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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
DOE OSTI2017

Deposition and post-processing techniques for transparent conductive films

In one embodiment, a method is provided for fabrication of a semitransparent conductive mesh. A first solution having conductive nanowires suspended therein and a second solution having nanoparticles suspended therein are sprayed toward a substrate, the spraying forming a mist. The mist is processed, while on the substrate, to provide a semitransparent conductive material in the form of a mesh having the conductive nanowires and nanoparticles. The nanoparticles are configured and arranged to direct light passing through the mesh. Connections between the nanowires provide conductivity through the mesh.

36 MATERIALS SCIENCE↗
NASA NTRS1985

Fabrication of ceramic substrate-reinforced and free forms by mandrel plasma spraying metal-ceramic composites

Components fabricated of, or coated with, ceramics have lower parasitic cooling requirements. Techniques are discussed for fabricating thin-shell ceramic components and ceramic coatings for applications in rocket or jet engine environments. Thin ceramic shells with complex geometric forms involving convolutions and reentrant surfaces were fabricated by mandrel removal. Mandrel removal was combined with electroplating or plasma spraying and isostatic pressing to form a metal support for the ceramic. Rocket engine thrust chambers coated with 0.08 mm (3 mil) of ZrO2-8Y2O3 had no failures and a tenfold increase in engine life. Some measured mechanical properties of the plasma-sprayed ceramic are presented.

Quentmeyer, R. J.↗
NASA NTRS2012

Pharmaceutical Product Development: Intranasal Scopolamine (INSCOP) Metered Dose Spray

Motion sickness (MS) has been a problem associated with space flight, the modern military and commercial air and water transportation for many years. Clinical studies have shown that scopolamine is the most effective medication for the prevention of motion sickness (Dornhoffer et al, 2004); however, the two most common methods of administration (transdermal and oral) have performance limitations that compromise its utility. Intranasal administration offers a noninvasive treatment modality, and has been shown to counter many of the problems associated with oral and transdermal administration. With the elimination of the first pass effect by the liver, intranasal delivery achieves higher and more reliable bioavailability than an equivalent oral dose. This allows for the potential of enhanced efficacy at a reduced dose, thus minimizing the occurrence of untoward side effects. An Intranasal scopolamine (INSCOP) gel formulation was prepared and tested in four ground-based clinical trials under an active Investigational New Drug (IND) application with the Food and Drug Administration (FDA). Although there were early indicators that the intranasal gel formulation was effective, there were aspects of formulation viscosity and the delivery system that were less desirable. The INSCOP gel formulation has since been reformulated into an aqueous spray dosage form packaged in a precise, metered dose delivery system; thereby enhancing dose uniformity, increased user satisfaction and palatability, and a potentially more rapid onset of action. Recent reports of new therapeutic indications for scopolamine has prompted a wide spread interest in new scopolamine dosage forms. The novel dosage form and delivery system of INSCOP spray shows promise as an effective treatment for motion sickness targeted at the armed forces, spaceflight, and commercial sea, air, and space travel markets, as well as prospective psychotherapy for mental and emotional disorders.

Putcha, Lakshmi↗
NASA NTRS1990

Effects of turbulence mixing, variable properties, and vaporization on spray droplet combustion

Combustion of liquid fuels in the form of spray droplets is simulated numerically. Various vaporization models are examined as to their performance in finite element calculations involving a turbulent flow field. The Eulerian coordinate for the gas and Lagrangian coordinate for the liquid spray droplets are coupled through source terms being updated in the equations of continuity, momentum, and energy. The k-epsilon and modified eddy breakup models are used for simulating turbulent spray combustion flow field. Numerical results for the droplet trajectories, droplet heating, recirculation characteristics, and effects of evaporation models are evaluated. It is also shown that the finite element method is advantageous in dealing with complex geometries, complex boundary conditions, adaptive unstructured grids.

