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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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DOE OSTI2020

Progress and Technology Assessment of Melt-Cast Ceramic Waste Forms

The Savannah River National Laboratory (SRNL) conducted research from FY2011 – FY2020 to develop ceramic waste forms to treat High-Level Waste (HLW) resulting from reprocessing of commercial Used Nuclear Fuel (UNF) as part of the Department of Energy (DOE) office of Nuclear Energy (NE) Fuel Cycle Technologies (FCT) research program. The objective of the research was to develop a reference ceramic waste form and process technology needed to immobilize the combined HLW raffinate stream, including undissolved solids and soluble technetium, and potentially the TRU waste stream resulting from reprocessing processes. This report compiles the relevant literature produced under, and pertinent to, the program objectives and provides a perspective on the technology development as well as prospects for future.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2001

A Winning Cast

Howmet Research Corporation was the first to commercialize an innovative cast metal technology developed at Auburn University, Auburn, Alabama. With funding assistance from NASA's Marshall Space Flight Center, Auburn University's Solidification Design Center (a NASA Commercial Space Center), developed accurate nickel-based superalloy data for casting molten metals. Through a contract agreement, Howmet used the data to develop computer model predictions of molten metals and molding materials in cast metal manufacturing. Howmet Metal Mold (HMM), part of Howmet Corporation Specialty Products, of Whitehall, Michigan, utilizes metal molds to manufacture net shape castings in various alloys and amorphous metal (metallic glass). By implementing the thermophysical property data from by Auburn researchers, Howmet employs its newly developed computer model predictions to offer customers high-quality, low-cost, products with significantly improved mechanical properties. Components fabricated with this new process replace components originally made from forgings or billet. Compared with products manufactured through traditional casting methods, Howmet's computer-modeled castings come out on top.

Source record↗

DOE OSTI2019

Geometric Form of Gating System Elements and Its Influence on the Initial Filling Phase

Flow of cast steel through twenty-four variants of gating system was examined with the use of numerical modeling conducted in MAGMA. The main goal of the research was to determine the impact of the gating system elements’ geometric form on the kinetics in the initial filling phase, which is crucial in terms of castings quality. The evaluation was based on flow kinetics, maximal height, and the velocity of metal entering the mold. The variables included the geometric form of the sprue and the cross runner, as well as geometric form, length, and expansion of the ingate. Results allow to form valuable conclusions that can lead to improvement in the castings manufacturing technology. Results show that application of proper expansion of the ingate and suitable geometric form of the gating system can significantly reduce the velocity of metal entering the mold cavity, as well as eradicate the jetting, which positively impacts the soundness of the casting.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Microstructure and Electrical Transport Properties of Bi{sub 3}TiNbO{sub 9} High-Temperature Piezoceramics

High-density ceramic samples of the Bi{sub 3}TiNbO{sub 9} ferroelectric phase with a layered perovskite-like structure have been produced by tape casting slurry technology and hot pressing processes. The samples have been characterized by X-ray diffraction and dielectric, piezoelectric, and pyroelectric measurements. The results demonstrate that the samples have a well-defined texture due to the preferential orientation of the basal planes of their platelike grains across the pressing axis or along the film casting direction. The Curie temperature of the samples has been determined to be T{sub C} = 1180 K. The samples have anisotropic electrical transport characteristics. Their piezoelectric constants d{sub 33} in directions perpendicular and parallel to the texture plane is 22 and 5 pC/N, respectively. The conclusion has been drawn that the synthesized materials are potentially attractive for producing high-temperature piezoelectric elements.

36 MATERIALS SCIENCE↗

DOE OSTI2021

From casting to 3D printing geopolymers: A proof of concept

The objective of this paper is to define a mix design strategy allowing the implementation of geopolymer in powder bed 3D printing. In a selective binder approach, an aluminosilicate powder bed is activated through the deposit of an alkaline silicate solution. We first show that, in comparison to casting, this technology requires mastering the spreading of the liquid into the powder bed to ensure that the reaction takes place where it is needed. A series of experiments at the drop level, mimicking the 3D printing process, were performed to determine the printing solution composition for a given powder bed packing. We then highlight the relationship between the compressive strength of the printed geopolymer and the powder bed saturation, controlled by the printing parameters. Finally, SEM/EDX analysis confirm the formation of geopolymer with desired Si/Al and Na/Al ratios in the resulting printed material.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Lightweight ceramic components for propulsion applications

