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DOE OSTI2020

Tribochemical Conversion of Methane to Graphene and Other Carbon Nanostructures: Implications for Friction and Wear

Tribochemistry involves chemical reactions occurring at sliding contact interfaces in the presence of gaseous and/or liquid media. It often leads to the formation of a solid reaction film (also termed boundary film) which controls friction and wear and hence the efficiency and reliability of moving mechanical systems (such as engines). Here we demonstrate tribochemical conversion of methane to graphene, nano-onion, and disordered carbons on the sliding surfaces of Ni-, Cu-, and CuNi-containing VN coatings at atmospheric pressure and room temperature, providing 2-3 orders of magnitude reduction in wear and similar to 50% reduction in friction compared to those of the uncoated steels. Transmission electron microscopy confirms that graphene forms preferably on metal rich nanoclusters of the composite coatings, while the carbon nano-onions are scattered throughout the carbon tribofilm. Ab initio molecular dynamics simulations elucidate underlying mechanisms involved in the tribochemical conversion of methane to carbon- based nanostructures in support of microscopic observations. These scientific findings may lead to new materials technologies that can use methane as a source for continuous and in situ lubrication. For example, there is an urgent need to curtail the uses of lubricating oils in natural gas compressors and engines as they contaminate the natural gas being compressed or burnt.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Residual strain-stress in manganese steel railway crossing determined by synchrotron and laboratory X-rays

The residual stress within the nose of a worn manganese steel railway crossing was investigated. The macroscopic residual stress at the running surface was determined in areas with and without visual faults by laboratory X-rays. To get information about the penetration depth of the residual stress, synchrotron X-ray diffraction was used to map the distribution of local (within grain) residual strains below the running surface. The laboratory X-ray measurements revealed significant compressive stress on the rail running surface. The synchrotron measurements documented that local strains exist through the entire depth investigated. Relations between residual stress, plastic deformation, and crack formation are analysed, leading to a discussion on potentials/limitations of the two experimental methods for investigations of residual stress in large engineering components.

differentia aperture synchrotron diffraction↗

DOE OSTI2022

Accidental Disassembly of a Multi Branch Outlet Strip with Surge Protector (Investigation Report)

On December 16 a worker attempted to disconnect a computer plug from a multi outlet surge protector strip. The plastic housing of the surge protector disintegrated while the plug was pulled exposing the bare conductors of the internal wiring. The worker disconnected the wall plug on the multi outlet strip and de-energized the outlet strip. The worker contacted the FOD and the FOD called the ISR DESO for advice. The DESO collected the pieces and performed an autopsy on the device.

42 ENGINEERING↗

NASA NTRS1983

American Society for Engineering Education/NASA Summer Faculty Fellowship Program 1982

A program of summer faculty fellowships for engineering and science educators is described. The program involves participation in cooperative research and study. Results of the program evaluation are summarized. The research fellows indicated satisfaction with the program. Benefits of the program cited include: (1) enhancement of professional abilities; (2) contact with professionals in a chosen area of research; (3) familiarity with research facilities; and (4) development of new research techniques and their adaptation to an academic setting. Abstracts of each of the research projects undertaken are presented.

Spencer, J. H.↗

NASA NTRS1994

Current research activities at the NASA-sponsored Illinois Computing Laboratory of Aerospace Systems and Software

The Illinois Computing Laboratory of Aerospace Systems and Software (ICLASS) was established to: (1) pursue research in the areas of aerospace computing systems, software and applications of critical importance to NASA, and (2) to develop and maintain close contacts between researchers at ICLASS and at various NASA centers to stimulate interaction and cooperation, and facilitate technology transfer. Current ICLASS activities are in the areas of parallel architectures and algorithms, reliable and fault tolerant computing, real time systems, distributed systems, software engineering and artificial intelligence.

Smith, Kathryn A.↗

NASA NTRS2013

Robotic Sample Manipulator for Handling Astromaterials Inside the Geolab Microgravity Glovebox

Future human and robotic sample return missions will require isolation containment systems with strict protocols and procedures for reducing inorganic and organic contamination. Robotic handling and manipulation of astromaterials may be required for preliminary examination inside such an isolation containment system. In addition, examination of astromaterials in microgravity will require constant contact to secure samples during manipulation. The National Space Grant Foundation exploration habitat (XHab) academic innovative challenge 2012 administered through the NASA advanced exploration systems (AES) deep space habitat (DSH) project awarded funding to the University of Bridgeport team to develop an engineering design for tools to facilitate holding and handling geological samples for analysis in a microgravity glovebox environment. The Bridgeport XHab team developed a robotic arm system with a three-finger gripper that could manipulate geologic samples within the existing GeoLab glovebox integrated into NASA's DSH called the GeoLab Robotic Sample Manipulator (see fig. 1 and 2). This hardware was deployed and tested during the 2012 DSH mission operations tests [1].

