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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 NTRS1986

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimeter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, C. C.↗
NASA NTRS1987

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimenter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, Ching-Cheh↗
NASA NTRS1995

Analysis of LDEF experiment AO187-2 chemical and isotopic measurements of micrometeoroids by secondary ion mass spectrometry

#Experiment AO187-2, that was flown on board the Long Duration Exposure Facility(LDEF), was designed to measure the chemical and isotopic compositions of interplanetary dust impinging on the spacecraft from outer space. Information on the nature and composition of orbital debris was also anticipated. The spacecraft maintained a constant orientation with respect to its velocity vector thereby defining leading and trailing edges that faced respectively into and away from the direction of motion. Arrays of individual capture cells each 80.8 sq cm in size and totaling 237 in number were exposed on both the leading and trailing edges of LDEF. Each cell consisted of a pure Ge target surface slightly separated from a thin (2.5 micrometers) metallized plastic 'entrance foil.' The basic concept was that incoming projectiles would penetrate the foil, strike the Ge target plate at high velocity producing a vapor-liquid cloud that would re-deposit material on the underside of the plastic foil. This material would then be analyzed using the sensitive surface analysis technique of Secondary Ion Mass Spectrometry (SIMS). In practice, most of the plastic entrance foils failed during the extended period of orbital exposure probably due to a combination of UV embrittlement, large densities of impact events and (for the leading edge) the effects of atomic oxygen erosion in orbit. However the foils failed gradually and most remained in place on the capture cells for a significant fraction of the duration of the flight . Because most of the impactors were small (less than 10 micrometers) they were heated and dispersed in traversing the entrance foils producing clouds of molten droplets and vapor that produced easily identifiable 'extended impacts' on the Ge target plates. Fortunately, it proved possible to make ion probe measurements of projectile compositions from material deposited on the Ge in the extended impact structures.

Zinner, Ernst↗
NASA NTRS2010

Remaining Technical Challenges and Future Plans for Oil-Free Turbomachinery

The application of Oil-Free technologies (foil gas bearings, solid lubricants and advanced analysis and predictive modeling tools) to advanced turbomachinery has been underway for several decades. During that time, full commercialization has occurred in aircraft air cycle machines, turbocompressors and cryocoolers and ever-larger microturbines. Emerging products in the automotive sector (turbochargers and superchargers) indicate that high volume serial production of foil bearings is imminent. Demonstration of foil bearings in APU s and select locations in propulsion gas turbines illustrates that such technology also has a place in these future systems. Foil bearing designs, predictive tools and advanced solid lubricants have been reported that can satisfy anticipated requirements but a major question remains regarding the scalability of foil bearings to ever larger sizes to support heavier rotors. In this paper, the technological history, primary physics, engineering practicalities and existing experimental and experiential database for scaling foil bearings are reviewed and the major remaining technical challenges are identified.

DellaCorte, Christopher↗
DOE OSTI2024

The impact of helium on plasma-driven hydrogen permeation and implications for direct internal recycling in the fusion fuel cycle

Abstract Metal foil pumps (MFPs) are the leading technology for direct internal recycling (DIR) of hydrogen isotopes from the plasma exhaust in future fusion plants. MFPs rely on the concept of superpermeation, where superthermal H atoms directly absorb into the metal foil, rapidly diffuse, and desorb downstream. To date, studies of superpermeation have predominantly employed either pure hydrogen or in some cases trace levels of impurities. The plasma exhaust is expected to contain just ∼1% helium, but in DIR the source gas would be enriched in helium as hydrogen isotopes are extracted. In this work, we explore the impact of helium on hydrogen superpermeation at low temperature (75 °C–200 °C) using Pd-based foils. To first order, the flux scaled linearly with the hydrogen mole fraction. Stable permeation was observed until the helium fraction reached ∼80%, where the flux began to decline slowly with time. In addition, short term (1–5 min) exposure to pure helium plasma significantly attenuated subsequent hydrogen plasma permeation, and the degree was more dramatic at elevated temperature. This attenuation was correlated with He retention in the foils, which was detected by time-of-flight secondary ion mass spectrometry at low levels (<0.1 at. %) and limited to the near surface (<10 nm). Similar trends were observed among all alloys (Pd, PdAg, PdCu), and the foils were restored to full performance with an Ar + sputter clean. The potential for helium plasma exposure to impact MFP performance under these conditions has not been previously reported, and these findings have significant implications to the design and implementation of practical DIR systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

