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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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Free-Piston Stirling Power Conversion Unit for Fission Power System, Phase II Final Report

In Phase II, the manufacture and testing of two 6-kW(sub e)Stirling engines was completed. The engines were delivered in an opposed 12-kW(sub e) arrangement with a common expansion space heater head. As described in the Phase I report, the engines were designed to be sealed both hermetically and with a bolted O-ring seal. The completed Phase II convertor is in the bolted configuration to allow future disassembly. By the end of Phase II, the convertor had passed all of the final testing requirements in preparation for delivery to the NASA Glenn Research Center. The electronic controller also was fabricated and tested during Phase II. The controller sets both piston amplitudes and maintains the phasing between them. It also sets the operating frequency of the machine. Details of the controller are described in the Phase I final report. Fabrication of the direct-current to direct-current (DC-DC) output stage, which would have stepped down the main controller output voltage from ~700 to 120 V(sub DC), was omitted from this phase of the project for budgetary reasons. However, the main controller was successfully built, tested with the engines, and delivered. We experienced very few development issues with this high-power controller. The project extended significantly longer than originally planned because of yearly funding delays. The team also experienced several hardware difficulties along the development path. Most of these were related to the different thermal expansions of adjacent parts constructed of different materials. This issue was made worse by the large size of the machine. Thermal expansion problems also caused difficulties in the brazing of the opposed stainless steel sodium-potassium (NaK) heater head. Despite repeated attempts Sunpower was not able to successfully braze the opposed head under this project. Near the end of the project, Glenn fabricated an opposed Inconel NaK head, which was installed prior to delivery for testing at Glenn. Engine development prior to this was performed using both single- and dual-opposed (common expansion space) Inconel heads with clamp-on electric heaters.

Free-piston Stirling Power Conversion Unit↗
NASA NTRSDate not supplied

Welding in Space: Past, Present, and Future

It has been over fifty years since the first welds were made in space by Soviet cosmonauts on Soyuz-6 in October of 1969. The United States performed bead-on-plate welding, brazing, and metal melting experiments onboard the Skylab orbital space station several years later in 1973. Finally, Soviet cosmonauts departed their Salyut-7 capsule and made the first (and last) welds in open space in 1984. Progress on further demonstrations of welding in space stagnated, and subsequent microgravity welding research work shifted to lower-cost earth-based experiments that include drop towers and parabolic flights. With the advent of the International Space Station, relevant microgravity research was undertaken in the field of metal solidification science, and limited studies of brazing and soldering were undertaken; however, no welds have ever been on the Space Station. Therefore, it has been almost 40 years since a weld was made in space. Much like terrestrial construction and manufacturing industries, welding, joining, and allied processes will be enabling technologies for In-space Assembly and Manufacturing (ISAM) in the nascent “Space Economy”, a sector that is expected to approach a value of 10^12 USD within the next decade. It is critical that the welding and joining research community, along with the welding industry, engages the space industry to advance the understanding of those critical manufacturing processes which must be evaluated and matured in the extreme environments of space. Such environments include variable gravity (microgravity in low earth orbit, 0.17 gravity on the lunar surface, and 0.38 gravity on the martian surface), reduced pressure (extreme vacuum in space and the lunar surface to a predominantly CO2 atmosphere on Mars), and extreme temperatures (between 40 and 400 K). Past experiments and analyses are reviewed to suggest requirements that the welding and joining community should target to make strides on closing the current space welding gaps. Efforts to continue welding in space are currently underway at NASA in conjunction with academia and industry. Those are explored along with future agency goals which are seen as opportunities to engage the welding community on this historic effort.

in-space assembly and manufacturing↗
DOE OSTI2014

High temperature thermoelectrics

In accordance with one embodiment of the present disclosure, a thermoelectric device includes a plurality of thermoelectric elements that each include a diffusion barrier. The diffusion barrier includes a refractory metal. The thermoelectric device also includes a plurality of conductors coupled to the plurality of thermoelectric elements. The plurality of conductors include aluminum. In addition, the thermoelectric device includes at least one plate coupled to the plurality of thermoelectric elements using a braze. The braze includes aluminum.

