SEARCH · Search NASA

Results for “Material processing flows”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3

All sources NASA NTRS DOE OSTI

NASA NTRS2002

Studies of Gas-Particle Interactions in a Microgravity Flow Cell

The ability to transport particulate materials predictably and efficiently using a flowing gas is likely to play an important role in the development of lunar and Martian environments that are hospitable to humans. Lunar soil contains significant amounts of oxygen, hydrogen and other critical materials that are chemically bound in various minerals. Through appropriate processing, these resources may be recovered for use in propulsion, life support systems and mining operations. Similarly, it is believed that Martian soil contains significant amounts of water which can be electrolyzed into oxygen and hydrogen, again for propellants and life support. The transport of such granular soils from where they are mined and between stages of their processing is likely to involve pneumatic transport carried out in systems of pipes using flows of the liberated gases. On earth, the transport and processing of solid materials are also crucial in a number of applications from the chemical, mining, power and oil industries. For these flows, an appreciation has recently developed for the influence of collisional interactions among particles, both in suspensions where the flow is laminar and turbulent. Collisions between such particles can transfer a significant amount of momentum within the flow and at the boundaries. This provides an additional resistance to the passage of the gas, but it also introduces a mechanism that promotes more homogeneous flows and, at least in small-diameter pipes, may forestall the development of clusters.

Louge, Michel Y.↗

NASA NTRS1974

Thermal analysis of M552 experiment for materials processing in space

Analytical and experimental studies made of heat flow in the exothermic brazing unit in the M552 experiment are described. The emphasis of the studies was placed on heat flow in the tube and the sleeve during a period from ignition to the time when the brazing alloy solidifies. Experiments were made of three specimens tested in a ground-based laboratory. Heat flow was determined by thermocouples. The analytical study covered two phases: (1) the effect of reduced gravity on heat flow in the exothermic brazing unit; and (2) the development of analytical models. The major mode of heat transfer was conduction and the effect of gravity was minimal. Good agreements were obtained between experimental and analytical results indicating the soundness of the analytical models.

Muraki, T.↗

NASA NTRS1984

Fundamentals of Alloy Solidification Applied to Industrial Processes

Solidification processes and phenomena, segregation, porosity, gravity effects, fluid flow, undercooling, as well as processing of materials in the microgravity environment of space, now available on space shuttle flights were discussed.

Source record↗

NASA NTRS1989

Bars within bars - A mechanism for fuelling active galactic nuclei

A mechanism, applicable to AGN and nuclear starburst galaxies in which there is accretion onto a supermassive black hole (SBH), is proposed which brings in gas from large to small scales by successive dynamical instabilities. On the large scale, a stellar bar sweeps the interstellar medium into a gaseous disk a few hundred pc in radius. Under certain conditions, this disk can become unstable again, allowing material to flow inwards until turbulent viscous processes control angular-momentum transport. This flow pattern may feed viscosity-driven accretion flows around an SBH or lead to the formation of an SBH if none was present initially.

Shlosman, Isaac↗

NASA NTRS1992

ASRM test report: Autoclave cure process development

ASRM insulated segments will be autoclave cured following insulation pre-form installation and strip wind operations. Following competitive bidding, Aerojet ASRM Division (AAD) Purchase Order 100142 was awarded to American Fuel Cell and Coated Fabrics Company, Inc. (Amfuel), Magnolia, AR, for subcontracted insulation autoclave cure process development. Autoclave cure process development test requirements were included in Task 3 of TM05514, Manufacturing Process Development Specification for Integrated Insulation Characterization and Stripwind Process Development. The test objective was to establish autoclave cure process parameters for ASRM insulated segments. Six tasks were completed to: (1) evaluate cure parameters that control acceptable vulcanization of ASRM Kevlar-filled EPDM insulation material; (2) identify first and second order impact parameters on the autoclave cure process; and (3) evaluate insulation material flow-out characteristics to support pre-form configuration design.

