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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 sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Microsample Characterization of Coatings for Grcop-84 for High Heat Flux Applications

A multidisciplinary Johns Hopkins University-NASA Glenn team is undertaking a collaborative research program to elucidate and model the thermal stability and mechanical integrity of candidate coatings for GRCop-84. GRCop-84 is a high conductivity, high strength copper alloy that was recently developed at NASA Glenn for use in high temperature, high heat flux applications. With potential applications in rocket motor combustion chamber liners, nozzle ramps and other actively cooled structures, this new material offers great potential for decreasing weight and increasing reliability of third generation reusable launch vehicles. Current emphasis has turned toward the development of environmentally resistant and thermal barrier coatings for this alloy. Metallic coatings such as NiCrAlY and Cu-8-30%Cr have shown promise in: prohibiting blanching, reducing dog-house failures, increasing operating temperatures and decreasing cooling requirements. The focus of this research program is to develop a fundamental understanding of the substrate-coating interactions that occur during thermal cycling (inter-diffusion, viscoplasticity, morphological evolution, crack formation, etc.) and to derive a science-based protocol for future coating selection, optimization and reliability assurance. The microsample tensile testing approach adopted for this study allows us to characterize small-scale and highly scale-specific coatings and properties in a way not possible by conventional means. In addition to providing much needed design data, the integration of microsample testing with detailed microstructural observations provides a mechanistic foundation for coating optimization and life prediction modeling.

Hemker, Kevin↗
NASA NTRS1997

High heat flux loop heat pipes

Loop heat pipes (LHPs) can transport very large thermal power loads over long distances, through flexible, small diameter tubes against gravitational heads. In order to overcome the evaporator limit of LHPs, which is of about 0.07 MW/sq m, work was carried out to improve the efficiency by threefold to tenfold. The vapor passage geometry for the high heat flux conditions is shown. A bidisperse wick material within the circumferential vapor passages was used. Along with heat flux enhancement, several underlying issues were demonstrated, including the fabrication of bidisperse powder with controlled properties and the fabrication of a device geometry capable of replacing vapor passages with bidisperse powder.

North, Mark T.↗
NASA NTRS1988

Durability of thermal barrier coatings in a high heat flux environment

Thermal shock is a significant factor in the limited service life of Space Shuttle Main Engine (SSME) high pressure, fuel turbopump (HPFTP) turbine blades. Addition of advanced thermal barrier coatings (TBCs) to the blades could serve to dampen the thermal shock, thereby increasing the life of the blades. However, testing and use of TBCs to date is performed primarily under moderate heat flux conditions which are typical of aircraft turbines. Only limited testing was conducted that addresses high heat flux and severe thermal shock conditions. Therefore, it is not clear if TBCs can survive severe thermal shocks or provide adequate thermal shock protection to the HPFTP turbine blades. The purpose is to experimentally evaluate the potential durability and protective capability of a variety of advanced TBCs in a cyclic thermal shock environment. A secondary goal is to identify significant parameters affecting TBC life during high heat flux testing. Parameters investigated include top coat thickness, bond coat thickness, substrate type, and substrate geometry.

Brindley, William J.↗
DOE OSTI2022

Near-field acoustical holography and acoustic power analysis of a simulated, highly heated supersonic jet

Although near-field acoustical holography (NAH) and acoustic intensity analysis have previously been used to investigate the apparent jet noise sources produced by military aircraft, explicit connections to supersonic jet characteristics cannot be made due to a lack of information about the exhaust plume. Here, to begin to bridge this gap and better understand the source information yielded by NAH, the current study instead applies NAH to a virtual measurement of the near-field pressures of a highly heated laboratory-scale supersonic jet generated by large-eddy simulation (LES). The holographic reconstructions of the pressure, particle velocity, and acoustic intensity are found to match the LES-generated acoustic field well and are used to calculate the acoustic power of the jet. The jet's calculated overall acoustic power is compared to the free-stream mechanical power, resulting in an acoustic efficiency of 1.5%. Ray-tracing of the acoustic intensity to the jet centerline generates an axial distribution of the acoustic power origin, showing that almost all the power originates from the supersonic portion of the flow and with the distribution peak upstream of the potential core tip. Holographic reconstruction of the pressures along the nozzle lipline captures the general spectral shape of the LES-generated pressures, though it underestimates the amplitude.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Review of Thermal Contact Resistance of Flexible Graphite Materials for Thermal Interfaces in High Heat Flux Applications