Kim, Y. M.↗
NASA NTRS2004

Composite-Material Tanks with Chemically Resistant Liners

Lightweight composite-material tanks with chemically resistant liners have been developed for storage of chemically reactive and/or unstable fluids . especially hydrogen peroxide. These tanks are similar, in some respects, to the ones described in gLightweight Composite-Material Tanks for Cryogenic Liquids h (MFS-31379), NASA Tech Briefs, Vol. 25, No. 1 (January, 2001), page 58; however, the present tanks are fabricated by a different procedure and they do not incorporate insulation that would be needed to prevent boil-off of cryogenic fluids. The manufacture of a tank of this type begins with the fabrication of a reusable multisegmented aluminum mandrel in the shape and size of the desired interior volume. One or more segments of the mandrel can be aluminum bosses that will be incorporated into the tank as end fittings. The mandrel is coated with a mold-release material. The mandrel is then heated to a temperature of about 400 F (approximately equal to 200 C) and coated with a thermoplastic liner material to the desired thickness [typically approxiamtely equal to 15 mils (approximately equal to 0.38 mm)] by thermal spraying. In the thermal-spraying process, the liner material in powder form is sprayed and heated to the melting temperature by a propane torch and the molten particles land on the mandrel. The sprayed liner and mandrel are allowed to cool, then the outer surface of the liner is chemically and/or mechanically etched to enhance bonding of a composite overwrap. The etched liner is wrapped with multiple layers of an epoxy resin reinforced with graphite fibers; the wrapping can be done either by manual application of epoxy-impregnated graphite cloth or by winding of epoxy-impregnated filaments. The entire assembly is heated in an autoclave to cure the epoxy. After the curing process, the multisegmented mandrel is disassembled and removed from inside, leaving the finished tank. If the tank is to be used for storing hydrogen peroxide, then the liner material should be fluorinated ethylene/propylene (FEP), and one or more FEP O ring(s) should be used in the aluminum end fitting(s). This choice of materials is dictated by experimental observations that pure aluminum and FEP are the only materials suitable for long-term storage of hydrogen peroxide and that other materials tend to catalyze the decomposition of hydrogen peroxide to oxygen and water. Other thermoplastic liner materials that are suitable for some applications include nylon 6 and polyethylene. The processing temperatures for nylon 6 are lower than those for FEP. Nylon 6 is compatible with propane, natural gas, and other petroleum-based fuels. Polyethylene is compatible with petroleum- based products and can be used for short-term storage of hydrogen peroxide.

DeLay, Thomas K.↗
DOE OSTI2014

Compression ignition engine having fuel system for non-sooting combustion and method

A direct injection compression ignition internal combustion engine includes a fuel system having a nozzle extending into a cylinder of the engine and a plurality of spray orifices formed in the nozzle. Each of the spray orifices has an inner diameter dimension of about 0.09 mm or less, and define inter-orifice angles between adjacent spray orifice center axes of about 36.degree. or greater such that spray plumes of injected fuel from each of the spray orifices combust within the cylinder according to a non-sooting lifted flame and gas entrainment combustion pattern. Related methodology is also disclosed.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1966

Multilayer refractory nozzles produced by plasma-spray process

Multilayer rocket nozzles formed by plasma spraying have good thermal shock resistance and can be reheated in an oxidizing environment without loss of coating adherence. Suggested application of this process are for the production of refractory components, which can be formed as surfaces of revolution.