It is demonstrated that two ceramic engine components of reduced weight can be efficiently produced and employed at higher combustion gas temperatures. The engine components, containing internal cooling and hydraulic passages, are fabricated in a process involving platelet technology, tape casting, and multilayer ceramic packaging techniques. Traditional metal platelet design techniques are used to fabricate components from ceramic tape which are then laminated and processed to densities of close to 100 percent. A methane cooled regenerator for an air turbo ramjet engine and a rocket engine bipropellant injector are fabricated from silicon nitride. The two components are tested under conditions similar to the pressurization, thrusts, and temperatures encountered in a combustion gas environment. The survivability and leak-free nature of the components demonstrate that more complex ceramic engine components can be fabricated using these techniques.

Franklin, J. E.↗

NASA NTRS1984

High Reynolds number tests of the cast 10-2/DOA 2 airfoil in the Langley 0.3-meter transonic cryogenic tunnel, phase 2

Wind tunnel tests of an advanced technology airfoil, the CAST 10-2/DOA 2, were conducted in the Langley 0.3-Meter Transonic Cryogenic Tunnel (0.3-m TCT). This was the third of a series of tests conducted in a cooperative airfoil research program between the National Aeronautics and Space Administration and the Deutsche Forschungsund Versuchsanstalt fur Luft- und Raumfahrt e. V. For these tests, temperature was varied from 270 K to 110 K at pressures from 1.5 to 5.75 atmospheres. Mach number was varied from 0.60 to 0.80, and the Reynolds number (based on airfoil chord) was varied from 2 to 20 million. The aerodynamic data for the 7.62 cm chord airfoil model used in these tests is presented without analysis. Descriptions of the 0.3-m TCT, the airfoil model, the test instrumentation, and the testing procedures are included.

Dress, D. A.↗

NASA NTRS1983

High Reynolds number tests of the CAST 10-2/DOA 2 airfoil in the Langley 0.3-meter transonic cryogenic tunnel, phase 1

A wind tunnel investigation of an advanced technology airfoil, the CAST 10-2/DOA 2, was conducted in the Langley 0.3 meter Transonic Cryogenic Tunnel (0.3 m TCT). This was the first of a series of tests conducted in a cooperative National Aeronautics and Space Administration (NASA) and the Deutsche Forschungs- und Versuchsanstalt fur Luft- und Raumfahrt e. V. (DFVLR) airfoil research program. Test temperature was varied from 280 K to 100 K to pressures from slightly above 1 to 5.8 atmospheres. Mach number was varied from 0.60 to 0.80, and the Reynolds number (based on airfoil chord) was varied from 4 x 10 to the 8th power to 45 x 10 to the 6th power. This report presents the experimental aerodynamic data obtained for the airfoil and includes descriptions of the airfoil model, the 0.3 m TCT, the test instrumentation, and the testing procedures.

Dress, D. A.↗

NASA NTRS1981

Energy efficient engine high-pressure turbine single crystal vane and blade fabrication technology report

The objective of the High-Pressure Turbine Fabrication Program was to demonstrate the application and feasibility of Pratt & Whitney Aircraft-developed two-piece, single crystal casting and bonding technology on the turbine blade and vane configurations required for the high-pressure turbine in the Energy Efficient Engine. During the first phase of the program, casting feasibility was demonstrated. Several blade and vane halves were made for the bonding trials, plus solid blades and vanes were successfully cast for materials evaluation tests. Specimens exhibited the required microstructure and chemical composition. Bonding feasibility was demonstrated in the second phase of the effort. Bonding yields of 75 percent for the vane and 30 percent for the blade were achieved, and methods for improving these yield percentages were identified. A bond process was established for PWA 1480 single crystal material which incorporated a transient liquid phase interlayer. Bond properties were substantiated and sensitivities determined. Tooling die materials were identified, and an advanced differential thermal expansion tooling concept was incorporated into the bond process.

Giamei, A. F.↗

NASA NTRS1996

Producing Foils From Direct Cast Titanium Alloy Strip

This research was undertaken to demonstrate the feasibility of producing high-quality, thin-gage, titanium foil from direct cast titanium strip. Melt Overflow Rapid Solidification Technology (MORST) was used to cast several different titanium alloys into 500 microns thick strip, 10 cm wide and up to 3 m long. The strip was then either ground, hot pack rolled or cold rolled, as appropriate, into foil. Gamma titanium aluminide (TiAl) was cast and ground to approximately 100 microns thick foil and alpha-2 titanium aluminide (Ti3AI) was cast and hot pack rolled to approximately 70 microns thick foil. CP Ti, Ti6Al2Sn4Zr2Mo, and Ti22AI23Nb (Orthorhombic), were successfully cast and cold-rolled into good quality foil (less than 125 microns thick). The foils were generally fully dense with smooth surfaces, had fine, uniform microstructures, and demonstrated mechanical properties equivalent to conventionally produced titanium. By eliminating many manufacturing steps, this technology has the potential to produce thin gage, titanium foil with good engineering properties at significantly reduced cost relative to conventional ingot metallurgy processing.