Nachbar, D. L.↗

NASA NTRS1998

Magnetic Damping of Solid Solution Semiconductor Alloys

The objective of this study is to conduct the Earth-based research sufficient to successfully propose a flight experiment (1) to experimentally test the validity of the modeling predictions applicable to the magnetic damping of convective flows in conductive melts as this applies to the bulk growth of solid solution semiconducting materials in the reduced gravitational levels available in low Earth orbit and (2) to assess the effectiveness of steady magnetic fields in reducing the fluid flows occurring in these materials during space processing. To achieve the objectives of this investigation, we are carrying out a comprehensive program in the Bridgman and floating-zone configurations using the solid solution alloy system Ge-Si. This alloy system was chosen because it has been studied extensively in environments that have not simultaneously included both low gravity and an applied magnetic field. Also, all compositions have a high electrical conductivity, and the materials parameters permit high growth rates compared to many other commonly studied alloy semiconductors. An important supporting investigation is determining the role, if any, that thermoelectromagnetic convection (TEMC) plays during growth of these materials in a magnetic field. Some compositional anomalies observed by us in magnetic grown crystals can only be explained by TEMC; this has significant implications for the deployment of a Magnetic Damping Furnace in space. This effect will be especially important in solid solutions where the growth interface is, in general, neither isothermal nor isoconcentrational. It could be important in single melting point materials, also, if faceting takes place producing a non-isothermal interface.

Szofran, Frank R.↗

NASA NTRS2003

Flow Visualization of Low Prandtl Number Fluids using Electrochemical Measurements

It is well established that residual flows exist in contained liquid metal processes. In 1-g processing, buoyancy forces often drive these flows and their magnitudes can be substantial. It is also known that residual flows can exist during microgravity processing, and although greatly reduced in magnitude, they can influence the properties of the processed materials. Unfortunately, there are very few techniques to visualize flows in opaque, high temperature liquid metals, and those available are not easily adapted to flight investigation. In this study, a novel technique is developed that uses liquid tin as the model fluid and solid-state electrochemical cells constructed from Yttria-Stabilized Zirconia (YSZ) to establish and measure dissolved oxygen boundary conditions. The melt serves as a common electrode for each of the electrochemical cells in this design, while independent reference electrodes are maintained at the outside surfaces of the electrolyte. By constructing isolated electrochemical cells at various locations along the container walls, oxygen is introduced or extracted by imposing a known electrical potential or passing a given current between the melt and the reference electrode. This programmed titration then establishes a known oxygen concentration boundary condition at the selected electrolyte-melt interface. Using the other cells, the concentration of oxygen at the electrolyte-melt interface is also monitored by measuring the open-circuit potentials developed between the melt and reference electrodes. Thus the electrochemical cells serve to both establish boundary conditions for the passive tracer and sense its path. Rayleigh-Benard convection was used to validate the electrochemical approach to flow visualization. Thus, a numerical characterization of the second critical Rayleigh numbers in liquid tin was conducted for a variety of Cartesian aspect ratios. The extremely low Prandtl number of tin represents the lowest value studied numerically. Additionally, flow field oscillations are visualized and the effect of tilt on convecting systems is quantified. Experimental studies of the effect of convection in liquid tin are presented. Three geometries are studied: (1) double electrochemical cell with vertical concentration gradients; (2) double cell with horizontal concentration gradients; and (3) multiple cells with vertical temperature gradients. The first critical Rayleigh number transition is detected with geometry (1) and it is concluded that current measurements are not as affected by convection as EMF measurements. The system is compared with numerical simulations in geometry (2), and oscillating convection is detected with geometry (3).