Bliton, J. L.↗
DOE OSTI2018

Maintaining Hydrophobic Drug Supersaturation in a Micelle Corona Reservoir

In this work, two poly(N-isopropylacrylamide-co-N,N-dimethylacrylamide) (PND) statistical copolymers and a series of three poly(N-isopropylacrylamide-co-N,N-dimethylacrylamide)- b-polystyrene (PND-b-PS-C12) diblock polymers were synthesized by reversible addition-fragmentation chain transfer (RAFT) polymerization, in which the molecular weight of the thermoresponsive PND corona block was held constant while the polystyrene core block length was varied. The corona thickness and density of the micelles in phosphate-buffered saline (PBS, pH = 6.5) were quantified by a combination of dynamic light scattering (DLS) and small-angle X-ray scattering (SAXS). Two hydrophobic model drugs, phenytoin and nilutamide, were used to examine the drug-polymer interactions in aqueous solution. Intermolecular interactions between the diblock polymer micelle corona and both drugs were revealed by 2D 1H nuclear Overhauser effect spectroscopy (NOESY). The drug-polymer “binding” strength, quantified by diffusion ordered NMR spectroscopy (DOSY), increased as corona density of the diblock polymer micelle increased for both drugs. The in vitro dissolution of the amorphous solid dispersions was systematically investigated as a function of drug type, drug loading, and the solution-state assembly of the polymers by using either a selective or nonselective spray drying solvent. Forming micelles prior to spray drying significantly enhanced phenytoin dissolution and supersaturation maintenance for the diblock polymers by storing the drug molecules in the corona.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Open-air spray deposition of PCBM/BCP electron transport layer for inverted perovskite solar cells

A [6,6]-phenyl C61 butyric acid methyl ester (PCBM) and bathocuproine (BCP) electron transport layer (ETL) is spray deposited in open air directly on top of a perovskite at linear speeds of 9 m/min. The PCBM precursor ink contains a binary mixture of 1:1 chlorobenzene:chloroform, which optimizes spray wettability on the perovskite surface and allows quick solvent evaporation. A near-infrared heating module additionally provides a flash cure (<5 s) for the formation of smooth, large-area PCBM films (∼20 cm 2 ). A BCP solution in isopropanol is subsequently sprayed to form an ultrathin (<5 nm) film and characterized with a suite of high-resolution metrologies. The spray-deposition processing and near-infrared treatment do not damage the underlying perovskite. Inverted architecture devices containing the sprayed ETL achieve a champion efficiency of 20.3% and demonstrate stable performance without additional interlayers or surface treatments. Here, the technoeconomic cost of the open-air spray process is compared against traditional vacuum-based evaporation, resulting in a decrease in manufacturing costs by 26%.

14 SOLAR ENERGY↗
NASA NTRS1985

Fabrication of strain-isolated ceramic coated combustor components

The use of strain-isolated ceramic coated material to produce an AGT1500 combustor scroll-shaped transition duct which requires no air for film cooling is investigated. The scroll receives the exhaust of the can-style combustor liner and turns it into the annular inlet of the high pressure gas producer turbine nozzle. Strain-isolation of plasma sprayed thermal barrier coating is achieved by placing a compliant pad between the structural base metal and the ceramic coating. The compliant pad is brazed to the metal structure. In order to achieve a good braze bond, the strain-isolating compliant pad and base metal must be closely matched in shape and tightly fixtured for joining. The complex geometry of the AGT1500 scroll makes it impractical to attack pads to the supporting structure in its finished shape. Instead the pads are brazed to flat stock and post-formed into scroll sections. While test samples were successfully post-formed, plasma sprayed, and subjected to cyclic heating, the forming of full scale parts by normal methods resulted in tearing of the Hastelloy-X base metal because of embrittlement by the braze material. Several solutions were explored which finally resulted in the successful forming of full scale scroll parts.

