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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Radio Frequency Plasma Synthesis of Boron Nitride Nanotubes (BNNTs) for Structural Applications: Part I

It is evident that nanotubes, such as carbon, boron nitride and even silicon, offer great potential for many aerospace applications. The opportunity exists to harness the extremely high strength and stiffness exhibited by high-purity, low-defect nanotubes in structural materials. Even though the technology associated with carbon nanotube (CNT) development is mature, the mechanical property benefits have yet to be fully realized. Boron nitride nanotubes (BNNTs) offer similar structural benefits, but exhibit superior chemical and thermal stability. A broader range of potential structural applications results, particularly as reinforcing agents for metal- and ceramic- based composites. However, synthesis of BNNTs is more challenging than CNTs mainly because of the higher processing temperatures required, and mass production techniques have yet to emerge. A promising technique is radio frequency plasma spray (RFPS), which is an inductively coupled, very high temperature process. The lack of electrodes and the self- contained, inert gas environment lend themselves to an ultraclean product. It is the aim of this White Paper to survey the state of the art with regard to nano-material production by analyzing the pros and cons of existing methods. The intention is to combine the best concepts and apply the NASA Langley Research Center (LaRC) RFPS facility to reliably synthesize large quantities of consistent, high-purity BNNTs.

Hales, Stephen J.↗
NASA NTRS2019

Additive Manufacturing Technologies for Aerospace Applications

An overview will be provided on NASA GRC activities in additive manufacturing (AM) technology development for advanced high performance, propulsion component designs in electric motors and turbine engine systems in future electrified aircraft. AM offers significant benefits over conventional manufacturing to fabricate components that are more compact, lighter weight, geometrically complex, innovatively cooled, integrated, multi-material, and multifunctional. For turbine engine applications, silicon carbide (SiC) based composites are being pursued using binder jetting. For electric motor applications, additive processes are being applied toward optimized component designs to include the housing, rotor, and stators with 3-D printing and wire imbedded coils and with direct printed 3-phase coils. The will be an emphasis on capabilities in additive manufacturing.

Halbig, Michael C.↗
NASA NTRS2019

Enabling Additive Manufacturing Technologies for Advanced Aero Propulsion Materials & Components

Additive manufacturing (AM) technologies are enabling for advanced high performance, propulsion component designs in electric motors1-2 and turbine engine systems in future electrified aircraft. AM offers significant benefits over conventional manufacturing to fabricate components that are more compact, lighter weight, geometrically complex, innovatively cooled, integrated, multi-material, and multifunctional. For turbine engine applications, silicon carbide (SiC) based composites are being pursued using binder jetting and laminated object manufacturing (LOM) for components such as shrouds, vanes, and recuperators. For electric motor applications, additive processes are being applied toward optimized component designs to include the housing, rotor, and stators with 3-D printing and wire imbedded coils and with direct printed 3-phase coils. The electrical conductivity of silver conductor coils optimized by evaluating alternate sintering methods and additions of graphene and carbon nanostructures will be presented. Potential benefits of new electric motor components in improving temperature capability, efficiency, and power density for reductions in energy consumption and emissions will be discussed.

Halbig, Michael C.↗
NASA NTRS2020

The Evolution of Icelandic Volcano Emissions, as Observed From Space in the Era of NASA's Earth Observing System (EOS)

Volcanoes are natural phenomena that have global environmental impacts. Satellite remote sensing can help classify volcanic eruptions and track the dispersion of emissions. We assess multiple volcanic eruptions in Iceland (Eyjafjallajökull 2010, Grímsvötn 2011 and Holuhraun 2014-2015), using space-borne observations to infer information about the geological dynamics of each volcano and the properties and evolution of plume particles. We derive qualitative constraints on plume particle size, shape and light-absorption characteristics from Multi-angle Imaging SpectroRadiometer (MISR) space-borne imagery. With the MISR Research Algorithm (RA), we distinguish sulfate/water-dominated volcanic plumes from Holuhraun and ash-dominated plumes from Eyjafjallajökull and Grímsvötn, and even identify subtler changes in ash particle size and light-absorption within plumes. Additionally, plume heights are retrieved geometrically from MISR. These are combined with surface thermal anomalies from the MODerate resolution Imaging Spectroradiometer (MODIS) and SO2 concentrations derived from the Ozone Monitoring Instrument (OMI) to synthesize eruption remote-sensing chronologies. Signals related to differences in particle properties are identified and linked to evolving magma composition at Eyjafjallajökull. The results illustrate the potential to distinguish qualitative differences in eruptive magma composition based on particle light absorption and plume profile from remote-sensing. For the sulfate-rich Holuhraun plumes, the influence of aerosol hygroscopic growth during transport is inferred from such data. Three processes appear to dominate plume evolution in Iceland: downwind aerosol formation; particle hydration; and particle deposition. This work demonstrates enhanced MISR capabilities, and more generally, remote-sensing analysis that can be applied globally, especially where suborbital volcano observations are limited or entirely absent.