A lightweight and metal-free current collector for battery anode applications

The requirement for high energy density batteries is driving the development of high-capacity electrode materials while reducing the amount of inactive battery components such as separators, binders, and current collectors. Though current collectors are an inactive component, they are still required for successful working of a battery cell. Conventional current collectors include aluminum foil for cathode and copper foil for anode. Copper foil is quite heavy (8.7 mg/cm 2 ) for 10μm thickness. Therefore, there is a need for a lightweight current collector for anode applications. In this work, a metal-free current collector comprised of aligned carbon fiber (CFs) layer filled with carbon nanotubes (CNTs) mixed in polymer (P) is developed to be used as a current collector for anodes. Further, anodes coated on the CF-CNT-P showed lower charge transfer resistance and improved rate capability compared with the anodes fabricated on conventional copper foil-based current collectors. The CF-CNT-P are lighter (≈1.5 mg/cm 2 ) than the commonly used copper foil (8.7 mg/cm 2 ), which will increase the gravimetric energy density.

25 ENERGY STORAGE↗
DOE OSTI2020

Characterization Report for the MP-1 Experiment Fabrication Campaign

This report covers the results of MP 1 fuel characterization analysis to provide a detailed understanding of the as-fabricated fuel that would be irradiated in the MP 1 (Mini-Plate 1) experiment. The work was performed at Pacific Northwest National Laboratory (PNNL), Idaho National Laboratory (INL), and Los Alamos National Laboratory (LANL). Characterization of the as-fabricated fuel was performed in accordance with Characterization Plan for the Fabrication of U 10Mo for the MP 1 Experiment, hereinafter the MP 1 Characterization Plan (MAQP 2016). Under the MP 1 Characterization Plan, fuel foils at different points in the foil fabrication process (e.g., hot rolled annealed, cold rolled annealed) were studied to understand the effect of various thermomechanical processes on the fuel microstructure. Samples were sent to each of the three organizations so that testing and analysis could be performed independently using similar equipment and a standardized set of measurement and analysis procedures. The MP 1 experiment will provide an opportunity to understand the effects of processing conditions on the final fuel microstructure, to compare independently obtained results, and achieve a three-way validation. PNNL characterized 28 uranium–10 wt% molybdenum (U 10Mo) samples. Six pieces/specimens from each sample/foil were sectioned, in accordance with the MP 1 Characterization Plan. Similarly, INL and LANL also examined 24 and 17 U 10Mo specimens, respectively. These total 69 samples consist of six types of MP 1 characterization foils fabricated by Babcock and Wilcox Technologies (BWXT) from ingots produced by the Y-12 National Security Complex: • 0.047 in.-thick hot-rolled and annealed samples with and without Zr layers • 0.02 in.-thick cold-rolled and annealed samples with and without Zr layers • 0.01 in.-thick cold-rolled and annealed samples with and without Zr layers. Microstructure, chemical composition, carbide morphology, U 10Mo foil thickness, Zr thickness, mechanical properties (microhardness), and density were evaluated in both longitudinal and transverse directions for foils of the three different thicknesses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Hydrogen Diffusion Coefficient Measures on Thin Film Uranium Oxide

Thin films of uranium oxides, putatively UO 2 and U 3 O 8 , were deposited on palladium/silver (75/25) foil discs (10 μm thick, 10 mm diameter). Methodology for sealing these foils, applying a hydrogen pressure (~ 1 atm) to the oxide side, and measuring the pressure on the permeate side (opposite side of foil) is reported. The experimental apparatus is held at 100 °C to speed diffusion, aided by the pressure differential across the foil (~1 atm (750 torr) on oxide side, initially low vacuum on permeate side, ~1x 10 -4 torr). Early results indicate an effective diffusion coefficient of roughly 7.66 x 10 -17 +/- 2.22 x 10 -17 cm 2 /sec for UO 2 . These values are in line with expectations and prior measures relative to large lag times for system baseline (substrate only). Evaluation of the technique for U 3 O 8 thin films suggests further development will be needed to extend the technique to more oxidized films (U 3 O 8 , UO 3 ). Characterization of the foils (thickness and speciation) post diffusion experiments will be carried out by SIGMA (Eric Tegtmeier and Andy Richards) in FY24 which will sharpen the uncertainty quantification for UO 2 diffusion coefficients, aiding the nucleation model for DRACO.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Characterization Report for the MP-1 Experiment Fabrication Campaign (Rev.1)

