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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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At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

NASA NTRS2003

High Conductivity Materials for High Heat Flux Applications in Space Propulsion Systems

GRCop-84 is a new copper base alloy with an excellent combination of strength and conductivity and has been developed to the point that it is a strong candidate for near term rocket engine applications. This work sought to establish the feasibility of new alloys with capabilities beyond GRCop-84. The use of coatings as environmental and thermal barriers adds further capability into the Copper base structure. Finally, Nickel-Aluminum based systems have also been explored.

Nathal, M. V.↗

NASA NTRS2016

Hybrid Heat Pipes for Lunar and Martian Surface and High Heat Flux Space Applications

Novel hybrid wick heat pipes are developed to operate against gravity on planetary surfaces, operate in space carrying power over long distances and act as thermosyphons on the planetary surface for Lunar and Martian landers and rovers. These hybrid heat pipes will be capable of operating at the higher heat flux requirements expected in NASA's future spacecraft and on the next generation of polar rovers and equatorial landers. In addition, the sintered evaporator wicks mitigate the start-up problems in vertical gravity aided heat pipes because of large number of nucleation sites in wicks which will allow easy boiling initiation. ACT, NASA Marshall Space Flight Center, and NASA Johnson Space Center, are working together on the Advanced Passive Thermal experiment (APTx) to test and validate the operation of a hybrid wick VCHP with warm reservoir and HiK"TM" plates in microgravity environment on the ISS.

Ababneh, Mohammed T.↗

NASA NTRS2005

Variable Gravity Effects on the Cooling Performance of a Single Phase Confined Spray

The objective of this paper is to discuss the testing of a spray cooling experiment designed to be flown on NASA's KC-135 Reduced Gravity Testing Platform. Spray cooling is an example of a thermal management technique that may be utilized in high flux heat acquisition and high thermal energy transport concepts. Many researchers have investigated the utility of spray cooling for the thermal management of devices generating high heat fluxes. However, there has been little research addressing the physics and ultimate performance of spray cooling in a variable gravity environment. An experimental package, consisting of a spray chamber coupled to a fluid delivery loop system, was fabricated for variable gravity flight tests. The spray chamber contains two opposing nozzles spraying on target Indium Tin Oxide (ITO) heaters. These heaters are mounted on glass pedestals, which are part of a sump system to remove unconstrained liquid from the test chamber. Liquid is collected in the sumps and returned to the fluid delivery loop. Thermocouples mounted in and around the pedestals are used to determine both the heat loss through the underside of the IT0 heater and the heat extracted by the spray. A series of flight tests were carried out aboard the KC-135, utilizing the ability of the aircraft to produce various gravity conditions. During the flight tests, for a fixed flow rate, heat input was varied at 20, 30, 50, and 80W with variable gravities of 0.01, 0.16, 0.36, and 1.8g. Flight test data was compared to terrestrial baseline data in addition to analytical and numerical solutions to evaluate the heat transfer in the heater and support structure . There were significant differences observed in the spray cooling performance as a result of variable gravity conditions and heat inputs. In general, the Nussult number at the heater surface was found to increase with decreasing gravity conditions for heat loads greater than 30W.

Michalak, Travis↗

NASA NTRS1998

Experimental Measurements of Temperature and Heat Flux in a High Temperature Black Body Cavity

During hypersonic flight, high temperatures and high heat fluxes are generated. The Flight Loads Laboratory (FLL) at Dryden Flight Research Center (DFRC) is equipped to calibrate high heat fluxes up to 1100 kW/sq m. There are numerous uncertainties associated with these heat flux calibrations, as the process is transient, there are expected to be interactions between transient conduction, natural and forced convection, radiation, and possibly an insignificant degree of oxidation of the graphite cavity. Better understanding, of these mechanisms during the calibration process, will provide more reliable heat transfer data during either ground testing or flight testing of hypersonic vehicles.

Abdelmessih, Amanie N.↗

NASA NTRS1999

Numerical Analysis of Convection/Transpiration Cooling

An innovative concept utilizing the natural porosity of refractory-composite materials and hydrogen coolant to provide CONvective and TRANspiration (CONTRAN) cooling and oxidation protection has been numerically studied for surfaces exposed to a high heat flux high temperature environment such as hypersonic vehicle engine combustor walls. A boundary layer code and a porous media finite difference code were utilized to analyze the effect of convection and transpiration cooling on surface heat flux and temperature. The boundary layer code determined that transpiration flow is able to provide blocking of the surface heat flux only if it is above a minimum level due to heat addition from combustion of the hydrogen transpirant. The porous media analysis indicated that cooling of the surface is attained with coolant flow rates that are in the same range as those required for blocking, indicating that a coupled analysis would be beneficial.