Crunkleton, D.↗

NASA NTRS1997

Diamines Containing Pendent Phenylethynyl Groups

Controlled molecular weight imide oligomers and co-oligomers containing pendent phenylethynyl groups (PEPIs) and endcapped with nonreactive or phenylethynyl groups have been prepared by the cyclodehydration of the precursor amide acid oligomers or co-oligomers containing pendent phenylethynyl groups and endcapped with nonreactive or phenylethynyl groups. The amine terminated amide acid oligomers or co-oligomers are prepared from the reaction of dianhydride(s) with an excess of diamine(s) and diamine containing pendent phenylethynyl groups and subsequently endcapped with a phenylethynyl phthalic anhydride or monofunctional anhydride. The anhydride terminated amide acid oligomers and co-oligomers are prepared from the reaction of diamine(s) and diamine containing pendent phenylethynyl group(s) with an excess of dianhydride(s) and subsequently endcapped with a phenylethynyl amine or monofunctional amine. The polymerizations are carried out in polar aprotic solvents such as and N,N-dimethylacetamide under nitrogen at room temperature. The amide acid oligomers or co-oligomers are subsequently cyclodehydrated either thermally or chemically to the corresponding imide oligomers. The polymers and copolymers prepared from these materials exhibit a unique and unexpected combination of properties that includes higher glass transition temperatures after curing and higher retention of neat resin, adhesive and carbon fiber reinforced mechanical properties at temperatures up to 204 C under wet conditions without sacrificing melt flow behavior and processability as compared to similar materials. These materials are useful as adhesives, coatings, films, moldings, and composite matrices.

Connell, John W.↗

NASA NTRS2006

Heat Transfer of Thermocapillary Convection in a Two-Layered Fluid System Under the Influence of Magnetic Field

Heat transfer of a two-layer fluid system has been of great importance in a variety of industrial applications. For example, the phenomena of immiscible fluids can be found in materials processing and heat exchangers. Typically in solidification from a melt, the convective motion is the dominant factor that affects the uniformity of material properties. In the layered flow, thermocapillary forces can come into an important play, which was first emphasized by a previous investigator in 1958. Under extraterrestrial environments without gravity, thermocapillary effects can be a more dominant factor, which alters material properties in processing. Control and optimization of heat transfer in an immiscible fluid system need complete understanding of the flow phenomena that can be induced by surface tension at a fluid interface. The present work is focused on understanding of the magnetic field effects on thermocapillary convection, in order to optimize material processing. That is, it involves the study of the complicated phenomena to alter the flow motion in crystal growth. In this effort, the Marangoni convection in a cavity with differentially heated sidewalls is investigated with and without the influence of a magnetic field. As a first step, numerical analyses are performed, by thoroughly investigating influences of all pertinent physical parameters. Experiments are then conducted, with preliminary results, for comparison with the numerical analyses.

Ramachandran, N.↗

NASA NTRS1999

Friction Stir Welding of Curved Plates

Friction stir welding (FSW) is a remarkable technology for making butt and lap joints in aluminum alloys. The process operates by passing a rotating tool between two closely butted plates. This process generates heat and the heated material is stirred from both sides of the plates to generate a high quality weld. Application of this technique has a very broad field for NASA. In particular, NASA is interested in using this welding process to manufacture tanks and curved elements. Therefore, this research has been oriented to the study the FSW of curved plates. The study has covered a number of topics that are important in the model development and to uncover the physical process involve in the welding itself. The materials used for the experimental welds were as close to each other as we could possibly find, aluminum 5454-0 and 5456-0 with properties listed at http://matweb.com. The application of FSW to curved plates needs to consider the behavior that we observed in this study. There is going to be larger force in the normal direction (Fz) as the curvature of the plate increases. A particular model needs to be derived for each material and thickness. A more complete study should also include parameters such as spin rate, tool velocity, and power used. The force in the direction of motion (Fx) needs to be reconsidered to make sure of its variability with respect to other parameters such as velocity, thickness, etc. It seems like the curvature does not play a role in this case. Variations in temperature were found with respect to the curvature. However, these changes seem to be smaller than the effect on Fz. The temperatures were all below the melting point. We understand now that the process of FSW produces a three dimensional flow of material that takes place during the weld. This flow needs to be study in a more detailed way to see in which directions the flow of material is stronger. It could be possible to model the flow using a 2-dimensional model in the particular directions where the flow moves faster. More experimental information is required to enrich the knowledge about FSW, and from this point, derive useful mathematical formulas to optimize the process and the design of the machines that will perform it. More experiments and experimental equipment are required to uncover the mathematics of the process.