Bell, Mary S.↗

NASA NTRS2008

Stable Electrical Operation of 6H-SiC JFETs and ICs for Thousands of Hours at 500 C

The fabrication and testing of the first semiconductor transistors and small-scale integrated circuits (ICs) to achieve up to 3000 h of stable electrical operation at 500 C in air ambient is reported. These devices are based on an epitaxial 6H-SiC junction field-effect transistor process that successfully integrated high temperature ohmic contacts, dielectric passivation, and ceramic packaging. Important device and circuit parameters exhibited less than 10% of change over the course of the 500 C operational testing. These results establish a new technology foundation for realizing durable 500 C ICs for combustion-engine sensing and control, deep-well drilling, and other harsh-environment applications.

Neudeck, Philip G.↗

NASA NTRS2017

Mars Ascent Vehicle (MAV) Concept - Launch System Development

A Mars Ascent Vehicle (MAV) would be one component of potential Mars Sample Return (MSR) and would have to launch from the surface of Mars into orbit about Mars with a soil sample. A MAV is a small lightweight rocket that must survive various environmental conditions, including powered ascent through the Martian atmosphere. A concept for the MAV system design includes a launch tube mounted on top of a mobile rover or a stationary lander. The launch tube must thermally insulate the MAV on the surface of Mars, and then guide the MAV during the initial portion of the launch. A mechanical erector system is also necessary for moving the MAV and launch tube from a stowed configuration to a launch configuration. The launch system would have to perform these tasks while also meeting many design constraints. This paper is a systems engineering perspective that will examine the current development of the launch system including design concepts, design trades, driving issues, and analyses performed. Design trades include different launch configurations that would prevent rover or lander tip-over, as well as re-contact between the MAV and the launch tube. Additional trades include options for guiding the MAV out of the launch tube, whether using launch rails or sabots, and finding a reliable but simple mechanical erector system. Analyses include investigating the impact of ignition overpressure based on launch configuration, launch loads and sensitivities to the launch system design, and Entry, Descent and Landing loads. The key considerations for these design trades are overall system mass, size, and reliability.

Sonneveldt, Bryan↗

NASA NTRS2014

Inspiring the Next Generation: The International Space Station Education Accomplishments

The International Space Station (ISS) has a unique ability to capture the imagination of both students and teachers worldwide. Since 2000, the presence of humans onboard ISS has provided a foundation for numerous educational activities aimed at capturing that interest and motivating study in the sciences, technology, engineering and mathematics (STEM). Over 43 million students around the world have participated in ISS-related educational activities. Projects such as YouTube Space Lab, Sally Ride Earth Knowledge-based Acquired by Middle Schools (EarthKAM), SPHERES (Synchronized Position Hold Engage and Reorient Experimental Satellites) Zero-Robotics, Tomatosphere, and MAI-75 events among others have allowed for global student, teacher and public access to space through student classroom investigations and real-time audio and video contacts with crewmembers. Educational activities are not limited to STEM but encompass all aspects of the human condition. This is well illustrated in the Uchu Renshi project, a chain poem initiated by an astronaut while in space and continued and completed by people on Earth. With ISS operations now extended to 2024, projects like these and their accompanying educational materials are available to more students around the world. From very early on in the program's history, students have been provided with a unique opportunity to get involved and participate in science and engineering projects. Many of these projects support inquiry-based learning that allows students to ask questions, develop hypothesis-derived experiments, obtain supporting evidence and identify solutions or explanations. This approach to learning is well-published as one of the most effective ways to inspire students to pursue careers in scientific and technology fields. Ever since the first space station element was launched, a wide range of student experiments and educational activities have been performed, both individually and collaboratively, by all the international partner agencies, National Aeronautics and Space Administration (NASA), Canadian Space Agency (CSA), European Space Agency, (ESA), Japan Aerospace Exploration Agency (JAXA) and Russian Federal Space Agency (Roscosmos), and a number of non-participating countries, some under commercial agreements. Many of these programs still continue, and others are being developed and added to the stations tasks on a regular basis. These diverse student experiments and programs fall into one of the following categories: student-developed experiments; students performing classroom versions of ISS experiments; students participating in ISS investigator experiments; education competitions; students participating in ISS Engineering Education; Education Demonstrations and Cultural Activities. This paper summarizes some of the main student experiments and educational activities that have been conducted on the space station.