This report covers the results of MP 1 fuel characterization analysis to provide a detailed understanding of the as-fabricated fuel that would be irradiated in the MP 1 (Mini-Plate 1) experiment. The work was performed at Pacific Northwest National Laboratory (PNNL), Idaho National Laboratory (INL), and Los Alamos National Laboratory (LANL). Characterization of the as-fabricated fuel was performed in accordance with Characterization Plan for the Fabrication of U 10Mo for the MP 1 Experiment, hereinafter the MP 1 Characterization Plan (MAQP 2016). Under the MP 1 Characterization Plan, fuel foils at different points in the foil fabrication process (e.g., hot rolled annealed, cold rolled annealed) were studied to understand the effect of various thermomechanical processes on the fuel microstructure. Samples were sent to each of the three organizations so that testing and analysis could be performed independently using similar equipment and a standardized set of measurement and analysis procedures. The MP 1 experiment will provide an opportunity to understand the effects of processing conditions on the final fuel microstructure, to compare independently obtained results, and achieve a three-way validation. PNNL characterized 28 uranium–10 wt% molybdenum (U 10Mo) samples. Six pieces/specimens from each sample/foil were sectioned, in accordance with the MP 1 Characterization Plan. Similarly, INL and LANL also examined 24 and 17 U 10Mo specimens, respectively. These total 69 samples consist of six types of MP 1 characterization foils fabricated by Babcock and Wilcox Technologies (BWXT) from ingots produced by the Y-12 National Security Complex: (a.) 0.047 in.-thick hot-rolled and annealed samples with and without Zr layers; (b.) 0.02 in.-thick cold-rolled and annealed samples with and without Zr layers; and (c.) 0.01 in.-thick cold-rolled and annealed samples with and without Zr layers. Microstructure, chemical composition, carbide morphology, U 10Mo foil thickness, Zr thickness, mechanical properties (microhardness), and density were evaluated in both longitudinal and transverse directions for foils of the three different thicknesses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Creep and Fatigue Characterization of High Strength Alloy Thin Sections in Advanced CO2 Heat Exchangers

The objective of this work was to characterize and model elevated temperature creep and fatigue behavior for thin sheet and foil forms of gamma-prime strengthened alloys in wrought form and as-processed folded and brazed constructions. This work was motivated by the demanding temperature and pressure service conditions of the GEN3 Concentrated Solar Power (CSP) and supercritical CO2 (sCO2) power cycle working fluid. More specifically, the possibility of leveraging the superior creep strength of gamma-prime alloys in folded-fin and brazed-plate heat exchanger constructions. Gamma-prime alloys represent a step-change in raw-material strength over solid-solution strengthened alloys. And the folded-fin and brazed-plate heat exchanger architecture is lightweight and leverages cost-effective material stock forms. The investigation contained two parallel paths. (1) The first is referred to as a fundamental investigation where Oak Ridge National Laboratory conducts uniaxial creep testing on thin sheet and foil in wrought form. This effort aimed to serve as a benchmark against a relatively sparse existing database and a baseline comparison for path number 2. (2) The second path is referred to as the practical investigation where Brayton Energy manufactures plate-fin heat exchangers and performs pressurized creep and fatigue testing. This effort aimed to de-risk heat exchanger manufacturing process for service under sCO2 CSP conditions. A total of 14 uniaxial creep tests were completed using Haynes 282 thin sheet and foil. A variety of heat treatments were specified to coincide with path number 2. Baseline metallography of test samples and creep strength performance are contained. Benchmarks relatively to existing thick-form Haynes 282 are made, as well as to other thin-form Nickel-based superalloys. Description of a wrought-form modeling approach for thin gamma-prime alloys is also discussed. A total of 11 pressurized creep and fatigue tests were completed successfully with Haynes 282 heat exchanger prototypes. Manufacturing processing details, testing details, testing results, and failure analysis are discussed. Additionally, creep modeling techniques to predict failure are discussed, and modeling to support technological-to-market. In conclusion, Haynes 282 foils were demonstrated to yield rupture two-to-three orders of magnitude higher than Haynes 230 foils under similar conditions. And the manufactured heat exchanger prototypes demonstrated strength similar to the wrought constituents. Both of which contribute to elevated performance potential or cost savings in practice. Discussion is included.