Stuart, T. A.↗

NASA NTRS2017

Synthetic Vision System Commercial Aircraft Flight Deck Display Technologies for Unusual Attitude Recovery

A Commercial Aviation Safety Team (CAST) study of 18 worldwide loss-of-control accidents and incidents determined that the lack of external visual references was associated with a flight crew's loss of attitude awareness or energy state awareness in 17 of these events. Therefore, CAST recommended development and implementation of virtual day-Visual Meteorological Condition (VMC) display systems, such as synthetic vision systems, which can promote flight crew attitude awareness similar to a day-VMC environment. This paper describes the results of a high-fidelity, large transport aircraft simulation experiment that evaluated virtual day-VMC displays and a "background attitude indicator" concept as an aid to pilots in recovery from unusual attitudes. Twelve commercial airline pilots performed multiple unusual attitude recoveries and both quantitative and qualitative dependent measures were collected. Experimental results and future research directions under this CAST initiative and the NASA "Technologies for Airplane State Awareness" research project are described.

Prinzel, Lawrence J., III↗

DOE OSTI2019

Manufacture of Wear-Resistant Cast-Iron Grinding Balls without Shrinkage Defects

A manufacturing technology has been developed for wear-resistant cast-iron grinding balls without shrinkage defects. In this method, the balls are cast in single-use sand–clay molds. A new approach to designing the casting system is developed. By numerical modeling, the time dependence of solidification is derived. As a trial, grinding balls are produced by the proposed technology.

42 ENGINEERING↗

NASA NTRS1984

Polycrystalline Silicon Sheets for Solar Cells by the Improved Spinning Method

Cost reduction of silicon materials in the photovoltaic program of materials was examined. The current process of producing silicon sheets is based entirely on the conventional Czochralski ingot growth and wafering used in the semiconductor industry. The current technology cannot meet the cost reduction demands for producing low cost silicon sheets. Alternative sheet production processes such as unconventional crystallization are needed. The production of polycrystalline silicon sheets by unconventional ingot technology is the casting technique. Though large grain sheets were obtained by this technique, silicon ribbon growth overcomes deficiencies of the casting process by obtaining the sheet directly from the melt. The need to solve difficulties of growth stability and impurity effects are examined. The direct formation process of polycrystalline silicon sheets with large grain size, smooth surface, and sharp edges from the melt with a high growth rate which will yield low cost silicon sheets for solar cells and the photovoltaic characteristics associated with this type of sheet to include an EBIC study of the grain boundaries are described.

Maeda, Y.↗

NASA NTRS1991

Ceramic regenerator program

The feasibility of fabricating an Air Turbo Ramjet (ATR) regenerator containing intricate hydraulic passages from a ceramic material in order to allow operation with high temperature combustion gas and to reduce weight as compared with metallic materials was demonstrated. Platelet technology, ceramic tape casting, and multilayer ceramic packaging techniques were used in this fabrication of subscale silicon nitride components. Proof-of-concept demonstrations were performed to simulate a methane cooled regenerator for an ATR engine. The regenerator vane was designed to operate at realistic service conditions, i.e., 600 psi in a 3500 R (3040 F), 500 fps combustion gas environment. A total of six regenerators were fabricated and tested. The regenerators were shown to be able to withstand internal pressurization to 1575 psi. They were subjected to testing in 500 fps, 3560 R (3100 F) air/propane combustion products and were operated satisfactorily for an excess of 100 hr and 40 thermal cycles which exceeded 2460 R (2000 F).

Franklin, Jerrold E.↗

NASA NTRS2008

Assessing MODIS-based Products and Techniques for Detecting Gypsy Moth Defoliation

The project showed potential of MODIS and VIIRS time series data for contributing defoliation detection products to the USFS forest threat early warning system. This study yielded the first satellite-based wall-to-wall 2001 gypsy moth defoliation map for the study area. Initial results led to follow-on work to map 2007 gypsy moth defoliation over the eastern United States (in progress). MODIS-based defoliation maps offer promise for aiding aerial sketch maps either in planning surveys and/or adjusting acreage estimates of annual defoliation. More work still needs to be done to assess potential of technology for "now casts"of defoliation.