remote sensting↗
NASA NTRSDate not supplied

In-situ Lunar Launch and Landing Pad Construction with Regolith-Thermoset Polymer Composite Materials

Lunar launch and landing pads are necessary to mitigate risks to lander/ascent vehicles and surrounding surface assets from rocket plume ejected regolith. The current state of the art of landing and launching from the lunar surface is to land/launch on unprepared regolith surfaces. Though this has been a relatively successful approach, significant risks exist for the Artemis Program due to higher thrust levels leading to increased ejecta and cratering, presence of co-located assets in the ejecta path, and potential strict surface levelness requirements. Regolith-thermoset polymer composite materials were developed and evaluated for off Earth launch and landing pad applications. Performance under hot fire conditions was assessed for two simulated Starship lunar launch/landing environments, one targeting thermal conditions and the second targeting pressure conditions. Paver test articles were prepared at 20% and 11% polymer mass fractions. Sintered paver test articles were prepared with 20% polymer grouting filling the seams between pavers. Though significant erosion was experienced during the more extreme thermal testing conditions, all test articles successfully mitigated regolith ejecta from plume effects. A concept for preparing and emplacing the materials was developed and tested in laboratory conditions. The testing evaluated the feasibility of using twin and single screw extruder technology to mix, convey and deposit materials. Both the twin and single screw extruders were capable of processing and extruding the composite with a maximum of 90% mass fraction of regolith achieved by the twin screw extruder.A primary risk for application of regolith-thermoset polymer composites as lunar launch/landingpad is the mass of polymer required to be landed on the moon. Calculations were performed that show that a 100 m diameter, 0.025 m thick pad with polymer mass fraction of 15% will require a payload mass of 72 mt to the Lunar surface. This is below the planned Starship payload capacity to the lunar surface of 100 mt. The regolith-thermoset polymer composite based construction approach proved feasibility in three critical areas: performance under launch/landing conditions, demonstration of a mixing and depositing strategy, and fitting within the planned lunar payload capacity. It is recommended that materials and systems be developed to TRL 6 for a small-scale lunar demonstration of emplacement of a launch/landing pad via a CLPS mission to support Artemis Program roadmap gap closure activities.

ISRU↗
NASA NTRS2021

Solid Particle Erosion of a Plasma Spray – Physical Vapor Deposition Environmental Barrier Coating in a Combustion Environment

Environmental barrier coatings (EBCs) were developed to reduce the susceptibility of SiC-based composites to the rapid volatilization and surface recession that occurs in the presence of water vapor. Extensive research and development has been performed on EBCs, and their corresponding failure mechanisms under different environmental conditions. However, one key failure mechanism, solid particle erosion (SPE), has not been thoroughly investigated. As a result, the present work investigates the SPE behavior of a ytterbium disilicate (Yb2Si2O7) environmental barrier coating (EBC) deposited via plasma spray-physical vapor deposition (PS-PVD). Erosion testing was performed at elevated temperature (1,200 °C) in a simulated combustion environment at the NASA Glenn Research Center Erosion Burner Rig Facility. Alumina (Al2O3) particles were used as the eroding media. A range of particle kinetic energies and impingement angles were investigated along with the effect of coating surface roughness. The post-erosion damage morphology was characterized using scanning electron microscopy (SEM). The SPE behavior of the PS-PVD EBC was shown to be comparable to other EBC systems reported in the literature.

