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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Experimental Studies of Open Rotor Installation Effects

Open rotor propulsion technologies offer an opportunity for reducing fuel burn. At the same time, great challenges arise from this radically different engine architecture in terms of aircraft system integration. The aeroacoustic effects of integration are one of those key challenges and, furthermore, can offer the possibility for total aircraft system noise reduction. The inter-relationship of the aerodynamic and aeroacoustic system integration effects is particularly important to enable future application. An extensive model scale test campaign was conducted to investigate a broad range of these open rotor installation effects for both a conventional and an unconventional airframe. The experimental campaign was conducted in the Boeing Low Speed Aeroacoustic Facility with specially designed modifications for efficient positioning of the open rotor rig relative to the airframe. The airframe was traversed remotely relative to the fixed open rotor rig providing for the investigation of a large number of installation positions. Eight positions around the main wing of the conventional airframe and eleven positions above the hybrid wing body airframe were documented. Other parameters investigated in the test campaign included forward flight simulation Mach number, angle of attack, rotor speed, and airframe control surface deployment. In addition, both airframes were modified for alternate configurations. The conventional airframe was configured with both a T and a U tail while the unconventional hybrid wing body airframe was configured with different vertical control surfaces. An extensive instrumentation package was deployed. The acoustics were documented with a fixed array of far field microphones, a traversing array of in-flow microphones, an out-of-flow traversing phased array, and unsteady pressure transducers mounted flush on the surface of the airframes. In addition, mean flow surveys were measured with an articulating arm traversing system. The flow field surveys were particularly valuable in documenting flow distortion effects for the various installation positions and those created by angle of attack. This presentation will report the key results obtained for open rotor installation effects and discuss future prospects with the perspective of these results.

Michael J Czech↗
DOE OSTI2023

Machinability comparison of additively manufactured and traditionally wrought Ti-6Al-4V alloys using single-point cutting

Post-machining is often needed to provide high dimensional accuracy and fine surface finish for additively manufactured Ti-6Al-4V (Ti64). The material inhomogeneity, such as pores and microstructures, can affect the machining behavior of this already difficult-machine alloy. This study adopts a holistic approach to compare the machinability of additively manufactured and traditionally wrought Ti64 in terms of key machining factors, including forces, temperature, and vibration and the major machining outcomes including tool life, surface finish, and dimensional accuracy. Stress-relief annealing is applied to each of the part conditions as a secondary variable to observe the additional effects. The results show that AM is not particularly more difficult to machine in terms of cutting force and temperature, but it creates high cutting vibrations across a wide range of frequencies (to and over 5 kHz). The high vibrations do not lead to worse surface finish or dimensional accuracy but tend to worsen the tool life by chipping off the cutting edge. The vibration can be attributed to the brittle martensitic microstructure found in additively manufactured Ti64, which is also evidenced by the more serrated chips. Stress-relieving is found to change the microstructure and reduce the level of vibration to that of the wrought counterpart.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Effect of Oxygen Adsorption for Vacancy-Induced d{sup 0} Magnetism in HfO{sub 2} (110) Surface

Based on the density functional theory, we investigated the electronic structures and magnetic properties of the oxygen adsorption on the defective cubic HfO{sub 2} (110) surface. The adsorption capacities of the perfect and defective surfaces follow in the sequence as: oxygen-deficient model >perfect surface >hafnium-deficient model. When the oxygen molecules adsorb on the nonmagnetic perfect HfO{sub 2} surface, the system has a local magnetic moment and the antiferromagnetic coupling is more stable. For the defective cubic HfO{sub 2} (110) surface, it is found that the oxygen vacancy is more easy to form than the hafnium vacancy by comparing the vacancy formation energy. And the hafnium vacancy could induce a large magnetic moment while the oxygen vacancy alone could not. After adsorption of the oxygen molecule, the nonmagnetic oxygen-deficient HfO{sub 2} model is transformed into the magnetic surface. On the contrary, the introduction of adsorbed oxygen molecule causes the magnetic moment of hafnium-deficient HfO{sub 2} surface to reduce. Additionally, if the oxygen molecules adsorb on the defective HfO{sub 2} (110) surface, the ferromagnetic coupling is energetically favorable.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Antiwear Properties of Binary Ashless Blend of Phosphonium Ionic Liquids and Borate Esters in Partially Formulated Oil (No Zn)