Rutter, S.↗
DOE OSTI2022

A numerical framework for simulating the atmospheric variability of supermicron marine biogenic ice nucleating particles

Abstract. We present a framework for estimating concentrations of episodically elevated high-temperature marine ice nucleating particles (INPs) in the sea surface microlayer and their subsequent emission into the atmospheric boundary layer. These episodic INPs have been observed in multiple ship-based and coastal field campaigns, but the processes controlling their ocean concentrations and transfer to the atmosphere are not yet fully understood. We use a combination of empirical constraints and simulation outputs from an Earth system model to explore different hypotheses for explaining the variability of INP concentrations, and the occurrence of episodic INPs, in the marine atmosphere. In our calculations, we examine the following two proposed oceanic sources of high-temperature INPs: heterotrophic bacteria and marine biopolymer aggregates (MBPAs). Furthermore, we assume that the emission of these INPs is determined by the production of supermicron sea spray aerosol formed from jet drops, with an entrainment probability that is described by Poisson statistics. The concentration of jet drops is derived from the number concentration of supermicron sea spray aerosol calculated from model runs. We then derive the resulting number concentrations of marine high-temperature INPs (at 253 K) in the atmospheric boundary layer and compare their variability to atmospheric observations of INP variability. Specifically, we compare against concentrations of episodically occurring high-temperature INPs observed during field campaigns in the Southern Ocean, the Equatorial Pacific, and the North Atlantic. In this case study, we evaluate our framework at 253 K because reliable observational data at this temperature are available across three different ocean regions, but suitable data are sparse at higher temperatures. We find that heterotrophic bacteria and MBPAs acting as INPs provide only a partial explanation for the observed high INP concentrations. We note, however, that there are still substantial knowledge gaps, particularly concerning the identity of the oceanic INPs contributing most frequently to episodic high-temperature INPs, their specific ice nucleation activity, and the enrichment of their concentrations during the sea–air transfer process. Therefore, targeted measurements investigating the composition of these marine INPs and drivers for their emissions are needed, ideally in combination with modeling studies focused on the potential cloud impacts of these high-temperature INPs.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1984

Intermodulation Product Levels in Flame-sprayed Materials

A preliminary investigation on intermodulation product (IMP) levels of fiberglass-backed flame-sprayed surfaces was completed. The purpose was to demonstrate the use of modified techniques and materials in combustion flame spraying of formed surfaces in reducing intermodulation products. The approach used improved metal wire stock without impurities or with smaller droplet sizes, high-temperature release agents, wire stock with low electrical resistance, variations in spraying distances, and intense buffing processes which amalgamate the material gaps and droplets in an effort to fabricate IMP-free lightweight and low cost subreflectors. Positive material candidates were found with an IMP level around -150 dB, which is comparable to solid aluminum surfaces used as a reference.

Yung, C. S.↗
DOE OSTI2026

Comparative Study of Zinc Cold-Spray Coating and Pre-treatments for Magnesium Alloys

Magnesium (Mg) alloys are appealing for automotive lightweighting owing to their high specific strength. However, their susceptibility to corrosion in harsh environments remains a major challenge. Conventional industrial pre-treatment coatings, including zinc phosphate, chromate conversion, and non-chromate conversion, often exhibit discontinuities and microcracks, leading to localized corrosion near fasteners and parting lines. Here, this study investigates cold-sprayed zinc (Zn) coatings as a novel pre-treatment alternative for high-pressure die cast (HPDC) AZ91 Mg alloys, demonstrating significant improvements in wear and corrosion performance. Cold spray produces uniform and robust coatings, reducing wear rate by over 50% and reducing corrosion rate by over 99.3%, as measured by evolved hydrogen release, compared to traditional pre-treatments. Multimodal corrosion testing reveals that Zn cold-spray coatings form a protective layer during exposure, minimizing general and filiform corrosion, and exhibiting corrosion potential (E corr ) that is nobler by ~ 400 mV than the surfaces of both pre-treated and uncoated AZ91. Scalability of cold spray for selective application around multimaterial joints further strengthens their industrial viability. This work establishes Zn cold-spray coatings as highly effective pre-treatment solutions for the advancement of corrosion resistant Mg alloy components in automotive applications.

multimodal corrosion↗
DOE OSTI2015

Synthesis of nanocrystalline Cu{sub 2}ZnSnS{sub 4} thin films grown by the spray-pyrolysis technique