In this report the data is reviewed on thermal contact conductance (TCC) and/or thermal contact resistance (TCR) at material interfaces which employs flexible graphite (FG) materials as thermal interface materials (TIM). FG materials are often used as TIM due to their conforming nature. While the overall TCR can be estimated straightforward from measured data, the interface TCR is much more difficult to obtain. The report also discusses the interfacial thermal contact conductance between FG-tungsten and FG-Glidcop-Al15, which are envisioned for high-heat flux applications.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Thermal Control Utilizing an Thermal Control Utilizing an Two-Phase Loop with High Heat Flux Source

The electric field applied in dielectric fluids causes an imbalance in the dissociation-recombination reaction generated free space charges. The generated charges are redistributed by the applied electric field resulting in the heterocharge layers in the Vicinity of the electrodes. Proper design of the electrodes generates net axial flow motion pumping the fluid. The electrohydrodynamic (EHD) conduction pump is a new device that pumps dielectric fluids utilizing heterocharge layers formed by imposition of electrostatic fields. This paper evaluates the experimental performance of a two-phase breadboard thermal control loop consisting of an EHD conduction pump, condenser, pre-heater, high heat flux evaporator (HE), transport lines, and reservoir (accumulator). The generated pressure head and the maximum applicable heat flux are experimentally determined at various applied voltages and sink temperatures. Recovery from dryout condition by increasing the applied voltage to the pump is also demonstrated.

Jeong, Seong-Il↗
NASA NTRS1988

Thermostructural analysis with experimental verification in a high heat flux facility of a simulated cowl lip

Three-dimensional FEM analyses using the NASTRAN and MARC codes have been used to predict the thermal and structural response of active cooling schemes proposed for a hypersonic vehicle's propulsion system cowl lip under high aerothermodynamic heating loads. In order to experimentally verify these analyses, a hydrogen/oxygen rocket engine has been modified to employ the exhaust stream as a high enthalpy/high heat flux source for the evaluation of various actively cooled, simulated cowl lip segments as well as flat structural segments.

Melis, Matthew E.↗
DOE OSTI2025

Fast-ion-driven Alfvén eigenmodes during ICRF-heated high β p plasmas on EAST

Fast-ion-driven Alfvén eigenmodes (AEs) are observed during ICRF-heated high-β p plasmas on EAST. Multiple high frequency modes are observed for shot 112670 at f TAE1 ~ 145 kHz, δB/B ~ 4 × 10 –4 and f TAE2 ~ 175 kHz, δB/B ~ 1.2 × 10 –5 measured by high-frequency Mirnov coils, at B 0 ~ 2.45 T, I p ~ 350kA, n e ramp-up from 3.5 × 10 19 to 4 × 10 19 m −3 at P ECRH ~ 2 MW, PLHW ~ 2 MW, and P ICRH ~ 2.1 MW. Here, 37 MHz ICRF minority hydrogen heating scheme, located at plasma core, creates fast ion population which drives TAEs unstable from TORIC + SFFPQL. In the experiment, it is observed that the evolution of mode frequency depends on electron density, following the theoretical TAE frequency characteristic $f_{{{\text{th}}}} = V_{{\text{a}}} /(4\pi qR) \propto \sqrt {n_{{\text{e}}} }$. As the electron density increases, the amplitude of the AE mode progressively diminishes. Higher plasma density shortens the fast-ion slowing-down time, reduces the heating efficiency of minority hydrogen, weakens the high-energy tail, and consequently decreases the fast-ion beta. Based on the diagnostic results from the microwave reflectometer and electron cyclotron emission (ECE) diagnostics, the TAE is located within the plasma core, consistent with the narrower core region of the TAE gap observed in the continuous spectrum.