Here, interaction of ionic liquid (IL) and borate esters (SBs) as antiwear (AW) additives with steel surfaces in tribological contacts was examined using blends which contained no prior AW additives but all the other ingredients present in a fully formulated engine oil. In detail, low phosphorus oil blends were prepared by adding trihexyltetradecylphosphonium bis(2-ethylhexyl)phosphate (P_DEHP) at 700ppm phosphorus and 2-methoxy-4,4,6-trimethyl-1,3,2-dioxaborinane or trimethoxyboroxine at 200ppm boron treat rate to a partially formulated oil. The tribological properties of these novel ionic liquid (IL) additive and IL+SB additive mixtures were compared with those of zinc dialkyldithiophosphate (ZDDP) at equal phosphorus levels in the oil blends. Tribological experiments with a reciprocating cylinder on flat contact revealed that both P_DEHP and binary mixtures of P_DEHP+SB offer superior wear protection than ZDDP and the partially formulated oil without AW additives, expressed by a wear reduction of minimum 50%. X-ray absorption near edge structure spectroscopy (XANES) analysis revealed that tribologically formed films are primarily composed of calcium phosphate for oils with AW additives. The interaction of P_DEHP with SB results in additional boron oxide/boric acid and to some extent boron phosphate domains incorporated into the tribofilms.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Effect of Electropulsing-Assisted Ultrasonic Nanocrystalline Surface Modification on the Surface Mechanical Properties and Microstructure of Ti-6Al-4V Alloy

The effect of electropulsing-assisted ultrasonic nanocrystalline surface modification (EP-UNSM) on surface mechanical properties and microstructure of Ti-6Al-4V alloy is investigated. Compared to conventional ultrasonic nanocrystalline surface modification (UNSM), EP-UNSM can effectively facilitate surface roughness and morphology, leading to excellent surface roughness (reduced from Ra 0.918 to Ra 0.028 μm by UNSM and Ra 0.019 μm by EP-UNSM) and smoother morphology with less cracks and defects. Surface friction coefficients are enhanced, resulting in lower and smoother friction coefficients. In addition, the surface-strengthened layer and ultra-refined grains are significantly enhanced with more severe plastic deformation and a greater surface hardness (a maximum hardness value of 407 HV and an effective depth of 550 μm, in comparison with the maximum hardness value of 364 HV and effective depth of 300 μm obtained by conventional UNSM). Remarkable enhancement of surface mechanical properties can be attributed to the refined gradient microstructure and the enhanced severe plastic deformation layer induced by coupling the effects of UNSM and electropulsing. The accelerated dislocation mobility and atom diffusion caused by the thermal and athermal effects of electropulsing treatment may be the primary intrinsic reasons for these improvements.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Indium as a surfactant: Effects on growth morphology and background impurity in GaN films grown by ammonia-assisted molecular beam epitaxy

We report on the improvement of the surface morphology of c-plane GaN films grown at high growth rates (~1 µm/h) using ammonia molecular beam epitaxy through a series of growth optimizations as well as the introduction of indium as a surfactant. The indium surfactant was expected to help with the adatom mobility and, thus, provide smoother growth surfaces. Through a combination of varying V/III ratios, In flux, and growth temperatures, an optimal condition for surface morphology, characterized by atomic force microscopy, was achieved. At higher Ga fluxes for fast growth rates (~1 µm/h and beam equivalent pressures of ~5 × 10 –7 Torr), higher ammonia flows were necessary to preserve the surface morphology. In addition, indium was an effective surfactant—reducing the roughness and improving the overall surface morphology. However, excessive indium causes the surface morphology to degrade, potentially due to the enhancement of the Ga desorption from the surface as a result of the reaction of indium with ammonia for high indium fluxes. The indium surfactant also resulted in a reduction of background Si impurity concentrations in the film. These effects allow for the growth of thick drift layers with low background dopant concentrations for vertical GaN power devices.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Design of equipment for lunar dust removal