14 SOLAR ENERGY↗
DOE OSTI2024

Modelling Beam Loss Within the LANSCE Proton Storage Ring

Several upgrades are being considered for the proton storage ring (PSR) at the Los Alamos Neutron Science Center (LANSCE) to reduce beam loss and thereby reduce the cooldown period of the PSR following a beam run. First, we have considered an increased beam pipe diameter would reduce beam loss due to beam scraping caused by misalignments and tuning errors. However, this would require increased pole-to-pole gap height within the dipoles and quadrupoles, which would change their effective length and alter their fringe fields. The effect of different magnet gaps on the beam optical parameters and on beam loss was studied using the simulation codes MAD-X and PyORBIT. Second, we are developing a detailed particle tracking model within the framework of the simulation package General Particle Tracer (GPT) for the PSR H - stripping system. This model will be used to study the effect of the stripper foil parameters (position, composition, areal density, depth, etc.) on first-turn losses, where most of the observed beam loss and emittance growth occurs due to foil scattering, foil stripping, and Lorentz stripping. The model implements C++ custom elements created to model foil scattering, foil stripping, and Lorentz stripping, as these are not built-in features of GPT. The preliminary results of the MAD-X and PyORBIT simulations, as well as the GPT simulation model, is described in this tech note.

43 PARTICLE ACCELERATORS↗
NASA NTRS1971

The measurement of radiation exposure of astronauts by radiochemical techniques

Gamma analyses of the neutron-activated fecal samples from the Apollo 12 and 13 missions were completed, and the data are being evaluated. Samples of the exposed Apollo 12 solar wind composition foil and blank foils were obtained for analysis of the Po-2/0 (Pb-210, Rn-222) content. It is expected that the determination of the Po-210 content of these foils will yield the concentration of radon atoms incident on the foil while exposed to the lunar atmosphere, and this indirectly will permit an estimate of the average uranium concentration of the lunar surface. Proposals to measure the cosmic-ray intensity and energy spectra inside and outside of late Apollo and Project Skylab spacecraft by exposing and subsequently analyzing pure metal foils, and to measure the elemental mass balance in Project Skylab astronauts by instrumental neutron activation analysis of the intake and excreta are summarized.

Brodzinski, R. L.↗
NASA NTRS1973

Method of making porous conductive supports for electrodes

Porous conductive supports for electrochemical cell electrodes are made by electroforming thin corrugated nickel foil, and by stacking pieces of the corrugated foil alternatively with pieces of thin flat nickel foil. Corrugations in successive corrugated pieces are oriented at different angles. Adjacent pieces of foil are bonded by heating in a hydrogen atmosphere and then cutting the stack in planes perpendicular to the foils.

Schaer, G. R.↗
NASA NTRS1974

Magnetospheric particle composition experiment

Thin foils of aluminum and platinum were mounted on the exterior of the Skylab spacecraft where they were bombarded by particles that penetrate to the 400-km spacecraft altitude, including auroral particles precipitating from the earth magnetosphere. These foils have a high trapping efficiency for both charged and neutral particles above 1 keV and a decreasing but appreciable efficiency below that energy. Some sections of the foils were double layered to obtain an estimate of the energy of the entrapped particles. The foils were retrieved and returned for analysis in an ultrahigh-vacuum mass spectrometer. So far, the noble gas components of the entrapped particles have been analyzed in selected sections of two foils. Helium-4, helium-3, neon-20, and neon-22 have been detected.