Glass, David E.↗

NASA NTRS1999

Numerical Analysis of Convection/Transpiration Cooling

An innovative concept utilizing the natural porosity of refractory-composite materials and hydrogen coolant to provide CONvective and TRANspiration (CONTRAN) cooling and oxidation protection has been numerically studied for surfaces exposed to a high heat flux, high temperature environment such as hypersonic vehicle engine combustor walls. A boundary layer code and a porous media finite difference code were utilized to analyze the effect of convection and transpiration cooling on surface heat flux and temperature. The boundary, layer code determined that transpiration flow is able to provide blocking of the surface heat flux only if it is above a minimum level due to heat addition from combustion of the hydrogen transpirant. The porous media analysis indicated that cooling of the surface is attained with coolant flow rates that are in the same range as those required for blocking, indicating that a coupled analysis would be beneficial.

Glass, David E.↗

NASA NTRSDate not supplied

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗

NASA NTRSDate not supplied

Advancement of Novel Additively Manufactured Alloys for Space Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using the laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of these AM-enabled novel alloys, AM processing development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗

NASA NTRSDate not supplied

Advancement of Metal Additive Manufacturing Processes and Alloys for Rocket Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗

NASA NTRSDate not supplied

Metal Additive Manufacturing Developments for Propulsion Applications

Additive Manufacturing↗

NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

NASA NTRS2008

Mobile Lid Convection Beneath Enceladus' South Polar Terrain

Enceladus' south polar region has a large heat flux, 55-110 milliwatts per square meter (or higher), that is spatially associated with cryovolcanic and tectonic activity. Tidal dissipation and vigorous convection in the underlying ice shell are possible sources of heat; however, prior predictions of the heat flux carried by stagnant lid convection range from F(sub conv) ~15 to 30 milliwatts per square meter, too low to explain the observed heat flux. The high heat flux and increased cryovolcanic and tectonic activity suggest that near-surface ice in the region has become rheologically and mechanically weakened enough to permit convective plumes to reach close to the surface. If the yield strength of Enceladus' lithosphere is less than ~1-10 kPa, convection may instead occur in the mobile lid" regime, which is characterized by large heat fluxes and large horizontal velocities in the near-surface ice. I show that model ice shells with effective surface viscosities between 10(exp 16) and 10(exp 17) Pa s and basal viscosities between 10(exp 13) and 10(exp 15) Pa s have convective heat fluxes comparable to that observed by the Cassini Composite Infrared Spectrometer. If this style of convection is occurring, the south polar terrain should be spreading horizontally with v~1-10 millimeter per year and should be resurfaced in ~0.1-10 Ma. On the basis of Cassini imaging data, the south polar terrain is ~0.5 Ma old, consistent with the mobile lid hypothesis. Maxwell viscoelastic tidal dissipation in such ice shells is not capable of generating enough heat to balance convective heat transport. However, tidal heat may also be generated in the near-surface along faults as suggested by Nimmo et al. and/or viscous dissipation within the ice shell may occur by other processes not accounted for by the canonical Maxwell dissipation model.

Barr, Amy C.↗

NASA NTRS2014

Thermal Testing of Woven TPS Materials in Extreme Entry Environments

NASAs future robotic missions to Venus and outer planets, namely, Saturn, Uranus, Neptune, result in extremely high entry conditions that exceed the capabilities of current mid density ablators (PICA or Avcoat). Therefore mission planners assume the use of a fully dense carbon phenolic heatshield similar to what was flown on Pioneer Venus and Galileo. Carbon phenolic (CP) is a robust TPS however its high density and thermal conductivity constrain mission planners to steep entries, high heat fluxes, high pressures and short entry durations, in order for CP to be feasible from a mass perspective. In 2012 the Game Changing Development Program in NASAs Space Technology Mission Directorate funded NASA ARC to investigate the feasibility of a Woven Thermal Protection System to meet the needs of NASAs most challenging entry missions. The high entry conditions pose certification challenges in existing ground based test facilities. Recent updates to NASAs IHF and AEDCs H3 high temperature arcjet test facilities enable higher heatflux (2000 Wcm2) and high pressure (5 atm) testing of TPS. Some recent thermal tests of woven TPS will be discussed in this paper. These upgrades have provided a way to test higher entry conditions of potential outer planet and Venus missions and provided a baseline against carbon phenolic material. The results of these tests have given preliminary insight to sample configuration and physical recession profile characteristics.