Solid particle erosion; environmental barrier coat↗
NASA NTRSDate not supplied

Development of an Additively Manufactured Subscale Secondary Sealed Container for the NASA FROSTE Project

This presentation details the development of an additively manufactured (AM) subscale test article for the secondary sealed container (SSC) as part of the NASA FROSTE project. FROSTE is focused on the collection of regolith samples from shadowed regions of the Moon and the preservation of those samples at cryogenic temperatures for return to Earth. Our team was integrated into the FROSTE program to leverage innovative design approaches and additive manufacturing capabilities in support of a scalable development strategy, where the subscale configuration serves as the development path toward a full-scale SSC. Scalmalloy was selected as the primary material for all AM components due to its favorable strength-to-weight ratio, thermal conductivity, and demonstrated performance in aerospace applications. Its aluminum-based composition supports robust mechanical behavior at cryogenic temperatures while enabling efficient heat transfer and control of thermal gradients within the containment system. The SSC architecture consists of an outer container assembly that houses a phase change material (PCM) tank, which in turn contains primary containers holding the regolith. Thermal management relies on controlled conductive and radiative heat transfer, including a thermal connection assembly that interfaces the PCM tank to an external cryocooler via a thermal strap, and IMLI surrounding the PCM tank to inhibit radiative heat transfer. The outer container assembly incorporates sealing interfaces, thermal connection ports, and I/O feedthroughs, with PTFE spring seals used at critical interfaces to maintain containment integrity. The PCM tank is manufactured as a single monolithic Scalmalloy component and incorporates an integral lattice structure to minimize thermal gradients, internal channels for thermocouple routing, and interface features for thermal connection assembly integration. The tank is centrally suspended within the outer container using support rings, with G10 insulating components employed to inhibit thermal leaks. This work describes the design methodology, AM approach, and key considerations used to inform the design.

regolith↗
DOE OSTI2021

Boron-10 containing biocompatible nanostructures

A method comprises providing a plurality of nanostructures comprising a base material. The plurality of nanostructures are exposed to a first material at a first deposition temperature. The plurality of nanoparticles are exposed to a second material at a second deposition temperature, and exposed to a Boron-10 (10B) containing material at a third deposition temperature so as to form a 10B-metal oxide based composite nanostructure.

Mane, Anil U.↗
DOE OSTI2022

Unconventional Highly Active and Stable Oxygen Reduction Catalysts Informed by Computational Design Strategies

As conventional strategies of engineering new MIEC materials for SOFCs over the past few decades would have eliminated a material like BFCZ75 from contention, this work suggests there is a need to re-think existing design criteria and develop and understand new rational materials design strategies that challenge conventional wisdom and chemical intuition. The ultimate goal of cathode design of SOFCs is to achieve a balance among electrical conductivity, ionic conductivity, oxygen exchange activity and long-term stability. Instead of searching for a replacement for unstable MIEC like LSCF, which works well in a ceria based composite electrode, some stable composites contain a highly conductive material mixing with a less conductive but highly ORR active and stable MIEC such as BFCZ75 or even triple-phase composites could be an alternative way to advance the current SOFC technology. (This work is published in May 2022 issue of Advanced Energy Materials. https://doi.org/10.1002/aenm.202201203 --&gt;)<br>

Liu, Jian↗
DOE OSTI2023

Highly filled carbon nanofiber reinforced polysiloxanes

Provided herein are polysiloxane-based composite materials comprising a high weight percentage of elemental components (e.g., elemental boron, elemental copper, elemental bismuth, elemental lead) and low levels of carbon nanofibers. The elemental components may be present in the composite materials at levels greater than 25% by weight. Also provided herein are methods of forming the composite materials that have desirable flexibility and shielding properties. The invention provides a versatile composite material that is compliant and moldable, while still comprising high levels of the elemental shielding components. The materials are particularly useful for applications in which radiation shielding or neutron capture are desired.