42 ENGINEERING↗
DOE OSTI2015

BNL 56 MHz HOM damper prototype fabrication at JLAB

A prototype Higher-Order Mode (HOM) Damper was fabricated at JLab for the Relativistic Heavy-Ion Collider’s (RHIC) 56 MHz cavity at Brookhaven National Laboratory (BNL). Primarily constructed from high RRR Niobium and Sapphire, the coaxial damper presented significant challenges in electron-beam welding (EBW), brazing and machining via acid etching. The results of the prototype operation brought about changes in the damper design, due to overheating braze alloys and possible multi-pacting. Five production HOM dampers are currently being fabricated at JLab. This paper outlines the challenges faced in the fabrication process, and the solutions put in place.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Electrochemical compressor refrigeration appartus with integral leak detection system

An electrochemical compressor system, such as an electrochemical refrigeration system includes a sealed vessel that reduces leak issues related to the electrochemical cell. The sealed vessel may be molded or formed from a polymer or a composite polymer having reinforcing materials, such as fibers therein. The sealed vessel may be plated with metal to reduce gas permeation through the wall of the vessel and to accommodate and improve the attachment of conduits, including metal conduits thereto. A metal conduit may be brazed onto a vessel and the brazing material may be selected for polymer to metal joining and for reduced contamination potential of the system. The electrochemical compressor system incorporates a leak sensor configured at least partially within the sealed rigid vessel that measures the pressure within the vessel.

Bahar, Bamdad↗
DOE OSTI2019

Burst resistant thin wall heat sink

An apparatus for cooling an electronic component has a planar top member of a thermal energy conductive material and a parallel planar bottom member of the material, the planar bottom member including a surface having regions configured for heat exchange contact with the electronic component. The planar top member has a plurality of stamped indent formations at a plurality of locations, each indent formation providing a contact surface such that the planar top member is affixed to the bottom member by braze or solder at each contact surface. Alternatively, the planar bottom member also has a plurality of stamped indent formations in alignment with indent formations of the top member. The planar top member is affixed to the bottom member by brazing or soldering each respective contact surface of an indent formation of the planar top member to an opposing contact surface of a corresponding indent formation of the parallel planar bottom member.

42 ENGINEERING↗
DOE OSTI2019

Practical Challenges and Failure Modes During Fabrication of Haynes 230 Micro-Pin Solar Receivers for High Temperature Supercritical Carbon Dioxide Operation

Printed circuit heat exchangers (PCHX) fabricated from high nickel alloys have shown promise as primary heat exchangers, recuperators, and solar receivers for high temperature and pressure supercritical carbon dioxide power cycles. There are numerous challenges in fabricating these devices including forming channel features, joining via diffusion or transient liquid phase bonding, and brazing/welding of headers. Commercial entities are understandably hesitant to share propriety best practices, and both commercial and non-commercial entities working on these components tend not to publically share failures and mistakes. However, sharing of this information could prevent similar costly errors and further the understanding of the coupled manufacturing, materials and mechanics issues in creating these components. Thus, in this paper, we document the challenges, failures, and mitigation methods uncovered in fabrication of prototype micro-pin based solar thermal receivers constructed of Haynes 230 and fabricated through a combination of photochemical machining (PCM), wire electrical discharge machining (EDM), transient liquid phase (TLP) bonding, vacuum brazing, and gas tungsten arc welding (GTAW). The receiver is designed to absorb concentrated solar fluxes greater than 140 W cm-2, while heating supercritical carbon dioxide from 550 °C to 720 °C at a pressure of 20 MPa to 25 MPa. The prototype receiver consists of a thin (~ 450 µm), Haynes 230 coversheet bonded to a 15 cm × 15 cm Haynes 230 micro-pin plate. The pieces are joined using a TLP bonding process with a nickel-phosphorus interlayer. Prior to bonding, micro-pins with height ~150 µm and diameter 300 µm are fabricated using PCM in the plate, and through slot features are made using wire EDM. Finally, flow headers are joined to the microchannel plate through a combination of vacuum brazing and GTAW. During hydrostatic proof testing, the prototype device failed when the coversheet delaminated from the pin array at a pressure of 290 bar. A failure analysis including scanning electron microscopy (SEM) to view failure sites and energy-dispersive X-ray spectroscopy (EDS) to evaluate elemental analysis of the failed areas was conducted. The failure modes can be broadly categorized as (1) failures potentially relating to reliquification of the transient liquid phase bonds between the micro-pins plate and coversheet during post-processing, (2) failures related to manufacturing defects, and (3) failures attributed to design.

