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NASA NTRS1989

Better PFAE's From Direct Fluorination

New low-molecular-weight perfluoroalkylethers (PFAE's) synthesized by direct fluorination in experimental study. Correlated viscosity and oxidation characteristics of PFAE's with structures to evaluate suitability as high-temperature lubricants and hydraulic fluids. Direct fluorination process attractive because it often involves single-step reaction and uses cheap starting materials. Versatile: produces highly branched ethers as well as polyethers containing more than two sequential carbon atoms in polymer chains. Such molecules cannot be made by conventional techniques.

Jones, W. R., Jr.↗

NASA NTRS1996

Multigrid Methods for EHL Problems

In many bearings and contacts, forces are transmitted through thin continuous fluid films which separate two contacting elements. Objects in contact are normally subjected to friction and wear which can be reduced effectively by using lubricants. If the lubricant film is sufficiently thin to prevent the opposing solids from coming into contact and carries the entire load, then we have hydrodynamic lubrication, where the lubricant film is determined by the motion and geometry of the solids. However, for loaded contacts of low geometrical conformity, such as gears, rolling contact bearings and cams, this is not the case due to high pressures and this is referred to as Elasto-Hydrodynamic Lubrication (EHL) In EHL, elastic deformation of the contacting elements and the increase in fluid viscosity with pressure are very significant and cannot be ignored. Since the deformation results in changing the geometry of the lubricating film, which in turn determines the pressure distribution, an EHL mathematical model must simultaneously satisfy the complex elasticity (integral) and the Reynolds lubrication (differential) equations. The nonlinear and coupled nature of the two equations makes numerical calculations computationally intensive. This is especially true for highly loaded problems found in practice. One novel feature of these problems is that the solution may exhibit sharp pressure spikes in the outlet region. To this date both finite element and finite difference methods have been used to solve EHL problems with perhaps greater emphasis on the use of the finite difference approach. In both cases, a major computational difficulty is ensuring convergence of the nonlinear equations solver to a steady state solution. Two successful methods for achieving this are direct iteration and multigrid methods. Direct iteration methods (e.g Gauss Seidel) have long been used in conjunction with finite difference discretizations on regular meshes. Perhaps one of the best examples of the application of such methods is the recent Effective Influence Method of Dowson and Wang. Multigrid methods have also been used with great success by Venner and Venner and Lubrecht with a good summary being given by Venner. As both these finite difference discretization based approaches appear to provide an efficient way of solving EHL problems, it is important to understand their relative merits. This paper is a first attempt at providing such an understanding in the context of EHL point contact problem, (contact of two spheres), in which the contact zone is a point and an ellipse or circle for unloaded and loaded dry contacts respectively. Since the film thickness and the contact width are generally small compared to the local radius of curvature of the two surfaces, the reduced geometry of the surfaces in the contact area can be accurately approximated to the contact between a paraboloid and a flat surface. The layout of the remainder of this paper is as follows. In section 2 we introduce the form of the equations to be solved. The Effective Influence Newton Method is described in Section 3 while Section 4 describes the Multigrid method to be used. Sections 5 and 6 describe the test problems to be used in the comparison between the two methods and compare the performance of the two methods. Section 7 concludes the paper with an argument of the two methods and suggests some future research directions.

Nurgat, Elyas↗

NASA NTRS1977

Lubricant rheology applied to elastohydrodynamic lubrication

Viscosity measurements in a high pressure rheometer, elastohydrodynamic simulator studies (including the development of a temperature measuring technique), and analytical fluid modeling for elastohydrodynamic contacts are described. The more recent research which is described concerns infrared temperature measurements in elastohydrodynamic contacts and the exploration of the glassy state of lubricants. A correlation, of engineering significance, was made between transient surface temperature measurements and surface roughness profiles. Measurements of glass transitions of lubricants and the study of the effect of rate processes on materials lead to the conclusion that typical lubricants go into the glassy state as they pass through the contact region of typical elastohydrodynamic contacts.

