and the zirconia-yttria coatings that were prepared by an alternate powder vendor were very sensitive to plasma spray parameters, in that high-quality coatings were only obtained when certain parameters were employed. The reasons for this important observation are not understood. Also not understood is that the first of two replicate specimens sprayed for Part 1 consistently performed better than the second specimen. Subsequent experiments did not display this spray order affect, possibly because a chiller was installed in the torch cooling water circuit. Also, large changes in coating density were observed after switching to a new lot of electrodes. Analyses of these findings were made possible, in part, because of the development of a sensitive density measurement technique described herein in detail. The measured thermal diffusivities did not display the expected strong relationship with porosity. This surprising result was believed to have been caused by increased microcracking of the denser coatings on the stainless steel substrates.

Miller, Robert A.↗
DOE OSTI2023

Quantifying Aging-Induced Irreversible Volume Change of Porous Electrodes

Automotive manufacturers are working to improve cell and pack design by increasing their performance, durability, and range. One of the critical factors to consider as the industry moves towards materials with higher energy density is the ability to consider the irreversible volume change characteristic of the accelerated SEI layer growth tied to the large volume change and particle cracking typically associated with active material strain. As the time from initial design to manufacture of electric vehicle is decreased in order to rapidly respond to consumer demands and widespread adoption of electric vehicles, the ability to link aging and volume change to end of life vehicle requirements using virtual tools is critical. In this study, apply a mechano-electrochemical model to determine the irreversible volume change at the electrode and cell level, allowing for virtual design iterations to predict the volume change at battery cell aged states.

Electrochemistry↗
NASA NTRS1986

Creep fatigue life prediction for engine hot section materials (isotropic): Fourth year progress review

As gas turbine technology continues to advance, the need for advanced life prediction methods for hot section components is becoming more and more evident. The complex local strain and temperature histories at critical locations must be accurately interpreted to account for the effects of various damage mechanisms (such as fatigue, creep, and oxidation) and their possible interactions. As part of the overall NASA HOST effort, this program is designed to investigate these fundamental damage processes, identify modeling strategies, and develop practical models which can be used to guide the early design and development of new engines and to increase the durability of existing engines.

Nelson, Richard S.↗
DOE OSTI2023

Durable Low-Cost Pressure Vessels for Bulk Hydrogen Storage

Long-duration energy storage (LDES) in the form of gaseous hydrogen is vital for fossil fuel power plants to reduce frequent shutdowns and rapid start-ups. It's also crucial in renewable energy power plants for grid stabilization. WireTough Cylinders (WTC) has developed a Type II-S pressure vessel that uses steel liners that are hoop-wrapped with multiple layers of high-strength, cost-effective, and readily available steel wires. This design enables the vessel to withstand significantly higher pressures. It addresses hydrogen embrittlement issues and cyclic loading from repeated pressurization and depressurization during service. The WireTough design is cost-efficient, robust, and fatigue-resistant (with a 30-year design life) and is ASME certified for ground storage of hydrogen at a maximum operating pressure (MOP) of 350 bar and a design pressure of 500 bar. The cylinder has a 645 mm outside diameter and a water capacity of 1,715 liters, capable of storing 40.7 KG of hydrogen at MOP. Two prototypes were successfully produced to showcase the manufacturing technologies, with one being certified under ASME Section VIII Division 3 rules. Preliminary design work for a similar Type II-S vessel with a 500 bar MOP was also completed. The 350 bar and 500 bar Type II-S vessels were shown respectively to be 47.5% to 60% more cost-effective and 55% and 62.5% lighter based on per KG of hydrogen stored, when compared with their Type 1 counterparts.