NASA has a long range goal of constructing a fully equipped, manned lunar base on the near side of the moon by the year 2015. During the Apollo Missions, lunar dust coated and fouled equipment surfaces and mechanisms exposed to the lunar environment. In addition, the atmosphere and internal surfaces of the lunar excursion module were contaminated by lunar dust which was brought in on articles passed through the airlock. Consequently, the need exists for device or appliance to remove lunar dust from surfaces of material objects used outside of the proposed lunar habitat. Additionally, several concepts were investigated for preventing the accumulation of lunar dust on mechanisms and finished surfaces. The character of the dust and the lunar environment present unique challenges for the removal of contamination from exposed surfaces. In addition to a study of lunar dust adhesion properties, the project examines the use of various energy domains for removing the dust from exposed surfaces. Also, prevention alternatives are examined for systems exposed to lunar dust. A concept utilizing a pressurized gas is presented for dust removal outside of an atmospherically controlled environment. The concept consists of a small astronaut/robotic compatible device which removes dust from contaminated surfaces by a small burst of gas.

Belden, Lacy↗
DOE OSTI2020

Kinetics of low-temperature methane activation on IrO 2 (1 1 0): Role of local surface hydroxide species

The ability of the IrO 2 (1 1 0) surface to promote CH 4 activation at low temperatures (~150 K) suggests possibilities for developing IrO 2 -based catalysts to selectively convert light alkanes to high-value chemicals. In this study, we present experimental results and microkinetic simulations, based on density functional theory (DFT) calculations, of temperature programmed reaction spectra (TPRS) obtained for CH 4 σ-complexes adsorbed on IrO 2 (1 1 0), and focus on clarifying how surface OH groups modify the branching between CH 4 desorption, activation and subsequent reactions during TPRS. Our DFT results predict that surface OH groups strongly destabilize CH 4 σ-complexes on IrO 2 (1 1 0) in addition to deactivating surface O-atoms that are needed to achieve CH 4 activation at low temperature. We demonstrate that a microkinetic model that incorporates the influence of surface OH groups on the CH 4 binding and reactivity reproduces experimental TPRS results which show that adsorbed CH 4 σ-complexes preferentially dissociate at low CH 4 coverage, but that an increasing fraction of the adsorbed CH 4 desorbs at low temperature (~120 K) with increasing initial CH 4 or H coverage. The simulations reveal that low-temperature CH4 desorption during TPRS arises primarily from CH 4 σ-complexes that are kinetically-trapped between adjacent surface OH groups, and are thus destabilized and unable to access reactive O-atoms. In addition, when the effect of adjacent OH groups is incorporated we find that the PBE-D3 functional incorporating dispersion provides CH 4 binding energies that agree more closely with that obtained from the TPRS experiments. Overall, our results demonstrate that the local effect of adjacent OH groups must be incorporated into any microkinetic models to properly capture the selectivity between extensive and partial oxidation in alkane conversion on IrO 2 (1 1 0) under reaction conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2010