Robison, Thomas Wayne↗
DOE OSTI2023

First-of-a-Kind Fuel-bearing Molten Chloride Irradiation Experiment

As a dozen MSR developers in the U.S. work toward an aggressive commercialization timeline, many of their fueled-salts—notably, chloride-based compositions—have never been irradiated. Licensing and operating these reactors requires an understanding of (1) the source term, radiation chemistry, and gas generation; (2) unanticipated irradiation-induced corrosion effects; and (3) the impact of burnup on thermophysical properties, all of which can be deduced through irradiation testing. Idaho National Laboratory (INL) is ideally suited to leverage its expertise in chloride salt chemistry, as well as its Neutron Radiography Reactor (NRAD) facility in the Hot Fuels Examination Facility (HFEF) at the Materials and Fuels Complex (MFC), to conduct the world’s first fuel-bearing chloride salt irradiation and fill in the knowledge gaps pertaining to salt chemistry under irradiation. Molten-salt Research Temperature-controlled Irradiation (MRTI) consists of a salt-containing capsule that is internally heated inside of a secondary containment. The experiment must rely on resistive heating to melt the salt before irradiation (to avoid the impact of radiolysis) and once the reactor is turned on and fission reactions commence in the salt, the resistive power can then be reduced. Salt-immersed thermocouples coupled to a controller allow for the heater power to be adjusted as needed to meet experimental objectives. The bulk of the experimental results will be achieved through Post-Irradiation Examination (PIE). At which point a range of different measurements are anticipated to assess the salt/plenum/wall composition, the capsule corrosion rate, and the evolution of salt properties.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Multi-Parameter Optical Fiber Sensing of Humidity, CH4, CO2, and Corrosion

In this work, the previously demonstrated capability of the optical fiber sensor (OFS) for successful monitoring of humidity has been extended to monitor the humidity, CH4, and CO2 with different gas composition based on the strain produced along the single mode fiber (SMF) sensor. This is enabled by absorption of H2O/gases on to the commercially available polyacrylate coated jacketed portion of the fiber resulting a change in strain. Under equilibrium, a differential microstrain was observed along the jacketed portion of the SMF with N2, CH4, and CO2 at different humidity conditions, while the unjacketed portion of the fiber was used only for sensing pressure/temperature induced strain. In case of N2 at 800 psig pressure, the observed microstrain was approximately 80, 65, 50 and 35 µε at 100, 75.0, 46.8, and 23.4 RH% respectively. Comparatively, a microstrain of approximately 95 µε was observed with 100% RH CH4 which demonstrates that SMF produces a measurable CH4 response alongside water. Similarly, the observed microstrain with CO2 was approximately 105, 90, 85, 80, and 70 µε at 100, 75.0, 46.8, 23.4, and 0 RH% respectively. Linear regression and principal component analysis of these dataset provided deconvolution of the impact of strain from H2O, CH4, and CO2 enabling good cross sensitivity. Additionally, modified OFS comprising of Fe coated fiber section was employed to monitor corrosion, using Fe as corrosion proxy, under harsh corrosive environment.

Mainali, Badri↗
DOE OSTI2024

Multi-Parameter Optical Fiber Sensing of Humidity, CH4, CO2, and Corrosion

In this work, the previously demonstrated capability of the optical fiber sensor (OFS) for successful monitoring of humidity has been extended to monitor the humidity, CH4, and CO2 with different gas composition based on the strain produced along the single mode fiber (SMF) sensor. This is enabled by absorption of H2O/gases on to the commercially available polyacrylate coated jacketed portion of the fiber resulting a change in strain. Under equilibrium, a differential microstrain was observed along the jacketed portion of the SMF with N2, CH4, and CO2 at different humidity conditions, while the unjacketed portion of the fiber was used only for sensing pressure/temperature induced strain. In case of N2 at 800 psig pressure, the observed microstrain was ~80, ~65, ~50 and ~35 µε at 100, 75.0, 46.8, and 23.4 RH% respectively. Comparatively, a microstrain of ~95 µε was observed with 100% RH CH4 which demonstrates that SMF produces a measurable CH4 response alongside water. Similarly, the observed microstrain with CO2 was ~105, ~90, ~85, ~ 80, and ~70 µε at 100, 75.0, 46.8, 23.4, and 0 RH% respectively. Linear regression and principal component analysis of these dataset provided deconvolution of the impact of strain from H2O, CH4, and CO2 enabling good cross sensitivity. Additionally, modified OFS comprising of Fe coated fiber section was employed to monitor corrosion based on the increase in backscattered intensity amplitude of the light being passed once corrosion occurs.