Pan, C. Y. [Chinese Academy of Sciences, Hefei (Ch↗
NASA NTRS1966

Light-intensity modulator withstands high heat fluxes

Mechanism modulates and controls the intensity of luminous radiation in light beams associated with high-intensity heat flux. This modulator incorporates two fluid-cooled, externally grooved, contracting metal cylinders which when rotated about their longitudinal axes present a circular aperture of varying size depending on the degree of rotation.

Maples, H. G.↗
NASA NTRS1994

Hypersonic Engine Leading Edge Experiments in a High Heat Flux, Supersonic Flow Environment

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding the sustained high thermal loads expected during hypersonic flight. Three aerothermal load related concerns are the boundary layer transition from laminar to turbulent flow, articulating panel seals in high temperature environments, and strut (or cowl) leading edges with shock-on-shock interactions. A multidisciplinary approach is required to address these technical concerns. A hydrogen/oxygen rocket engine heat source has been developed at the NASA Lewis Research Center as one element in a series of facilities at national laboratories designed to experimentally evaluate the heat transfer and structural response of the strut (or cowl) leading edge. A recent experimental program conducted in this facility is discussed and related to cooling technology capability. The specific objective of the experiment discussed is to evaluate the erosion and oxidation characteristics of a coating on a cowl leading edge (or strut leading edge) in a supersonic, high heat flux environment. Heat transfer analyses of a similar leading edge concept cooled with gaseous hydrogen is included to demonstrate the complexity of the problem resulting from plastic deformation of the structures. Macro-photographic data from a coated leading edge model show progressive degradation over several thermal cycles at aerothermal conditions representative of high Mach number flight.

Gladden, Herbert J.↗
NASA NTRS1989

Thermal modelling of various thermal barrier coatings in a high heat flux rocket engine

Traditional Air Plasma Sprayed (APS) ZrO2-Y2O3 Thermal Barrier Coatings (TBC's) and Low Pressure Plasma Sprayed (LPPS) ZrO2-Y2O3/Ni-Cr-Al-Y cermet coatings were tested in a H2/O2 rocked engine. The traditional ZrO2-Y2O3 (TBC's) showed considerable metal temperature reductions during testing in the hydrogen-rich environment. A thermal model was developed to predict the thermal response of the tubes with the various coatings. Good agreement was observed between predicted temperatures and measured temperatures at the inner wall of the tube and in the metal near the coating/metal interface. The thermal model was also used to examine the effect of the differences in the reported values of the thermal conductivity of plasma sprayed ZrO2-Y2O3 ceramic coatings, the effect of 100 micron (0.004 in.) thick metallic bond coat, the effect of tangential heat transfer around the tube, and the effect or radiation from the surface of the ceramic coating. It was shown that for the short duration testing in the rocket engine, the most important of these considerations was the effect of the uncertainty in the thermal conductivity of temperatures (greater than 100 C) predicted in the tube. The thermal model was also used to predict the thermal response of the coated rod in order to quantify the difference in the metal temperatures between the two substrate geometries and to explain the previously-observed increased life of coatings on rods over that on tubes. A thermal model was also developed to predict heat transfer to the leading edge of High Pressure Fuel Turbopump (HPFTP) blades during start-up of the space shuttle main engines. The ability of various TBC's to reduce metal temperatures during the two thermal excursions occurring on start-up was predicted. Temperature reductions of 150 to 470 C were predicted for 165 micron (0.0065 in.) coatings for the greater of the two thermal excursions.

Nesbitt, James A.↗
NASA NTRS2005

GRCop-84: A High-Temperature Copper Alloy for High-Heat-Flux Applications

GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) is a new high-temperature copper-based alloy. It possesses excellent high-temperature strength, creep resistance and low-cycle fatigue up to 700 C (1292 F) along with low thermal expansion and good conductivity. GRCop-84 can be processed and joined by a variety of methods such as extrusion, rolling, bending, stamping, brazing, friction stir welding, and electron beam welding. Considerable mechanical property data has been generated for as-produced material and following simulated braze cycles. The data shows that the alloy is extremely stable during thermal exposures. This paper reviews the major GRCop-84 mechanical and thermophysical properties and compares them to literature values for a variety of other high-temperature copper-based alloys.