Spray pyrolysis was used to deposit Cu{sub 2}ZnSnS{sub 4} (CZTS) thin films on soda lime glass substrates at 300 °C. Aqueous solutions of copper chloride, zinc chloride, stannous chloride and thiourea were mixed together to form the spray liquid. The sprayed films were annealed under vacuum at 350 °C, 400 °C and 450 °C. Structural and optical characterization was performed on the CZTS films using X-ray diffraction (XRD) and UV-VIS spectrophotometry. XRD results indicate that the films are single phase nanocrystalline CZTS. Optical studies show that the optical gap values are 1.44 eV for the as-grown film and 1.46 eV, 1.48 eV and 1.49 eV for the films annealed at 350 °C, 400 °C and 450 °C, respectively.

36 MATERIALS SCIENCE↗
NASA NTRS1996

The Development of Novel, High-Flux, Heat Transfer Cells for Thermal Control in Microgravity

In order to meet the future needs of thermal management and control in space applications such as the Space Lab, new heat-transfer technology capable of much larger heat fluxes must be developed. To this end, we describe complementary numerical and experimental investigations into the fundamental fluid mechanics and heat-transfer processes involved in a radically new, self contained, heat transfer cell for microgravity applications. In contrast to conventional heat pipes, the heat transfer in this cell is based on a forced droplet evaporation process using a fine spray. The spray is produced by a novel fluidic technology recently developed at Georgia Tech. This technology is based on a vibration induced droplet atomization process. In this technique, a liquid droplet is placed on a flexible membrane and is vibrated normal to itself. When the proper drop size is attained, the droplet resonates with the surface motion of the membrane and almost immediately bursts into a shower of very fine secondary droplets. The small droplets travel to the opposite end of the cell where they impact a heated surface and are evaporated. The vapor returns to the cold end of the cell and condenses to form the large droplets that are fragmented to form the spray. Preliminary estimates show that a heat transfer cell based on this technology would have a heat-flux capacity that is an order of magnitude higher than those of current heat pipes designs used in microgravity applications.

Smith, Marc K.↗
NASA NTRS1978

Evaluation of a locally homogeneous model of spray evaporation

Measurements were conducted on an evaporating spray in a stagnant environment. The spray was formed using an air-atomizing injector to yield a Sauter mean diameter of the order of 30 microns. The region where evaporation occurred extended approximately 1 m from the injector for the test conditions. Profiles of mean velocity, temperature, composition, and drop size distribution, as well as velocity fluctuations and Reynolds stress, were measured. The results are compared with a locally homogeneous two-phase flow model which implies no velocity difference and thermodynamic equilibrium between the phases. The flow was represented by a k-epsilon-g turbulence model employing a clipped Gaussian probability density function for mixture fraction fluctuations. The model provides a good representation of earlier single-phase jet measurements, but generally overestimates the rate of development of the spray. Using the model predictions to represent conditions along the centerline of the spray, drop life-history calculations were conducted which indicate that these discrepancies are due to slip and loss of thermodynamic equilibrium between the phases.

Shearer, A. J.↗
DOE OSTI2015

Mechanical and wear properties of aluminum coating prepared by cold spraying

In this study, aluminum (Al) powders were deposited onto Al substrates using cold spray to form a coating. The main objective is to investigate and compare the microstructure, mechanical and wear properties of Al coating to that of the Al substrate. The microstructure of the coating and substrate were observed using Scanning Electron Microscope (SEM). Hardness was evaluated using the Vickers Hardness test and wear properties were investigated using a pin-on-disk wear test machine. The elemental composition of the coating and substrate was determined using Energy-dispersive X-ray spectroscopy (EDX). Results showed that the friction coefficient and specific wear rate decreased while wear rate increased linearly with increasing load. It was found that the coating exhibit slightly better mechanical and wear properties compared to the substrate.

36 MATERIALS SCIENCE↗