Winer, W. O.↗

DOE OSTI2026

Insights into mixing of non-isothermal multi-polymer melts for complex plastics recycling

Catalytic recycling or upcycling of plastics is often limited not by catalyst performance, but by transport, arising from highly viscous, non-Newtonian polymer melts. In this work, we develop a reactor-scale framework that integrates rheological measurements, constitutive modeling, computational fluid dynamics (CFD), and experiments to quantify mixing, heat transfer, and dispersion in surrogate hydrocarbon melts representing mixed plastics systems. Temperature- and shear rate-dependent viscosity of low-density polyethylene (LDPE) and high-density polyethylene (HDPE) is measured to create two surrogate polymers (PLD and PHD) that capture the dominant shear-thinning flow behavior while neglecting strong elastic effects, enabling tractable simulation of non-isothermal, polymer-melt mixing using a Carreau-Arrhenius generalized Newtonian framework. Three-dimensional CFD simulations are employed to evaluate impeller performance in PLD using mixing time, cavern volume, thermal uniformity, and interfacial area for regimes in which viscoelastic effects are not dominant. We show that magnetic stir bars commonly used in lab-scale studies produce large thermal gradients (~60 °C) and poor mixing, even under idealized power delivery and polymer flow conditions. In contrast, close-clearance anchor impellers achieve near-isothermal operation, reduce mixing times by up to 5×, and provide >90% active circulation volume. We further demonstrate that, at low pseudo-Deborah number (De*), motor power requirements can be predicted directly from shear rate-dependent rheology using the Carreau-Arrhenius framework, enabling rational selection of operating conditions. Extension to surrogate immiscible multi-polymer systems based on PLD and PHD shows that interfacial area is highly sensitive to operating conditions and impeller design, with coaxial anchor-turbine configurations enhancing dispersion by up to 4 × .

Close-clearance impellers↗

NASA NTRS1982

An experimental study of heat induced surface-tension driven flow

Laser Doppler anemometry, radiation thermometry, and time-lapse photography have been used to study heat induced surface-tension driven flows in silicone oil and Fluorinert FC-43 in large open containers. For silicone oil, the effect of the surface tension gradient on the velocity field was not apparent enough to be detected. Because of its high viscosity, the oil was insensitive to outside disturbances, and the flow was steady. In the case of FC-43, the fluid was noticeably influenced by outside disturbances, and the flow was unsteady. The work reported here is part of an effort to develop experimental techniques and select test fluids for future space experiments on fluid motion in materials processing.

Kamotani, Y.↗

NASA NTRS1984

Lubrication of Machine Elements

The understanding of hydrodynamic lubrication began with the classical experiments of Tower and Petrov. Reynolds used a reduced form of the Navier-Stokes equations and the continuity equation to generate a second order differential equation for the pressure in the narrow, converging gap of a bearing contact. Such a pressure enables a load to be transmitted between the surfaces with very low friction since the surfaces are completely separated by a film of fluid. In such a situation it is the physical properties of the lubricant, notably the dynamic viscosity, that dictate the behavior of the contact. The understanding of boundary lubrication is normally attributed to Hardy and Doubleday. In boundary lubrication it is the physical and chemical properties of thin films of molecular proportions and the surfaces to which they are attached that determine contact behavior. The lubricant viscosity is not an influential parameter. Research is devoted to a better understanding and more precise definition of other lubrication regimes between these extremes. One such regime, elastohydrodynamic lubrication, occurs in nonconformal contacts, where the pressures are high and the bearing surfaces deform elastically. In this situation the viscosity of the lubricant may raise considerably, and this further assists the formation of an effective fluid film. The science of these three lubrication regimes (hydrodynamic, elastohydrodynamic, and boundary) are described and the manner in which this science is used in the design of machine elements is examined.

Hamrock, Bernard J.↗

DOE OSTI2024

Predicting thermophysical properties of molten salts in the MgCl 2 -NaCl-KCl-LiCl system with a shell-model potential

Ternary eutectic salts composed of MgCl 2 , NaCl, and KCl, referred to as MNK salts, have recently emerged as promising candidates as high-temperature heat transfer fluids and thermal energy storage media. Here we performed classical molecular dynamics (MD) simulations to predict the densities, specific heat capacities, viscosities, and ionic self-diffusivities for MNK salts over a wide temperature range. The impact of LiCl additive on their thermophysical properties was also investigated. To capture the electronic polarization of Cl anions by neighboring cations, we developed a novel shell-model potential using the force-matching method and a dataset of ab initio calculated interatomic forces. Our extensive MD simulations predict structure and properties for pure salts and binary/ternary salt mixtures in the MgCl 2 -NaCl-KCl-LiCl system in overall good agreement with available experimental and theoretical data, which corroborates the accuracy and reliability of our developed potential.