Use of a Hybrid Edge Node-Centroid Node Approach to Thermal Modeling

A recent proposal submitted for an ESA mission required that models be delivered in ESARAD/ESATAN formats. ThermalDesktop was the preferable analysis code to be used for model development with a conversion done as the final step before delivery. However, due to some differences between the capabilities of the two codes, a unique approach was developed to take advantage of the edge node capability of ThermalDesktop while maintaining the centroid node approach used by ESARAD. In essence, two separate meshes were used: one for conduction and one for radiation. The conduction calculations were eliminated from the radiation surfaces and the capacitance and radiative calculations were eliminated from the conduction surfaces. The resulting conduction surface nodes were coincident with all nodes of the radiation surface and were subsequently merged, while the nodes along the edges remained free. Merging of nodes on the edges of adjacent surfaces provided the conductive links between surfaces. Lastly, all nodes along edges were placed into the subnetwork and the resulting supernetwork included only the nodes associated with radiation surfaces. This approach had both benefits and disadvantages. The use of centroid, surface based radiation reduces the overall size of the radiation network, which is often the most computationally intensive part of the modeling process. Furthermore, using the conduction surfaces and allowing ThermalDesktop to calculate the conduction network can save significant time by not having to manually generate the couplings. Lastly, the resulting GMM/TMM models can be exported to formats which do not support edge nodes. One drawback, however, is the necessity to maintain two sets of surfaces. This requires additional care on the part of the analyst to ensure communication between the conductive and radiative surfaces in the resulting overall network. However, with more frequent use of this technique, the benefits of this approach can far outweigh the additional effort.

Peabody, Hume L.↗
NASA NTRS2010

Use of a Hybrid Edge Node-Centroid Node Approach to Thermal Modeling

A recent proposal submitted for an ESA mission required that models be delivered in ESARAD/ESAT AN formats. ThermalDesktop was the preferable analysis code to be used for model development with a conversion done as the final step before delivery. However, due to some differences between the capabilities of the two codes, a unique approach was developed to take advantage of the edge node capability of ThermalDesktop while maintaining the centroid node approach used by ESARAD. In essence, two separate meshes were used: one for conduction and one for radiation. The conduction calculations were eliminated from the radiation surfaces and the capacitance and radiative calculations were eliminated from the conduction surfaces. The resulting conduction surface nodes were coincident with all nodes of the radiation surface and were subsequently merged, while the nodes along the edges remained free. Merging of nodes on the edges of adjacent surfaces provided the conductive links between surfaces. Lastly, all nodes along edges were placed into the subnetwork and the resulting supernetwork included only the nodes associated with radiation surfaces. This approach had both benefits and disadvantages. The use of centroid, surface based radiation reduces the overall size of the radiation network, which is often the most computationally intensive part of the modeling process. Furthermore, using the conduction surfaces and allowing ThermalDesktop to calculate the conduction network can save significant time by not having to manually generate the couplings. Lastly, the resulting GMM/TMM models can be exported to formats which do not support edge nodes. One drawback, however, is the necessity to maintain two sets of surfaces. This requires additional care on the part of the analyst to ensure communication between the conductive and radiative surfaces in the resulting overall network. However, with more frequent use of this technique, the benefits of this approach can far outweigh the additional effort.

Peabody, Hume L.↗
DOE OSTI2025

Parylene-N Coatings of Thin Foils for the Mitigation of Neutral Contaminant Desorption and Plasma Formation

Previous experiments utilizing the planar MITL foil platform (T.J. Smith et al. RSI 2021) on the 1-MA, 100-ns Mykonos facility have shown neutral atomic and molecular hydrogen in the gap after rapid heating of the foil surfaces before breakdown. Additionally, previous attempts at using parylene-N as a coating for power flow surfaces on the 1-MA, 100-ns Zebra facility have shown tamping of the electrothermal instability at thicknesses of 50-60 μm (T.M. Hutchinson et al. Phys. Rev. E 2018).

36 MATERIALS SCIENCE↗
NASA NTRS1993

Millimeter accuracy satellites for two color ranging

The principal technical challenge in designing a millimeter accuracy satellite to support two color observations at high altitudes is to provide high optical cross-section simultaneously with minimal pulse spreading. In order to address this issue, we provide, a brief review of some fundamental properties of optical retroreflectors when used in spacecraft target arrays, develop a simple model for a spherical geodetic satellite, and use the model to determine some basic design criteria for a new generation of geodetic satellites capable of supporting millimeter accuracy two color laser ranging. We find that increasing the satellite diameter provides: a larger surface area for additional cube mounting thereby leading to higher cross-sections; and makes the satellite surface a better match for the incoming planar phasefront of the laser beam. Restricting the retroreflector field of view (e.g. by recessing it in its holder) limits the target response to the fraction of the satellite surface which best matches the optical phasefront thereby controlling the amount of pulse spreading. In surveying the arrays carried by existing satellites, we find that European STARLETTE and ERS-1 satellites appear to be the best candidates for supporting near term two color experiments in space.