Mainali, Badri↗
DOE OSTI2024

Melting and solidification dynamics during laser melting of reaction-based metal matrix composites uncovered by in-situ synchrotron X-ray diffraction

Laser additive manufacturing (AM) of reaction-based metal matrix composites (MMCs) involves highly complex and non-equilibrium material transformation behavior, including melting, dissolution, precipitation, and solidification. Yet, the dynamics and interplay of these phase transformation processes remain poorly understood, posing substantial challenges in identifying the microstructure formation mechanism, and predicting and controlling the microstructure in the printed parts. Here, in this study, we performed the in-situ X-ray diffraction experiment to characterize the phase evolution dynamics of the 316L + 10 vol.%TiC system during laser melting, which provides direct and quantitative insights of the complex phase reaction and evolution dynamics under rapid heating and cooling conditions relevant to additive manufacturing of reaction-based MMCs. Further in-depth thermodynamic and kinetic calculations revealed that most of the phase evolution behavior observed in the in-situ X-ray diffraction experiment cannot be solely explained by widely used equilibrium thermodynamic models, and diffusion-controlled nonequilibrium dissolution and precipitation kinetics must be considered to elucidate the complex phase evolution behavior, including incomplete TiC dissolution, and three-step TiC precipitation. The three distinct types of precipitates generate unique hierarchical TiC micro- and nanostructures, which enhances the yield strength from 513 MPa to 877 MPa by 71 %, tensile strength from 628 MPa to 1054 MPa by 68 %, and Young's modulus from 193 GPa to 221 GPa by 14 %. The findings of our research provide the knowledge foundation for the design of unique microstructures and advanced MMC materials through laser AM.

36 MATERIALS SCIENCE↗
NASA NTRS2010

A Simple Technique for Creating Regional Composites of Sea Surface Temperature from MODIS for Use in Operational Mesoscale NWP

This paper describes a simple technique for creating regional, high-resolution, daytime and nighttime composites of sea surface temperature (SST) for use in operational numerical weather prediction (NWP). The composites are based on observations from NASA s Moderate Resolution Imaging Spectroradiometer (MODIS) aboard Aqua and Terra. The data used typically are available nearly in real time, are applicable anywhere on the globe, and are capable of roughly representing the diurnal cycle in SST. The composites resolution is much higher than that of many other standard SST products used for operational NWP, including the low- and high-resolution Real-Time Global (RTG) analyses. The difference in resolution is key because several studies have shown that highly resolved SSTs are important for driving the air sea interactions that shape patterns of static stability, vertical and horizontal wind shear, and divergence in the planetary boundary layer. The MODIS-based composites are compared to in situ observations from buoys and other platforms operated by the National Data Buoy Center (NDBC) off the coasts of New England, the mid-Atlantic, and Florida. Mean differences, mean absolute differences, and root-mean-square differences between the composites and the NDBC observations are all within tenths of a degree of those calculated between RTG analyses and the NDBC observations. This is true whether or not one accounts for the mean offset between the skin temperatures of the MODIS dataset and the bulk temperatures of the NDBC observations and RTG analyses. Near the coast, the MODIS-based composites tend to agree more with NDBC observations than do the RTG analyses. The opposite is true away from the coast. All of these differences in point-wise comparisons among the SST datasets are small compared to the 61.08C accuracy of the NDBC SST sensors. Because skin-temperature variations from land to water so strongly affect the development and life cycle of the sea breeze, this phenomenon was chosen for demonstrating the use of the MODIS-based composite in an NWP model. A simulated sea breeze in the vicinity of New York City and Long Island shows a small, net, but far from universal improvement when MODIS-based composites are used in place of RTG analyses. The timing of the sea breeze s arrival is more accurate at some stations, and the near-surface temperature, wind, and humidity within the breeze are more realistic.

Knievel, Jason C.↗
DOE OSTI2021

Calcium-silicate-based porous particles, composition, method of making and use thereof

A method for synthesizing calcium-silicate-based porous particles (CSPPs) is described. Control over CSPP morphology and pore size is achieved through a refined solution-based synthesis, allowing loading of a variety of sealants. These particles, upon external stimuli, release the loaded sealant into the surrounding material. Methods of loading the CSPPs with loading sealant are described. The CSPPs may be used in pure form or mixed with another material to deliver self-healing, sealing and multi-functional properties to a physical structure. The composition of the CSPPs is described, along with methods of use of the CSPPs.

Shahsavari, Rouzbeh↗