Spruce, Joseph P.↗

NASA NTRS2017

Utilization of the International Space Station for Crew Autonomous Scheduling Test (CAST)

The United States space policy is evolving toward missions beyond low Earth orbit. In an effort to meet that policy, NASA has recognized Autonomous Mission Operations (AMO) as a valuable capability. Identified within AMO capabilities is the potential for autonomous planning and replanning during human spaceflight operations. That is allowing crew members to collectively or individually participate in the development of their own schedules. Currently, dedicated mission operations planners collaborate with international partners to create daily plans for astronauts aboard the International Space Station (ISS), taking into account mission requirements, ground rules, and various vehicle and payload constraints. In future deep space operations the crew will require more independence from ground support due to communication transmission delays. Furthermore, crew members who are provided with the capability to schedule their own activities are able to leverage direct experience operating in the space environment, and possibly maximize their efficiency. CAST (Crew Autonomous Scheduling Test) is an ISS investigation designed to analyze three important hypotheses about crew autonomous scheduling. First, given appropriate inputs, the crew is able to create and execute a plan in a reasonable period of time without impacts to mission success. Second, the proximity of the planner, in this case the crew, to the planned operations increases their operational efficiency. Third, crew members are more satisfied when given a role in plan development. This paper presents the results from a single astronaut test subject who participated in five CAST sessions. The details on the operational philosophy of CAST are discussed, including the approach to crew training, selection criteria for test days, and data collection methods. CAST is a technology demonstration payload sponsored by the ISS Research Science and Technology Office, and performed by experts in Mission Operations Planning from the Flight Operations Directorate at NASA Johnson Space Center, and researchers across multiple NASA centers. It is hoped the results of this investigation will guide NASA's implementation of autonomous mission operations for long duration human space missions to Mars and beyond.

Healy, Matthew↗

NASA NTRS2017

Progress of Crew Autonomous Scheduling Test (CAST) On the ISS

The United States space policy is evolving toward missions beyond low Earth orbit. In an effort to meet that policy, NASA has recognized Autonomous Mission Operations (AMO) as a valuable capability. Identified within AMO capabilities is the potential for autonomous planning and replanning during human spaceflight operations. That is allowing crew members to collectively or individually participate in the development of their own schedules. Currently, dedicated mission operations planners collaborate with international partners to create daily plans for astronauts aboard the International Space Station (ISS), taking into account mission requirements, ground rules, and various vehicle and payload constraints. In future deep space operations the crew will require more independence from ground support due to communication transmission delays. Furthermore, crew members who are provided with the capability to schedule their own activities are able to leverage direct experience operating in the space environment, and possibly maximize their efficiency. CAST (Crew Autonomous Scheduling Test) is an ISS investigation designed to analyze three important hypotheses about crew autonomous scheduling. First, given appropriate inputs, the crew is able to create and execute a plan in a reasonable period of time without impacts to mission success. Second, the proximity of the planner, in this case the crew, to the planned operations increases their operational efficiency. Third, crew members are more satisfied when given a role in plan development. This presentation shows the progress done in this study with a single astronaut test subject participating in five CAST sessions. CAST is a technology demonstration payload sponsored by the ISS Research Science and Technology Office, and performed by experts in Mission Operations Planning from the Flight Operations Directorate at NASA Johnson Space Center, and researchers across multiple NASA centers.

Healy, Matthew↗

NASA NTRS2017

CAST Safety Enhancement Research on Airplane State Awareness and Prediction Technologies

Loss of control in flight (LOC-I) is the leading cause of fatal aircraft accidents. A study of LOC accidents and incidents, commissioned by the Commercial Aviation Safety Team (CAST) identified a growing trend in loss of Airplane State Awareness (ASA) by the flight crew. This has led to recommended safety enhancements that include flight deck technologies for improving current and predicted energy state awareness. In this talk, we discuss recent CAST motivated efforts to develop new information systems for predicting and assessing the future aircraft energy state and auto-flight configuration. The outputs from these systems can serve multiple purposes, including improved pilot alerting for anticipating and recovering from problematic flight conditions, as well as higher level flight safety assurance for autonomous operations.

Schuet, Stefan↗