Alleyne, Camille W.↗

DOE OSTI2022

Inhibition of Micro-pitting by Tribofilm-Forming ZrO 2 Nanocrystal Lubricant Additives: A Micro-pitting Rig and Transmission Electron Microscope Study

The drive to reduce fuel consumption in transportation has encouraged the emergence of low viscosity lubricants to reduce viscous losses in the engine, drivetrain, and other components. However, viscosity reduction increases the risk of surface damage, thus motivating the development of new anti-wear (AW) additives. Capped ZrO 2 nanocrystals (NCs) in base oils have been shown to form AW tribofilms within microscale sliding contacts. However, the potential of ZrO 2 NCs to protect surfaces subjected to rolling-sliding contact from macroscale damage, such as micro-pitting, remains unexplored. Here, we explore the ability of ZrO 2 NCs to form protective tribofilms under harsh conditions using a micro-pitting rig (MPR), consisting of a three ring-on-roller configuration. The experiments were conducted in polyalphaolephin (PAO) base oil, with and without 5 nm diameter ZrO 2 NCs, at two levels of slide-to-roll ratio (SRR) (30% and 0%) and at variable test durations up to long durations (119 h). MPR results showed the use of ZrO 2 NCs gives rise to the formation of a tribofilm covering the roller surfaces and decreases the initiation and propagation of micro-pits compared to tests in pure PAO base stock. Transmission electron microscopy (TEM) performed on focused ion beam (FIB) milled cross-sectional samples of the roller surfaces revealed the growth of dense and 50–100 nm thick ZrO 2 -based tribofilms independent of (SRR), indicating the potential for robust micro-pitting fatigue protection. Nevertheless, small cracks localized within the near surface region of the roller tested at the most severe conditions (30% SRR and 119 h) were observed. The initiation of these cracks was directly related to the presence of manganese sulphide (MnS) inclusions in the steel, revealed using TEM combined with energy dispersive spectroscopy (EDS). Furthermore, the results highlight the benefits of the protective tribofilms formed by ZrO 2 NCs and suggest approaches for further optimizing their use.

36 MATERIALS SCIENCE↗

DOE OSTI2021

CIGS photovoltaics: reviewing an evolving paradigm

Copper indium selenide chalcopyrite-structure alloys with gallium (CIGS) are unique among the highest performing photovoltaic (PV) semiconductor technologies. They are structurally disordered, nonstoichiometric materials that have been engineered to achieve remarkably low bulk nonradiative recombination levels. Nevertheless, their performance can be further improved. This review adopts a fundamental thermodynamic perspective to comparatively assess the root causes of present limitations on CIGS PV performance. The topics of selectivity and passivation of contacts to CIGS and its multinary alloys are covered, highlighting pathways to maximizing the electrochemical potential between those contacts under illumination. Further, an overview of absorber growth methods and resulting properties is also provided. We recommend that CIGS researchers consider strategies that have been successfully implemented in the more mature wafer-based GaAs and Si PV device technologies, based on the paradigm of an idealized PV device design using an isotropic absorber with minimal nonradiative recombination, maximal light trapping, and both electron-selective and hole-selective passivated contacts. We foresee that CIGS technology will reach the 25% efficiency level within the next few years through enhanced collection and reduced recombination. To significantly impact power-generation applications, cost-effective, manufacturable solutions are also essential.

14 SOLAR ENERGY↗

DOE OSTI2021

Laser-Interference Surface Preparation for Enhanced Coating Adhesion and Adhesive Joining of Multi-Materials (Final Project Report)