36 MATERIALS SCIENCE↗

NASA NTRS1952

The effect of high viscosity on the flow around a cylinder and around a sphere

For the determination of the flow velocity one is accustomed to measure the impact pressure, i.e., the pressure intensity in front of an obstacle. In incompressible fluids the impact pressure is yv(sup 2)/2g if the influence of viscosity can be neglected. Such an influence is appreciable, however, when the Reynolds number corresponding to impact tube radius is under about 100, and must consequently be considered, if the velocity determination is not to be faulty. The first investigation of this influence are included in the work of Miss M. Barker. In the following pages, experiments will be reported which determine the intensity of impact pressure on cylinders and spheres; furthermore a theory of the phenomenon will be developed which is in good agreement with the measurements.

FLOW - PLATES, FLAT - VISCOUS↗

NASA NTRS1990

ULTRA-SHARP nonoscillatory convection schemes for high-speed steady multidimensional flow

For convection-dominated flows, classical second-order methods are notoriously oscillatory and often unstable. For this reason, many computational fluid dynamicists have adopted various forms of (inherently stable) first-order upwinding over the past few decades. Although it is now well known that first-order convection schemes suffer from serious inaccuracies attributable to artificial viscosity or numerical diffusion under high convection conditions, these methods continue to enjoy widespread popularity for numerical heat transfer calculations, apparently due to a perceived lack of viable high accuracy alternatives. But alternatives are available. For example, nonoscillatory methods used in gasdynamics, including currently popular TVD schemes, can be easily adapted to multidimensional incompressible flow and convective transport. This, in itself, would be a major advance for numerical convective heat transfer, for example. But, as is shown, second-order TVD schemes form only a small, overly restrictive, subclass of a much more universal, and extremely simple, nonoscillatory flux-limiting strategy which can be applied to convection schemes of arbitrarily high order accuracy, while requiring only a simple tridiagonal ADI line-solver, as used in the majority of general purpose iterative codes for incompressible flow and numerical heat transfer. The new universal limiter and associated solution procedures form the so-called ULTRA-SHARP alternative for high resolution nonoscillatory multidimensional steady state high speed convective modelling.

Leonard, B. P.↗

NASA NTRS1979

A global geochemical model for the evolution of the mantle

It is proposed that the upper mantle transition region, 220 to 670 km, is composed of eclogite which has been derived from primitive mantle by about 20 percent partial melting and that this is the source and sink of oceanic crust. The remainder of the upper mantle is garnet peridotite which is the source of continental basalts and hotspot magmas. This region is enriched in incompatible elements by hydrous and CO2 rich metasomatic fluids which have depleted the underlying layers in the L.I.L. elements and L.R.E.E. The volatiles make this a low-velocity, high attenuation, low viscosity region. The eclogite layer is internally heated and its controls the convection pattern in the upper mantle. Plate tectonics is intermittent. The continental thermal anomaly at a depth of 150-220 km triggers kimberlite and carbonatite activity, alkali and flood basalt volcanism, vertical tectonics and continental breakup. Hot spots remain active after the continents leave and build the oceanic islands. Mantle plumes rise from a depth of about 220 km. Midocean ridge basalts rise from the depleted layer below this depth. Material from this layer can also be displaced upwards by subducted oceanic lithosphere to form back-arc basins.

Anderson, D. L.↗

NASA NTRS1988

Improving the accuracy of central difference schemes

General difference approximations to the fluid dynamic equations require an artificial viscosity in order to converge to a steady state. This artificial viscosity serves two purposes. One is to suppress high frequency noise which is not damped by the central differences. The second purpose is to introduce an entropy-like condition so that shocks can be captured. These viscosities need a coefficient to measure the amount of viscosity to be added. In the standard scheme, a scalar coefficient is used based on the spectral radius of the Jacobian of the convective flux. However, this can add too much viscosity to the slower waves. Hence, it is suggested that a matrix viscosity be used. This gives an appropriate viscosity for each wave component. With this matrix valued coefficient, the central difference scheme becomes closer to upwind biased methods.