Sanchez, Nestor↗

NASA NTRS2004

Utilizing Expert Knowledge in Estimating Future STS Costs

A method of estimating the costs of future space transportation systems (STSs) involves classical activity-based cost (ABC) modeling combined with systematic utilization of the knowledge and opinions of experts to extend the process-flow knowledge of existing systems to systems that involve new materials and/or new architectures. The expert knowledge is particularly helpful in filling gaps that arise in computational models of processes because of inconsistencies in historical cost data. Heretofore, the costs of planned STSs have been estimated following a "top-down" approach that tends to force the architectures of new systems to incorporate process flows like those of the space shuttles. In this ABC-based method, one makes assumptions about the processes, but otherwise follows a "bottoms up" approach that does not force the new system architecture to incorporate a space-shuttle-like process flow. Prototype software has been developed to implement this method. Through further development of software, it should be possible to extend the method beyond the space program to almost any setting in which there is a need to estimate the costs of a new system and to extend the applicable knowledge base in order to make the estimate.

Fortner, David B.↗

NASA NTRS2011

Radiation Modeling for the Reentry of the Hayabusa Sample Return Capsule

Predicted shock-layer emission signatures of the Japanese Hayabusa capsule during its reentry are presented for comparison with flight measurements made during an airborne observation mission using NASA s DC-8 Airborne Laboratory. For each altitude, lines of sight were extracted from flow field solutions computed using an inhouse high-fidelity CFD code, DPLR, at 11 points along the flight trajectory of the capsule. These lines of sight were used as inputs for the line-by-line radiation code NEQAIR, and emission spectra of the air plasma were computed in the wavelength range from 300 nm to 1600 nm, a range which covers all of the different experiments onboard the DC-8. In addition, the computed flow field solutions were post-processed with the material thermal response code FIAT, and the resulting surface temperatures of the heat shield were used to generate thermal emission spectra based on Planck radiation. Both spectra were summed and integrated over the flow field. The resulting emission at each trajectory point was propagated to the DC-8 position and transformed into incident irradiance. Comparisons with experimental data are shown.

Winter, Michael W.↗

NASA NTRS2019

Radiation Modeling for the Reentry of the Hayabusa Sample Return Capsule

Predicted shock-layer emission signatures during the reentry of the Japanese Hayabusa capsule are presented and compared with flight measurements conducted during an airborne observation mission in NASA's DC-8 Airborne Laboratory. For selected altitudes at 11 points along the flight trajectory of the capsule, lines of sight were extracted from flow field solutions computed using the in-house high-fidelity CFD code, DPLR. These lines of sight were used as inputs for the line-by-line radiation code NEQAIR, and emission spectra of the air plasma were computed in the wavelength range from 300 nm to 1600 nm, a range which covers all of the different experiments onboard the DC-8. In addition, the computed flow field solutions were post-processed with the material thermal response code FIAT, and the resulting surface temperatures of the heat shield were used to generate thermal emission spectra based on Planck radiation. Both spectra were summed and integrated over the flow field. The resulting emission at each trajectory point was propagated to the DC-8 position and transformed into incident irradiance to be finally compared with experimental data.

shock-layer radiation↗

NASA NTRS2001

Traveling Magnetic Field Applications for Materials Processing in Space

Including the capability to induce a controlled fluid flow in the melt can significantly enrich research on solidification phenomena in a microgravity environment. The traveling magnetic field (TMF) is a promising technique to achieve this goal and is the aim of our ground-based project. In this presentation we will discuss new theoretical as well as experimental results recently obtained by our group. In particular, we experimentally demonstrated efficient mixing of metal alloys in long tubes subjected to TMF during processing. Application of this technique can be an elegant solution to ensure melt homogenization prior to solidification in a microgravity environment where natural convection is generally absent. Results of our theoretical work on TMF induced flows, such as convection control in Bridgman as well as in the Traveling Heater method, will be presented. Possible applications of TMF on board the ISS will also be discussed.