This report investigates a laser-interference surface treatment as a non-contact, i.e., without major solid/liquid medium application or abrasion, and non-chemical surface preparation method for aerospace coating systems. It was proposed to use the laser-interference technique to structure surfaces of Al and/or Ti, creating "rough" surfaces with pre-engineered series of ridges and valleys at submicron scale. The science goal of this study was to develop an understanding of the surface microstructure, topology, and physical mechanisms that would improve adhesion and corrosion protection of Al2024-T3. Microstructure analysis indicates that the laser-interference structuring (LIS) was found to reduce the formation of CuMn-rich precipitates in Al 2024-T3 over a 500-800 nm depth from top surface. The X-cut and cross-hatch coating adhesion ratings indicate that the LIS specimens meet the performance requirements in the coating adhesion specifications by having a higher or identical ranking to those specimens prepared with current state-of-the-art chemical conversion or sulfuric acid anodizing. After the ASTM B117 corrosion exposure, it was found that the laser processed specimens exhibited only few blisters. It was found that the corrosion damage was minimized at a laser rastering speed of 4 mm/s, for which only 33% of specimens developed very minor corrosion damage. The ASTM D1654 creepage ratings, used to evaluate corrosion damage along the scribe lines, were found to be at least nine for all coated panels. These results indicate that the laser-interference technique with the additional acetone wiping has the potential to be further developed as a minor chemical surface preparation technique for chromate-containing epoxy primers coatings.

36 MATERIALS SCIENCE↗

NASA NTRS1999

Dynamic Testing of an Inflatable Structure Under Thermal Vacuum Conditions

The Marshall Space Flight Center's Space Transportation Programs Office is responsible for the development and demonstration of advanced launch vehicle and propulsion technologies. One of these advanced propulsion concepts being pursued is solar thermal propulsion. This concept employs a concentrated beam of sunlight to heat a working fluid within a solar thermal engine. Expansion of the fluid would provide thrust at an increased specific impulse. One way to concentrate the sun's light to a specific point in the engine cavity is to use a fresnel lens that is supported by an inflatable structure. Such propulsion systems could provide an inexpensive way of transferring and maintaining satellites to upper stage orbit trajectories. This paper describes the test hardware, procedures, and non-contacting measurement methodologies used to determine the modal characteristics of an inflatable concentrator under the thermal-vacuum conditions of space. These characteristics were necessary to identify for validation of a finite element model to be used for developing the spacecraft's pointing and control system.

Engberg, Robert↗

NASA NTRS2019

Tribological Performance of PM400 Bushings in Oscillatory Sliding from 25 to 927 °C

Small bore (6.35 millimeter) bushings, made from NASA PM400 solid lubricant composite, were evaluated in oscillatory sliding contact against a nickel-based superalloy shaft. Tests were conducted in air from 25 to 900 degrees Centigrade for extended periods (1 million cycles, plus or minus 15 degrees, 1 hertz) to assess the suitability of PM400 in gas turbine and reciprocating engine exhaust gas path control valve applications. Operating torque and estimated friction was monitored throughout the test duration and wear was measured at the end of test. In general, friction, torque and wear was low. At temperatures above 600 degrees Centigrade, bushing dimensional stability was achieved via short duration pre-test furnace exposure heat treatments. Preliminary test results show that bushings made from NASA PM400 are feasible for aerospace and industrial applications.

high temperature solid lubricants↗

NASA NTRS2019

Early Navigation Performance of the OSIRIS-REx Approach to Bennu

The New Frontiers-class OSIRIS-REx (Origins, Spectral Interpretation, Resource Identification, Security-Regolith Explorer) mission is the first American endeavor to return a sample from an asteroid. In preparation for retrieving the sample, OSIRIS-REx is conducting a campaign of challenging proximity-operations maneuvers and scientific observations, bringing the spacecraft closer and closer to the surface of near-Earth asteroid (101955) Bennu. Ultimately, the spacecraft will enter a 900-meter-radius orbit about Bennu and conduct a series of reconnaissance flybys of candidate sample sites before being guided into contact with the surface for the Touch and Go sample collection event. Between August and December 2018, the OSIRIS-REx team acquired the first optical observations of Bennu and used them for navigation. We conducted a series of maneuvers with the main engine, Trajectory Correction Maneuver, and Attitude Control System thruster sets to slow the OSIRIS-REx approach to Bennu and achieve rendezvous on December 3, 2018. This paper describes the trajectory design, navigation conops, and key navigation results from the Approach phase of the OSIRIS-REx mission.