Turkel, Eli↗

NASA NTRS2004

Torque Transient of Magnetically Drive Flow for Viscosity Measurement

Viscosity is a good indicator of structural changes for complex liquids, such as semiconductor melts with chain or ring structures. This paper discusses the theoretical and experimental results of the transient torque technique for non-intrusive viscosity measurement. Such a technique is essential for the high temperature viscosity measurement of high pressure and toxic semiconductor melts. In this paper, our previous work on oscillating cup technique was expanded to the transient process of a magnetically driven melt flow in a damped oscillation system. Based on the analytical solution for the fluid flow and cup oscillation, a semi-empirical model was established to extract the fluid viscosity. The analytical and experimental results indicated that such a technique has the advantage of short measurement time and straight forward data analysis procedures

Ban, Heng↗

DOE OSTI2026

Fragile-to-strong transition in liquid As 2 S 3 under pressure: The effect of melt metallization

The well-known classification of glass-forming melts into fragile and strong liquids has several notable exceptions, including water, silica, and certain phase-change materials (PCMs). These exceptional fluid systems exhibit a fragile-to-strong transition (FST) upon cooling: a transformation from a high-temperature liquid with fast atomic dynamics, low viscosity, and low flow activation energy, to a viscous supercooled melt with high energy barriers near the glass transition temperature T g . This behavior is critically important for non-volatile memories, photonic tensor cores, reconfigurable metamaterials, and other devices, that use PCMs, enabling nanosecond-scale crystallization in the fragile regime and long data retention in the strong regime near or below T g . A significant structural transformation is expected between these two viscosity regimes, along with a semiconductor-metal (SC-M) transition upon heating, driven by high internal pressure and associated density increase. By applying high external pressure to the canonical low-conducting chalcogenide melt As 2 S 3 , we observed both the FST and the SC-M transition, occurring simultaneously within the same domain of the P, T−phase space. These findings suggest that the FST is not limited to a few exceptional liquids but is a common phenomenon, at least in systems that exhibit melt metallization within specific regions of their P, T−phase diagrams.

first-principles molecular dynamics↗

DOE OSTI2026

Surfactant Effects on Carbon Black Slurries for Aqueous Flow-Electrode Applications

Aqueous carbon black (CB) slurries are promising for flow-electrode applications due to their low cost and high electrical conductivity. Here, in this study, we investigate the impact of introducing a nonionic surfactant (Tween 20) on the rheological and electrical properties of 5 wt % Vulcan XC72R CB slurries in a 50 mM NaCl aqueous solution. We observe a Tween 20 critical concentration around 1.2 wt % that triggers an abrupt transition from a conductive gel to a high-resistance Newtonian fluid. This sudden network collapse coincides with a 250-fold reduction in settled mass, a 1–2 order of magnitude drop in viscosity, and a nearly 100-fold decrease in slurry conductivity. Centrifuged pellet conductivity measurements support the conclusion that this performance loss is largely due to the destruction of the gel network, rather than increased particle-to-particle resistance. SEM imaging suggests that the network is built from large 10 to 50 μm agglomerates that are fully dissolved above the critical surfactant concentration. We found that subcritical surfactant addition improved slurry shelf stability over 90 days, but that electrochemical cell testing revealed progressive performance degradation during operation. These results highlight the need for strategies that maximize long-term electrical conductivity without compromising viscosity, sedimentation stability, or resistance to accumulation on internal surfaces.

Materials science↗

NASA NTRSDate not supplied

Advanced Single Phase Thermal Radiator for Moon-to-Mars Exploration

Pumped loop radiators are commonly used to reject large amounts of heat associated with crewed systems. The State-of-the-Art (SOA) for crewed systems is represented by the International Space Station (ISS) External Heat Rejection System (HRS) Thermal Radiators. The ISS HRS utilizes a manifold design with many parallel flow paths coupled to thin face-sheets and low viscosity ammonia as the working fluid, which may not be preferred due to toxicity concerns. Although contemporary coolant choices provide lower freezing points, the current SOA design may not be well positioned to provide both sufficient heat transfer and manageable pressure drop due to very different fluid thermo-physical properties, including higher viscosities. The planned development of an advanced single phase, pumped loop thermal radiator utilizing a serpentine flow path with high thermally conductive face-sheets is presented herein.