Degnan, John J.↗
DOE OSTI2022

Mitigation of rapid capacity decay in silicon-LiNi 0.6 Mn 0.2 Co 0.2 O 2 full batteries

Silicon (Si)-based materials have been considered as the most promising anode materials for high-energy-density lithium-ion batteries because of their higher storage capacity and similar operating voltage, as compared to the commercial graphite (Gr) anode. But the use of Si anodes including silicon-graphite (Si-Gr) blended anodes often leads to rapid capacity decay in Si-Gr/LiNixMnyCo z O 2 (x+y+z=1) full cells, which has been attributed to surface instability of the Si component. In addition to stabilizing the surface, this work investigates the potential of the Si-Gr blended anodes in a full-cell configuration and its impact on the capacity contribution from active components. Using dQ/dV plots of the full cells, a powerful but simple-to-implement differential potential approach is developed to decouple the capacity contribution and degradation from the graphite and silicon components. Data collected from three-electrode cells confirm the results from the differential potential approach, which suggests a voltage slippage to a higher voltage at the blended anode side. Additionally, the voltage slippage causes a reduced utilization of the Gr component and exacerbates side reactions between the Si-Gr anode and carbonate electrolytes. Furthermore, based on these failure mechanisms, we adopted a mitigation strategy to tune the open circuit voltage of the prelithiated anode while stabilizing the surface. As a result, the full cells with the modified Si-Gr anodes (mass loading, 2.5 mAh/cm 2 ) offer a highly reversible full-cell energy density of 390 Wh/kg (based on the mass of both anode and cathode materials in a full cell) with a cycling CE of 99.9% over 200 cycles.

25 ENERGY STORAGE↗
DOE OSTI2024

Surface Finishing and Coating Parameters Impact on Additively Manufactured Binder-Jetted Steel–Bronze Composites

In this paper, electroless nickel plating is explored for the protection of binder-jetting-based additively manufactured (AM) composite materials. Electroless nickel plating was attempted on binder-jetted composites composed of stainless steel and bronze, resulting in differences in the physicochemical properties. We investigated the impact of surface finishing, plating solution chemistry, and plating parameters to attain a wide range of surface morphologies and roughness levels. We employed the Keyence microscope to quantitatively evaluate dramatically different surface properties before and after the coating of AM composites. Scanning electron microscopy revealed a wide range of microstructural properties in relation to each combination of surface finishing and coating parameters. We studied chempolishing, plasma cleaning, and organic cleaning as the surface preparation methods prior to coating. We found that surface preparation dictated the surface roughness. Taguchi statistical analysis was performed to investigate the relative strength of experimental factors and interconnectedness among process parameters to attain optimum coating qualities. The quantitative impacts of phosphorous level, temperature, surface preparation, and time factor on the roughness of the nickel-plated surface were 17.95%, 8.2%, 50.02%, and 13.21%, respectively. On the other hand, the quantitative impacts of phosphorous level, temperature, surface preparation, and time factor on the thickness of nickel plating were 35.12%, 41.40%, 3.87%, and 18.24%, respectively. The optimum combination of the factors’ level projected the lowest roughness of Ra at 7.76 µm. The optimum combination of the factors’ level projected the maximum achievable thickness of ~149 µm. This paper provides insights into coating process for overcoming the sensitivity of AM composites in hazardous application spaces via robust coating.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Enhancing workability in sheet production of high silicon content electrical steel through large shear deformation