08 HYDROGEN↗
NASA NTRS1987

Durability of composites

Fiber reinforced materials (composites) are considered very seriously for use in primary loadbearing structures. However, the pace at which they will actually be introduced into the structural designs of the future very much depends on the solution of a critical problem, which is the inability to predict the long term behavior of the material in a given service environment. The research and development of integrity evaluation and lifetime prediction schemes for composite materials is thus a burning issue. The information presented is part of an ongoing program which is directed toward and accelerated determination of the endurance limits of composite materials. Real-time testing is simply not feasible because enough integrity has to be designed into composite structures such that they have a service life which is often as long as twenty or thirty years.

Hiel, Clem C.↗
NASA NTRS2002

Upper Temperature Limit of Environmental Barrier Coatings Based on Mullite and BSAS

Current state-of-the-art environmental barrier coatings (EBCs) for Si-based ceramics consist of three layers: a silicon bond coat, an intermediate mullite (3Al2O3-2SiO2) or mullite + BSAS (1-xBaO-xSrO-Al2O3-2SiO2) layer, and a BSAS top coat. Areas of concern for long-term durability are environmental durability, chemical compatibility, silica volatility, phase stability, and thermal conductivity. Variants of this family of EBCs were applied to monolithic SiC and melt infiltrated SiC/SiC composites. Reaction between BSAS and silica results in low melting (approx. 1300 C) glasses at T > 1400 C, which can cause the spallation of the EBC. At temperatures greater than 1400 C, the BSAS top coat also degrades by formation of a porous structure, and it suffers significant recession via silica volatilization in water vapor-containing atmospheres. All of these degradation mechanisms can be EBC life-limiting factors. BSAS undergoes a very sluggish phase transformation (hexagonal celsian to monoclinic celsian), the implications of which are not fully understood at this point. There was evidence of rapid sintering at temperatures as low as 1300 C, as inferred from the sharp increase in thermal conductivity.

Lee, Kang N.↗
NASA NTRS1994

Large-displacement structural durability analyses of simple bend specimen emulating rocket nozzle liners

Large-displacement elastic and elastic-plastic, finite-element stress-strain analyses of an oxygen-tree high-conductivity (OFHC) copper plate specimen were performed using an updated Lagrangian formulation. The plate specimen is intended for low-cost experiments that emulate the most important thermomechanical loading and failure modes of a more complex rocket nozzle. The plate, which is loaded in bending at 593 C, contains a centrally located and internally pressurized channel. The cyclic crack initiation lives were estimated using the results from the analyses and isothermal strain-controlled low-cycle fatigue data for OFHC copper. A comparison of the predicted and experimental cyclic lives showed that an elastic analysis predicts a longer cyclic life than that observed in experiments by a factor greater than 4. The results from elastic-plastic analysis for the plate bend specimen, however, predicted a cyclic life in close agreement with experiment, thus justifying the need for the more rigorous stress-strain analysis.

Arya, Vinod K.↗
NASA NTRS2015

Extreme Oxidative Durability of TBCs on Ti2AlC MAX Phases

APS and PS-PVD YSZ thermal barrier coatings, applied directly to oxidation resistant Ti2AlC substrates, were oxidized in interrupted furnace tests. Temperature was advanced in 50C intervals from 1100 to 1300C, each 500 h long with eleven cooling cycles. Damage only initiated on the APS coating at 1300C after 15 h, with complete delamination after 500 h. The PS-PVD coating survived all testing. Weight change and metallographic analyses indicate that the YSZ-Ti2AlC systems sustained alumina scale growth of 30-40 m. In comparison, widely used Pt-aluminide bondcoats on single crystal superalloy turbine blades exhibit TBC lives equivalent to alumina scale growth up to 7 m, equivalent to just 200 h at 1200C. It is demonstrated that 25x TBC life improvement (or 180C temperature increase) resulted from the close CTE match of Ti2AlC with those of alumina and YSZ.