In-Space Active Thermal Control↗

NASA NTRS1958

The Interaction of a Reflected Shock Wave with the Boundary Layer in a Shock Tube

Ideally, the reflection of a shock from the closed end of a shock tube provides, for laboratory study, a quantity of stationary gas at extremely high temperature. Because of the action of viscosity, however, the flow in the real case is not one-dimensional, and a boundary layer grows in the fluid following the initial shock wave. In this paper simplifying assumptions are made to allow an analysis of the interaction of the shock reflected from the closed end with the boundary layer of the initial shock afterflow. The analysis predicts that interactions of several different types will exist in different ranges of initial shock Mach number. It is shown that the cooling effect of the wall on the afterflow boundary layer accounts for the change in interaction type. An experiment is carried out which verifies the existence of the several interaction regions and shows that they are satisfactorily predicted by the theory. Along with these results, sufficient information is obtained from the experiments to make possible a model for the interaction in the most complicated case. This model is further verified by measurements made during the experiment. The case of interaction with a turbulent boundary layer is also considered. Identifying the type of interaction with the state of turbulence of the interacting boundary layer allows for an estimate of the state of turbulence of the boundary layer based on an experimental investigation of the type of interaction. A method is proposed whereby the effect of the boundary-layer interaction on the strength of the reflected shock may be calculated. The calculation indicates that the reflected shock is rapidly attenuated for a short distance after reflection, and this result compares favorably with available experimental results.

Mark, Herman↗

DOE OSTI2026

Heat Transfer Fluids as Co‐Diluents in Localized High‐Concentration Electrolytes for High‐Rate Lithium Metal Batteries With Enhanced Safety

Localized high-concentration electrolytes (LHCEs) have been identified as promising electrolyte formulations for lithium metal batteries, due to their effective interphase formation and promotion of compact Li deposition, yet their practical implementation is often limited by reduced ion transport kinetics. In this study, two industrially established fluorinated ethers are identified for the first time in battery research as effective co-diluents as they combine a broad electrochemical stability window with a low viscosity and intrinsic non-flammability. Incorporating these components, commonly used as heat transfer fluids, yields safer, less flammable electrolyte formulations with enhanced ion mobilities. In particular, the ternary co-diluent formulation shows improved ion mobility by reducing the electrolyte's viscosity while limiting excessive ion clustering. Based on the improved electrolyte transport kinetics, lower overvoltages and higher Coulombic efficiencies at current densities ≥ 1 mA cm −2 are achieved with the ternary co-diluent blend, resulting in markedly extended cycle life in an application-oriented zero-excess pouch cell compared with the baseline system. Complementary electrochemical and ex situ analysis of harvested electrodes at moderate current densities reveals no discernible differences in interphase morphology and composition, suggesting enhanced ion mobility as the primary cause of the improved high-rate performance.

electrolyte diluent↗

NASA NTRS2003

High-Pressure Transport Properties Of Fluids: Theory And Data From Levitated Drops At Combustion-Relevant Temperatures

Although the high pressure multicomponent fluid conservation equations have already been derived and approximately validated for binary mixtures by this PI, the validation of the multicomponent theory is hampered by the lack of existing mixing rules for property calculations. Classical gas dynamics theory can provide property mixing-rules at low pressures exclusively. While thermal conductivity and viscosity high-pressure mixing rules have been documented in the literature, there is no such equivalent for the diffusion coefficients and the thermal diffusion factors. The primary goal of this investigation is to extend the low pressure mixing rule theory to high pressures and validate the new theory with experimental data from levitated single drops. The two properties that will be addressed are the diffusion coefficients and the thermal diffusion factors. To validate/determine the property calculations, ground-based experiments from levitated drops are being conducted.

Bellan, Josette↗