Ellis, David L.↗
NASA NTRS2013

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗
DOE OSTI2020

Morphological and nanomechanical changes in tungsten in high heat flux conditions

Abstract Morphological and nanomechanical alteration of tungsten in extreme environments, like those in edge localized modes in nuclear fusion environments, up to 46.3 GWm −2 heat fluxes were experimentally simulated using electrothermal plasma. Surface and subsurface damage to the tungsten is seen mainly in the form of pore formation, cracks, and resolidified melt instabilities. Mirco voids, rosette-type microfeatures, core-shell structure, particle enrichment, and submicron channels all manifest in the damaged subsurface. The formation of voids in the subsurface was determined to originate from the ductile fracture of hot tungsten by plastic flow but not developed to cracking. The voids were preferentially settled in grain boundaries, interfaces. The directionality of elongated voids and grains is biased to the heat flow vector or plasma pathway, which is the likely consequence of the thermally driven grain growth and sliding in the high-temperature conditions. The presence of a border between the transient layer and heat-affected zone is observed and attributed to plasma shock and thermal spallation of fractural tungsten at high temperature. Plasma peening-like hardening effects in tungsten were observed in the range of 22.7–46.3 GWm −2 but least in the case of the lowest heat flux, 12.5 GWm −2 .

36 MATERIALS SCIENCE↗
DOE OSTI2023

Development and modeling for a small-scale, rapidly heated high explosives initiation time (HEIT) experiment

Most small-scale assessments of explosive sensitivity, including the popular drop-weight impact test, convolute thermal and mechanical phenomena to the extent that it has been extremely challenging to decipher how an explosive ignites and propagates reactions. For instance, an impact generates heat through a range of dissipation mechanisms, which can in turn, depending on the reaction rates of the explosive, lead to chemical decomposition. To deconvolute the various contributions to the sub-shock initiation and propagation of explosive reactions, we describe the development and modeling of the High Explosives Initiation Time (HEIT) test - a new, small-scale, high-throughput experiment designed to rapidly heat milligram quantities of energetic materials confined within small diameter steel needles. Specifically, we have modeled and designed a 250 joule pulsed power system capable of rapidly delivering electrical current to the needles, resulting in rapid heat delivery to the sample. In conclusion, the energy deposition rate into the sample is controlled by different transmission line topologies. Modeling in COMSOL is performed to understand the energy required to heat up the explosive sample.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Development of Readily Available & Robust High Heat Flux Gardon Gauges

Concentrated solar power (CSP) technologies deliver concentrated solar energy as a heat source to industrial processes, power generation cycles, and chemical cycles. CSP systems require accurate and reliable high flux measurements, and next generation CSP systems will require flux measurement up to 1000 W/cm2. Existing flux measurement devices do not comprehensively meet the flux rating, cycle life, cost, and lead-time needs of stakeholders, necessitating the development of an improved flux sensor. In this study, Sandia National Laboratories (SNL) partnered with Hukseflux Thermal Sensors to develop a low-cost, short lead-time, and robust flux sensor rated to 250 W/cm2. Three prototype circular foil gauge designs were assessed for performance at the National Solar Thermal Test Facility (NSTTF) at SNL. Each gauge design measured flux up to 250 W/cm2 with <5% measurement error. Following baseline error quantification, gauges were exposed to flux above 500 W/cm2 to assess gauge failure mechanisms. Gauges physically survived >500 W/cm2 flux exposure, but measurement error was found to increase after foil coatings reached 400 °C. The results of this study suggest that coating optical properties change at excessive temperatures and that foil coating temperature, rather than heat flux level, dictates the acceptable gauge measurement range.

McLaughlin, Luke (ORCID:0000000303711310)↗