Geiss, J.↗
NASA NTRS1988

Analytical study of graphite-epoxy tube response to thermal loads

The thermally-induced stresses and deformations in graphite-epoxy tubes with aluminum foil bonded to both inner and outer surfaces, and to the outer surface only are computed. Tubes fabricated from three material systems, T300/934, P75s/934, and P75s/BP907, and having a 1 inch inner radius and a lamination sequence of (+15/0 + or - 10/0)sub s are studied. Radial, axial, and circumferential stresses in the various layers of the tube, in the foil, and in the adhesive bonding the foil to the tubes are computed using an elasticity solution. The results indicate that the coatings have no detrimental effect on the stress state in the tube, particularly those stresses that lead to microcracking. The addition of the aluminum foil does, however, significantly influence the axial expansion of the T300/934 tube, the tube with the softer graphite fibers. The addition of foil can change the sign of the axial coefficient of thermal expansion. Twist tendencies of the tubes are only slightly affected by the addition of the coatings, but are of second order compared to the axial response.

Knott, Tamara W.↗
NASA NTRS2004

Automated Composites Processing Technology: Film Module

NASA's Marshall Space Flight Center (MSFC) has developed a technology that combines a film/adhesive laydown module with fiber placement technology to enable the processing of composite prepreg tow/tape and films, foils or adhesives on the same placement machine. The development of this technology grew out of NASA's need for lightweight, permeation-resistant cryogenic propellant tanks. Autoclave processing of high performance composites results in thermally-induced stresses due to differences in the coefficients of thermal expansion of the fiber and matrix resin components. These stresses, together with the reduction in temperature due to cryogen storage, tend to initiate microcracking within the composite tank wall. One way in which to mitigate this problem is to introduce a thin, crack-resistant polymer film or foil into the tank wall. Investigation into methods to automate the processing of thin film or foil materials into composites led to the development of this technology. The concept employs an automated film supply and feed module that may be designed to fit existing fiber placement machines, or may be designed as integral equipment to new machines. This patent-pending technology can be designed such that both film and foil materials may be processed simultaneously, leading to a decrease in part build cycle time. The module may be designed having a compaction device independent of the host machine, or may utilize the host machine's compactor. The film module functions are controlled by a dedicated system independent of the fiber placement machine controls. The film, foil, or adhesive is processed via pre-existing placement machine run programs, further reducing operational expense.

Hulcher, A. Bruce↗
NASA NTRS2009

Liquid Oxygen Rotating Friction Ignition Testing of Aluminum and Titanium with Monel and Inconel for Rocket Engine Propulsion System Contamination Investigation

Metallic contaminant was found in the liquid oxygen (LOX) pre-valve screen of the shuttle main engine propulsion system on two orbiter vehicles. To investigate the potential for an ignition, NASA Johnson Space Center White Sands Test Facility performed (modified) rotating friction ignition testing in LOX. This testing simulated a contaminant particle in the low-pressure oxygen turbo pump (LPOTP) and the high-pressure oxygen turbo pump (HPOTP) of the shuttle main propulsion system. Monel(R) K-500 and Inconel(R) 718 samples represented the LPOTP and HPOTP materials. Aluminum foil tape and titanium foil represented the contaminant particles. In both the Monel(R) and Inconel(R) material configurations, the aluminum foil tape samples did not ignite after 30 s of rubbing. In contrast, all of the titanium foil samples ignited regardless of the rubbing duration or material configuration. However, the titanium foil ignitions did not propagate to the Monel and Inconel materials.

Peralta, S.↗
NASA NTRS2009

Method of Suppressing Sublimation in Advanced Thermoelectric Devices

A method of applying a physical barrier to suppress thermal decomposition near a surface of a thermoelectric material including applying a continuous metal foil to a predetermined portion of the surface of the thermoelectric material, physically binding the continuous metal foil to the surface of the thermoelectric material using a binding member, and heating in a predetermined atmosphere the applied and physically bound continuous metal foil and the thermoelectric material to a sufficient temperature in order to promote bonding between the continuous metal foil and the surface of the thermoelectric material. The continuous metal foil forms a physical barrier to enclose a predetermined portion of the surface. Thermal decomposition is suppressed at the surface of the thermoelectric material enclosed by the physical barrier when the thermoelectric element is in operation.

Sakamoto, Jeffrey S.↗