protective coating↗
DOE OSTI2024

Experimental Considerations for Estimating Degradation in PV Modules

Carefully controlled laboratory experiments and measurements can enable the determination of acceleration factors suitable for extrapolation to durability and performance of a fielded PV module. Ideally, a single mechanism can be identified with appropriate acceleration factors for extrapolation to the field. However, even with a single mechanism, the inherent uncertainty in these factors leads to uncertainty in the extrapolation which is greater the higher the acceleration factor. This course will explain how because of the wide range of acceleration factors for a given degradation mode, utilizing acceleration factors greater than about 10x will typically lead to unacceptable uncertainty in the results. Therefore, if even just a rank ordering of materials is desired, acceleration factors must be minimized which requires a good general understanding of the scale of the different acceleration factors for the degradation mode of interest. In this tutorial we will discuss what the different purposes are for many of the accelerated stress tests used today. E.g., what is a qualification test, a highly accelerated stress test, a rank ordering test, or a service life prediction test. We will discuss how one can understand the relationship between test results and expected field performance. A single accelerated stress test condition cannot duplicate outdoor exposure for all possible degradation pathways; therefore, one must use targeted evaluation of material properties at different stress levels to determine the relevant acceleration factors and fit it to a model. We will also discuss how to interpret the results of experiments understanding what is relevant/not relevant, or not e valuated in a test. There are many common error people make in their test interpretations because they push the stress levels to be too harsh. This creates biases and can mask the relevant failure modes and mechanisms or will erroneously lead one to over design materials against things that aren't relevant. Several case studies will be presented to illustrate appropriate interpretation of accelerated stress testing results.

degradation↗
DOE OSTI2025

Enhanced Reversibility of Iron Metal Anode with a Solid Electrolyte Interphase in Concentrated Chloride Electrolytes

Iron is a promising candidate for a cost-effective anode for large-scale energy storage systems due to its natural abundance and well-established mass production. Recently, Fe-ion batteries (FeIBs) that use ferrous ions as the charge carrier have emerged as a potential storage solution. The electrolytes in FeIBs are necessarily acidic to render the ferrous ions more anodically stable, allowing a wide operation voltage window. However, the iron anode suffers severe hydrogen evolution reaction with a low Coulombic efficiency (CE) in an acidic environment, shortening the battery cycle life. Herein, a hybrid aqueous electrolyte that forms a solid-electrolyte interphase (SEI) layer on the Fe anode surface is introduced. The electrolyte mainly comprises FeCl 2 and ZnCl 2 as cosalts, where the Zn-Cl anionic complex species of the concentrated ZnCl 2 allows dimethyl carbonate (DMC) to be miscible with the aqueous ferrous electrolyte. SEI derived from DMC's decomposition passivates the iron surface, which leads to an average CE of 98.3% and much-improved cycling stability. As a result, this advancement shows the promise of efficient and durable FeIBs.

25 ENERGY STORAGE↗
DOE OSTI2020

Beyond the Polysulfide Shuttle and Lithium Dendrite Formation: Addressing the Sluggish Sulfur Redox Kinetics for Practical High-Energy Li-S Batteries

Electrolyte modulation simultaneously suppresses polysulfide the shuttle effect and lithium dendrite formation of lithium-sulfur (Li-S) batteries. However, the sluggish S redox kinetics, especially under high S loading and lean electrolyte operation, has been ignored, which dramatically limits the cycle life and energy density of practical Li-S pouch cells. In this work, we demonstrate that a rational combination of selenium doping, core-shell hollow host structure, and fluorinated ether electrolytes enables ultrastable Li stripping/plating and essentially no polysulfide shuttle as well as fast redox kinetics. Thus, high areal capacity (>4 mAh cm -2 ) with excellent cycle stability and Coulombic efficiency were both demonstrated in Li metal anode and thick S cathode (4.5 mg cm -2 ) with a low electrolyte/sulfur ratio (10 mu L mg(-1)). Overall, this research further demonstrates a durable Li-Se/S pouch cell with high specific capacity, validating the potential practical applications.

25 ENERGY STORAGE↗