Motakef, S.↗

NASA NTRS2001

Traveling Magnetic Field Applications for Materials Processing in Space

Including the capability to induce a controlled fluid flow in the melt can significantly enrich research on solidification phenomena in a microgravity environment. The traveling magnetic field (TMF) is a promising technique to achieve this goal and is the aim of our ground-based project. In this presentation we will discuss new theoretical as well as experimental results recently obtained by our group. In particular, we experimentally demonstrated efficient mixing of metal alloys in long tubes subjected to TMF during processing. Application of this technique can provide an elegant solution to ensure melt homogenization prior to solidification in a microgravity environment where natural convection is generally absent. Results of our experimental work of applying the TMF technique to alloy melts will be presented. Possible applications of TMF on board the International Space Station will also be discussed.

Grugel, R. N.↗

NASA NTRS1991

Scaling analysis applied to the NORVEX code development and thermal energy flight experiment

A scaling analysis is used to study the dominant flow processes that occur in molten phase change material (PCM) under 1 g and microgravity conditions. Results of the scaling analysis are applied to the development of the NORVEX (NASA Oak Ridge Void Experiment) computer program and the preparation of the Thermal Energy Storage (TES) flight experiment. The NORVEX computer program which is being developed to predict melting and freezing with void formation in a 1 g or microgravity environment of the PCM is described. NORVEX predictions are compared with the scaling and similarity results. The approach to be used to validate NORVEX with TES flight data is also discussed. Similarity and scaling show that the inertial terms must be included as part of the momentum equation in either the 1 g or microgravity environment (a creeping flow assumption is invalid). A 10(exp -4) environment was found to be a suitable microgravity environment for the proposed PCM.

Skarda, J. Raymond Lee↗

NASA NTRS1991

Scaling analysis applied to the NORVEX code development and thermal energy flight experiment

Skarda, J. R. L.↗

NASA NTRS1992

Low thrust chemical rocket technology

An on-going technology program to improve the performance of low thrust chemical rockets for spacecraft on-board propulsion applications is reviewed. Improved performance and lifetime is sought by the development of new predictive tools to understand the combustion and flow physics, introduction of high temperature materials and improved component designs to optimize performance, and use of higher performance propellants. Improved predictive technology is sought through the comparison of both local and global predictions with experimental data. Predictions are based on both the RPLUS Navier-Stokes code with finite rate kinetics and the JANNAF methodology. Data were obtained with laser-based diagnostics along with global performance measurements. Results indicate that the modeling of the injector and the combustion process needs improvement in these codes and flow visualization with a technique such as 2-D laser induced fluorescence (LIF) would aid in resolving issues of flow symmetry and shear layer combustion processes. High temperature material fabrication processes are under development and small rockets are being designed, fabricated, and tested using these new materials. Rhenium coated with iridium for oxidation protection was produced by the Chemical Vapor Deposition (CVD) process and enabled an 800 K increase in rocket operating temperature. Performance gains with this material in rockets using Earth storable propellants (nitrogen tetroxide and monomethylhydrazine or hydrazine) were obtained through component redesign to eliminate fuel film cooling and its associated combustion inefficiency while managing head end thermal soakback. Material interdiffusion and oxidation characteristics indicated that the requisite lifetimes of tens of hours were available for thruster applications. Rockets were designed, fabricated, and tested with thrusts of 22, 62, 440 and 550 N. Performance improvements of 10 to 20 seconds specific impulse were demonstrated. Higher performance propellants were evaluated: Space storable propellants, including liquid oxygen (LOX) as the oxidizer with nitrogen hydrides or hydrocarbon as fuels. Specifically, a LOX/hydrazine engine was designed, fabricated, and shown to have a 95 pct theoretical c-star which translates into a projected vacuum specific impulse of 345 seconds at an area ratio of 204:1. Further performance improvment can be obtained by the use of LOX/hydrogen propellants, especially for manned spacecraft applications, and specific designs must be developed and advanced through flight qualification.

Schneider, Steven J.↗