Enhanced workability, as characterized by the magnitude and heterogeneity of accommodated plastic strains during sheet processing, is demonstrated in high Si content Fe-Si alloys containing 4 and 6.5 wt% Si using two single-step, simple-shear deformation techniques – peeling and large strain extrusion machining (LSEM). The model Fe-Si material system was selected for its intrinsically poor material workability, and well-known applications potential in next-generation electric machines. In a comparative study of the deformation characteristics of the shear processes with conventional rolling, two distinct manifestations of workability are observed. For rolling, the relatively diffuse and unconfined deformation zone geometry leads to cracking at low strains, with sheet structures characterized by extensive deformation twinning and banding. Workpiece pre-heating is required to improve the workability in rolling. In contrast, peeling and LSEM produce continuous sheet at large plastic strains without cracking, the result of more confined deformation geometries that enhances the workability. Peeling, however, results in heterogeneous, shear-banded microstructures, pointing to a second type of workability issue – flow localization – that limits sheet processing. This shear banding is to a large extent facilitated by unrestricted flow at the sheet surface, unavoidable in peeling. With additional confinement of this free surface deformation and appropriately designed deformation zone geometry, LSEM is shown to suppress shear banding, resulting in continuous sheet with homogeneous microstructure. Thus LSEM is shown to produce the greatest enhancement in process workability for producing sheet. In conclusion, these workability findings are explained and discussed based on differences in process mechanics and deformation zone geometry.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Earth radiation budget measurements from satellites and their interpretation for climate modeling and studies

The annual and seasonal averaged Earth atmosphere radiation budgets derived from the most complete set of satellite observations available are presented. The budgets were derived from a composite of 48 monthly mean radiation budget maps. Annually and seasonally averaged radiation budgets are presented as global averages and zonal averages. The geographic distribution of the various radiation budget quantities is described. The annual cycle of the radiation budget was analyzed and the annual variability of net flux was shown to be largely dominated by the regular semi and annual cycles forced by external Earth-Sun geometry variations. Radiative transfer calculations were compared to the observed budget quantities and surface budgets were additionally computed with particular emphasis on discrepancies that exist between the present computations and previous surface budget estimates.

Vonderhaar, T. H.↗
NASA NTRS1990

Global mapping of minor atmospheric constituents with AIRS on EOS

The Atmospheric Infrared Sounder (AIRS) is a grating-array spectrometer on EOS. It covers the region from 650 to 3000/cm with spectral resolution of 1200. The prime objective of AIRS is the global retrieval of temperature and water vapor profiles and of surface temperatures. The wide spectral coverage of AIRS permits the measurement of a number of additional atmospheric and surface parameters. Of particular interest is the potential to produce daily global maps of the spatial distribution of the more abundant of the minor gases, e.g. ozone, CO, CH4, and N2O. This potential capability for CH4 and N2O is strongly affected by cloud residual. Using the CH4 band at 1306/cm as example, spatial averaging of AIRS data is required to measure a 10 percent change in the nominal CH4 column abundance. At 1300/cm, this requires cloud clearing at the 0.3 percent level. The mapping capability for ozone and CO in terms of rural/urban abundance patterns is not likely to be impacted with cloud-clearing residuals as high as 5 percent.

Aumann, H. H.↗
NASA NTRS1996

Sol-gel Technology and Advanced Electrochemical Energy Storage Materials

Advanced materials play an important role in the development of electrochemical energy devices such as batteries, fuel cells, and electrochemical capacitors. The sol-gel process is a versatile solution for use in the fabrication of ceramic materials with tailored stoichiometry, microstructure, and properties. This processing technique is particularly useful in producing porous materials with high surface area and low density, two of the most desirable characteristics for electrode materials. In addition,the porous surface of gels can be modified chemically to create tailored surface properties, and inorganic/organic micro-composites can be prepared for improved material performance device fabrication. Applications of several sol-gel derived electrode materials in different energy storage devices are illustrated in this paper. V2O5 gels are shown to be a promising cathode material for solid state lithium batteries. Carbon aerogels, amorphous RuO2 gels and sol-gel derived hafnium compounds have been studied as electrode materials for high energy density and high power density electrochemical capacitors.

Chung-tse Chu↗