14 SOLAR ENERGY↗
DOE OSTI2021

Burst resistant thin wall heat sink

An method for forming a cooling apparatus for cooling an electronic component. The apparatus has a planar top member of a thermal energy conductive material and a parallel planar bottom member of the material, the planar bottom member including a surface having regions configured for heat exchange contact with the electronic component. The planar top member has a plurality of stamped indent formations at a plurality of locations, each indent formation providing a contact surface such that the planar top member is affixed to the bottom member by braze or solder at each contact surface. Alternatively, the planar bottom member also has a plurality of stamped indent formations in alignment with indent formations of the top member. The planar top member is affixed to the bottom member by brazing or soldering each respective contact surface of an indent formation of the planar top member to an opposing contact surface of a corresponding indent formation of the parallel planar bottom member.

Coteus, Paul W.↗
DOE OSTI2018

Thermodynamic assessment of Ag–Cu–In

The Ag-Cu-In thermodynamic material system is of interest for brazing alloys and chalcopyrite thin-film photovoltaics. To advance these applications, Ag-Cu-In was assessed and a Calphad model was developed. Binary Ag-Cu and Cu-In parameters were taken from previous assessments, while Ag-In was re-assessed. Structure-based models were employed for ..beta..-bcc(A2)-Ag 3 In, ..gamma..-Ag 9 In 4 , and AgIn 2 to obtain good fit to enthalpy, phase boundary, and invariant reaction data for Ag-In. Ternary Ag-Cu-In parameters were optimized to achieve excellent fit to activity, enthalpy, and extensive phase equilibrium data. Relative to the previous Ag-Cu-In assessment, fit was improved while fewer parameters were used.

14 SOLAR ENERGY↗
DOE OSTI2018

Effect of Welding Parameters on the Corrosion Behavior of Dissimilar Alloy Welds of T6 AA6061 Al-Galvanized Mild Steel

Partial replacement of steel by Aluminium (Al) alloys is a promising approach adopted by automotive sector to improve fuel efficiency without compromising on the strength. However, this results in the generation of dissimilar welds of Al alloys and steel. Understanding the corrosion behavior of Al alloys–steel welds as a function of welding parameters is critical in the successful application of such alloys. The present study reports the intergranular corrosion behavior of T6 heat-treated AA6061 Al alloy-galvanized mild steel lap joints, welded by metal inert gas welding–brazing technique as a function of different welding parameters, viz. weld speed (4-6 m/min) and wire feed rate (0.8-0.9 m/min), following ASTM G 67-04. Weld characterization was performed by field emission scanning electron microscopy (FESEM), x-ray diffraction and nano-hardness measurement. Results indicate heavy dissolution and metal loss at the interface. A high volume fraction of Al-Fe intermetallics was precipitated at the weld interfaces, resulting in high hardness and higher localized corrosion. The thickness of Al-Fe intermetallic layer increased with increasing wire feed rate and lower weld speed which enhanced the severity of galvanic and intergranular corrosion.