TPS↗

NASA NTRS2015

Creep, Fatigue and Fracture Behavior of Environmental Barrier Coating and SiC-SiC Ceramic Matrix Composite Systems: The Role of Environment Effects

Advanced environmental barrier coating (EBC) systems for low emission SiCSiC CMC combustors and turbine airfoils have been developed to meet next generation engine emission and performance goals. This presentation will highlight the developments of NASAs current EBC system technologies for SiC-SiC ceramic matrix composite combustors and turbine airfoils, their performance evaluation and modeling progress towards improving the engine SiCSiC component temperature capability and long-term durability. Our emphasis has also been placed on the fundamental aspects of the EBC-CMC creep and fatigue behaviors, and their interactions with turbine engine oxidizing and moisture environments. The EBC-CMC environmental degradation and failure modes, under various simulated engine testing environments, in particular involving high heat flux, high pressure, high velocity combustion conditions, will be discussed aiming at quantifying the protective coating functions, performance and durability, and in conjunction with damage mechanics and fracture mechanics approaches.

Environmental Barrier Coatings↗

NASA NTRS2016

Environmental Barrier Coating Development for SiC/SiC Ceramic Matrix Composites: Recent Advances and Future Directions

This presentation briefly reviews the SiC/SiC major environmental and environment-fatigue degradations encountered in simulated turbine combustion environments, and thus NASA environmental barrier coating system evolution for protecting the SiC/SiC Ceramic Matrix Composites for meeting the engine performance requirements. The presentation will review several generations of NASA EBC materials systems, EBC-CMC component system technologies for SiC/SiC ceramic matrix composite combustors and turbine airfoils, highlighting the temperature capability and durability improvements in simulated engine high heat flux, high pressure, high velocity, and with mechanical creep and fatigue loading conditions. This paper will also focus on the performance requirements and design considerations of environmental barrier coatings for next generation turbine engine applications. The current development emphasis is placed on advanced NASA candidate environmental barrier coating systems for SiC/SiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. The efforts have been also directed to developing prime-reliant, self-healing 2700F EBC bond coat; and high stability, lower thermal conductivity, and durable EBC top coats. Major technical barriers in developing environmental barrier coating systems, the coating integrations with next generation CMCs having the improved environmental stability, erosion-impact resistance, and long-term fatigue-environment system durability performance will be described. The research and development opportunities for turbine engine environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling will be briefly discussed.

Environmental Barrier Coatings↗

NASA NTRS2016

Advanced Environmental Barrier Coating Development for SiC/SiC Ceramic Matrix Composites: NASA's Perspectives

This presentation reviews NASA environmental barrier coating (EBC) system development programs and the coating materials evolutions for protecting the SiC/SiC Ceramic Matrix Composites in order to meet the next generation engine performance requirements. The presentation focuses on several generations of NASA EBC systems, EBC-CMC component system technologies for SiC/SiC ceramic matrix composite combustors and turbine airfoils, highlighting the temperature capability and durability improvements in simulated engine high heat flux, high pressure, high velocity, and with mechanical creep and fatigue loading conditions. The current EBC development emphasis is placed on advanced NASA 2700F candidate environmental barrier coating systems for SiC/SiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. Major technical barriers in developing environmental barrier coating systems, the coating integrations with next generation CMCs having the improved environmental stability, erosion-impact resistance, and long-term fatigue-environment system durability performance are described. The research and development opportunities for advanced turbine airfoil environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling are discussed.

Ceramic Matrix Composites↗

NASA NTRS1982

Development of advanced high-temperature heat flux sensors

Various configurations of high temperature, heat flux sensors were studied to determine their suitability for use in experimental combustor liners of advanced aircraft gas turbine engines. It was determined that embedded thermocouple sensors, laminated sensors, and Gardon gauge sensors, were the most viable candidates. Sensors of all three types were fabricated, calibrated, and endurance tested. All three types of sensors met the fabricability survivability, and accuracy requirements established for their application.

Atkinson, W. H.↗