Antreasian, Peter G.↗

NASA NTRS2024

Bumper Implementation of LMEEM

The Hypervelocity Impact Technology (HVIT) group at the NASA Johnson Space Center (JSC) maintains the Bumper 3 computer program (referred to as “Bumper”) to perform Micrometeoroid and Orbital Debris (MMOD) risk assessments for spacecraft. To perform its calculations, this program requires detailed mathematical models of the space environments and can include those models representing orbital debris, micrometeoroids, and lunar ejecta. The lunar ejecta environment is a projectile environment specific to the lunar surface. Due to the Moon’s lack of an atmosphere, meteoroids frequently strike the lunar surface. When this happens, the impact ejects material radially away from the impact point, which can pose a potential impact hazard to surface-based hardware. This lunar ejecta environment was previously described in 1969, in NASA Special Publication SP-8013, which was used as the basis for a model that will be referred to in this document as the “SP-8013 environment model,” or simply, “SP-8013.” Since around 2020, this model has been used in MMOD risk assessments for the Human Landing System (HLS) program and other lunar surface programs. A new lunar meteoroid ejecta environment was developed via a computer code named Lunar Meteoroid Ejecta Engineering Model (LMEEM), produced by the Natural Environments Branch (NEB) at Marshall Space Flight Center (MSFC). A global lunar surface environment definition using LMEEM is to be provided in the Cross-Program Design Specification for Natural Environments (DSNE) Revision J in 2024. Contact the NASA MSFC Natural Environments Branch for an in-depth discussion of the LMEEM environment model and its derivation. This environment model will supersede SP-8013 for MMOD risk assessments. To perform such assessments, Bumper must read data from text files output by LMEEM and use that data in risk calculations. The purpose of this document is to: •Demonstrate verification that the Bumper code has properly implemented the LMEEM environment model (Section 3) •Discuss the LMEEM environment as understood through an initial environment file (Section 4) •Compare the calculated risk due to the SP-8013 and LMEEM models (Section 5)

Bumper↗

DOE OSTI2025

Development of a Western U.S. Fusion Energy Commercialization Hub

Fusion energy, if successfully commercialized and globally adopted, could substantially increase U.S. energy dominance and provide essentially unlimited baseload power for the national grid. It also stands to provide the U.S. with a strong source of economic growth through the 2030s and 2040s, giving the U.S. a new and highly internationally competitive industry for export. Fusion can also provide the increased electrical power generation capacity required to power current and future artificial intelligence (AI) activities. In October 2024, the CleanTech Alliance held a fusion energy commercialization regional hub workshop alongside its annual Seattle Fusion Week conference. The event brought together fusion companies, researchers, economic development experts, federal and state government representatives, and power utilities from the western states of Washington, California, Colorado and Nevada. Attendees discussed the potential of regionally focused commercialization of fusion energy in three pillars: technology, workforce, and economic development. Mel Clark, President & CEO, CleanTech Alliance, and Dr. Javier Garay, Associate Dean for Research and Professor of Mechanical and Aerospace Engineering, at the University of California San Diego (UCSD) and Founding Director of the UCSD Fusion Engineering institute, are co-PIs for this project. The project is sponsored by the U.S. Department of Energy’s Office of Fusion Energy Sciences (FES) through a Field Work Proposal to Pacific Northwest National Laboratory (PNNL) with Karl Mueller as point-of-contact. Chris Ajemian (Principal, Ajemian Consulting, LLC) and Dr. Christopher Keane (Professor of Physics and former Vice-President for Research, Washington State University) co-organized the workshop and were the editors for this report. This report details the current state of the work of the four western states to develop industry-led collaboration with national laboratories, universities, and government at all levels to hasten the commercialization of fusion energy. It provides a summary of fusion energy R&D needs, presents the ideas the attendees at the workshop identified for deepening regional collaboration, and makes findings and recommendations for next steps.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1990

A future perspective on technological obsolescenceat NASA, Langley Research Center

The present research effort was the first phase of a study to forecast whether technological obsolescence will be a problem for the engineers, scientists, and technicians at NASA Langley Research Center (LaRC). There were four goals of the research: to review the literature on technological obsolescence; to determine through interviews of division chiefs and branch heads Langley's perspective on future technological obsolescence; to begin making contacts with outside industries to find out how they view the possibility of technological obsolescence; and to make preliminary recommendations for dealing with the problem. A complete description of the findings of this research can be reviewed in a technical report in preparation. The following are a small subset of the key findings of the study: NASA's centers and divisions vary in their missions and because of this, in their capability to control obsolescence; research-oriented organizations within NASA are believed by respondents to keep up to date more than the project-oriented organizations; asked what are the signs of a professional's technological obsolescence, respondents had a variety of responses; top performing scientists were viewed as continuous learners, keeping up to date by a variety of means; when asked what incentives were available to aerospace technologists for keeping up to data, respondents specified a number of ideas; respondents identified many obstacles to professionals' keeping up to date in the future; and most respondents expressed some concern for the future of the professionals at NASA vis a vis the issue of professional obsolescence.

Mcintyre, Robert M.↗