36 MATERIALS SCIENCE↗
DOE OSTI2013

A digital miniature x-ray tube with a high-density triode carbon nanotube field emitter

We have fabricated a digital miniature x-ray tube (6 mm in diameter and 32 mm in length) with a high-density triode carbon nanotube (CNT) field emitter for special x-ray applications. The triode CNT emitter was densely formed within a diameter of below 4 mm with the focusing-functional gate. The brazing process enables us to obtain and maintain a desired vacuum level for the reliable electron emission from the CNT emitters after the vacuum packaging. The miniature x-ray tube exhibited a stable and reliable operation over 250 h in a pulse mode at an anode voltage of above 25 kV.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Development of an S-band cavity-type beam position monitor for a high power THz free-electron laser

A cavity-type beam position monitor (BPM) has been developed for a compact terahertz (THz) free-electron laser (FEL) system and ultra-short pulsed electron Linac system at the Korea Atomic Energy Research Institute (KAERI). Compared with other types of BPMs, the cavity-type BPM has higher sensitivity and faster response time even at low charge levels. When electron beam passes through the cavity-type BPM, it excites the dipole mode of the cavity of which amplitude depends linearly on the beam offset from the center of the cavity. Signals from the BPM were measured as a function of the beam offset by using an oscilloscope. The microtron accelerator for the KAERI THz FEL produces the electron beam with an energy of 6.5 MeV and pulse length of 5 μs with a micropulse of 10-20 ps at the frequency of 2.801 GHz. The macropulse beam current is 40 mA. Because the microtron provides multi-bunch system, output signal would be the superposition of each single bunch. So high output signal can be obtained from superposition of each single bunch. The designed position resolution of the cavity-type BPM in multi-bunch is submicron. Our cavity-type BPM is made of aluminum and vacuum can be maintained by indium sealing without brazing process, resulting in easy modification and cost saving. The resonance frequency of the cavity-type BPM is 2.803 GHz and the cavity-type BPM dimensions are 200 × 220 mm (length × height) with a pipe diameter of 38 mm. The measured position sensitivity was 6.19 (mV/mm)/mA and the measured isolation between the X and Y axis was −39 dB. By measuring the thermal noise of system, position resolution of the cavity-type BPM was estimated to be less than 1 μm. In this article, we present the test results of the S-band cavity-type BPM and prove the feasibility of the beam position measurement with high resolution using this device.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

Development of a high power electron beam welding gun with replaceable high voltage feed-through insulators

Ceramic to metal sealed feed-through insulators are commonly used in electron beam welding gun. The above feed-through insulators are susceptible to failure, as the brazing joints in them are not always very strong. Failure in one of these feed-through could render the complete gun unusable. This problem has already been faced in BARC, which led to the development of the electron gun with replaceable feed through insulators. A 24 kW Electron Beam Welding (EBW) gun with indigenous designed replaceable insulators is fabricated in BARC. Emphasis during the design of the gun had been to reduce the use of imported components to zero. This paper describes the design and fabrication of this gun and reports various simulations and tests performed. Beam trajectory of the gun is numerically computed and presented. Weld passes were carried out on stainless steel plates show satisfactory penetrations. (author)

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Large-Scale Welding Process Simulation by GPU Parallelized Computing

The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small coupons and reduced order (from three-dimensional [3D] to two-dimensional [2D]), or inherent strain approximations were used for large structures. In this current study, an explicit finite element code based on a graphics processing unit was utilized to perform 3D transient thermomechanical simulation of structural components during welding. Laser brazing of aluminum alloy panels as representative of automotive manufacturing scenarios was simulated to predict out-of-plane distortion under different clamping conditions. The predicted deformation pattern and magnitude were validated by laser scanning data of physical assemblies. In addition, the code was used to investigate residual stresses developed during multipass arc welding of a nuclear industry pressurizer surge nozzle and subsequent welding repair where a 3D simulation was necessary. Taking the experimental data as reference, the 3D model predicted better residual stress distribution than a typical 2D asymmetrical model. Stress evolution in welding repair was also presented and discussed in this study. Furthermore, the efficient numerical model made it feasible to use integrated computational welding engineering to simulate welding processes for large-scale structures.

97 MATHEMATICS AND COMPUTING↗