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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Alternate cathodes for sodium-metal chloride batteries

Various metal chlorides were tested as possible cathode materials for sodium-metal batteries (in addition to Fe and Ni chlorides, which have been already developed to a stage of commercialization), using an electrochemical cell consisting of a pyrex tube, heated to 250 C, with the metal wire as working electrode, concentric Ni foil as counterelectrode, and high-purity Al as reference electrode. In particular, the aim of this study was to identify metal chlorides insoluble even in neutral melts, possible at the interface during overcharge, in order to eliminate the failure mode of the cell through a cationic exchange of the dissolved metal ions with sodium beta-double-prime alumina solid electrolyte. Results indicate that Mo and Co are likely alternatives to FeCl2 and NiCl2 cathodes in sodium batteries. The open circuit voltages of Na/CoCl(x) and Na/MoCl(x) cells at 250 C would be 2.55 V and 2.64 V, respectively.

Ratnakumar, B. V.↗
NASA NTRS2008

New Materials for the Repair of Polyimide Electrical Wire Insulation

Two viable polyimide backbone materials have been identified that will allow the repair of polyimide electrical wire insulation found on the Space Shuttle and other aging aircraft. This identification is the outcome of ongoing efforts to assess the viability of using such polyimides and polyimide precursors (polyamic acids [PAAs]) as repair materials for aging polyimide electrical wire insulation. These repair materials were selected because they match the chemical makeup of the underlying wire insulation as closely as possible. This similarity allows for maximum compatibility, coupled with the outstanding physical properties of polyimides. The two polyimide backbone materials allow the polymer to be extremely flexible and to melt at low temperatures. A polymer chain end capping group that allows the polymer to crosslink into a nonflowable repair upon curing at around 200 C was also identified.

Source record↗
NASA NTRSDate not supplied

Thermally Conductive Melt-Processable Polyimide HBN Micro-Composites for High Temperature Electrical Insulation Applications

Thermoplastic polymers exhibit excellent dielectric properties and manufacturing robustness. These properties mark thermoplastics as competitive material candidates for electrical insulation applications. However, the high-temperature performance of most thermoplastics is insufficient to meet the electrical wiring requirements for next-generation air and space transportation engineering designs, with continuous operation temperature requirements of up to 200 °C among other design requirements. Furthermore, the low thermal conductivity (κ) of polymers as a material class leads to heat trapping within wires which can amplify thermal stresses. As a result, there is a need to investigate candidate thermoplastic systems for their high temperature, dielectric, and κ performance.

polyimide↗
NASA NTRS2021

Acoustic Communication in Deep Ice at Ocean Worlds

One of NASA priorities is the in-situ exploration of ocean worlds in the solar system where potentially there might be life under the ice shell. This requires reaching the ocean below extremely cold through significant deep ice. Jupiter’s moon, Europa, is such a challenging body, where it is estimated to have a 40 km thick ice shell. An approach for reaching the ocean has been conceived using a melting probe Cryobot concept that has been studied for a potential future mission. A lander is assumed to be the platform from which the Cryobot would be deployed. The ice penetrating vehicle concept consists of a cylindrical, narrow-body probe that encases a radioisotope heat/power source that would be used to do the penetration by melting through the icy crust. The baseline design of the probe includes a suite of science instruments to analyze the ice during descent and the liquid ocean underneath. For communication, a set of fiber optic wire as well as wireless RF in the very cold porous top layer is assumed, and then acoustic modules would be used for the communication in warmer denser ice over distance of 25 km between the modules. In addition to the acoustic communication modules, a sonar is part of the concept, for obstacle avoidance. The focus of this paper is on the use of elastic waves in the 1kHz range.

Lih, Shyh-Shiuh↗
NASA NTRS2002

Transient Torque Technique for Viscosity and Electrical Conductivity Determination of Semiconducting Liquids

A novel apparatus based on transient torque technique is constructed in MSFC/NASA. The apparatus uses a 125um diameter quartz fiber as torsion wire. A high sensitive angular detector is implemented to measure the deflection angle of the crucible containing the liquid. A rotating magnetic field (RMF) is used to induce a rotating flow of a conducting or semiconducting melts. By measuring the magnitude and transient behavior of the induced deflection angle, the electrical conductivity and viscosity of the melt can be measured simultaneously. High purity elements namely Hg, Ga, Zn and Te are tested at room temperature and high temperature up to 900 C.

Li, C.↗
NASA NTRS1997

A Laboratory Study on the Phase Transition for Polar Stratospheric Cloud Particles

The nucleation and growth of different phases of simulated polar stratospheric cloud (PSC) particles were investigated in the laboratory. Solutions and mixtures of solutions at concentrations 1 to 5 m (molality) of ammonium sulfate, ammonium bisulfate, sodium chloride, sulfuric acid, and nitric acid were supercooled to prescribed temperatures below their equilibrium melting point. These solutions were contained in small diameter glass tubing of volumes ranging from 2.6 to 0.04 ml. Samples were nucleated by insertion of an ice crystal, or in some cases by a liquid nitrogen cooled wire. Crystallization velocities were determined by timing the crystal growth front passages along the glass tubing. Solution mixtures containing aircraft exhaust (soot) were also examined. Crystallization rates increased as deltaT2, where deltaT is the supercooling for weak solutions (2 m or less). The higher concentrated solutions (greater than 3 m) showed rates significantly less than deltaT2. This reduced rate suggested an onset of a glass phase. Results were applied to the nucleation of highly concentrated solutions at various stages of polar stratospheric cloud development within the polar stratosphere.

Teets, Edward H., Jr.↗
NASA NTRS1991

Permanent wire splicing by an explosive joining process

The invention is an apparatus and method for wire splicing using an explosive joining process. The apparatus consists of a prebent, U-shaped strap of metal that slides over prepositioned wires. A standoff means separates the wires from the strap before joining. An adhesive means holds two ribbon explosives in position centered over the U-shaped strap. A detonating means connects to the ribbon explosives. The process involves spreading strands of each wire to be joined into a flat plane. The process then requires alternating each strand in alignment to form a mesh-like arrangement with an overlapped area. The strap slides over the strands of the wires, and the standoff means is positioned between the two surfaces. The detonating means then initiates the ribbon explosives that drive the strap to accomplish a high velocity, angular collision between the mating surfaces. This collision creates surface melts and collision bonding results in electron sharing linkups.

Bement, Laurence J.↗
NASA NTRS1997

Explosive Spot Joining of Metals

The invention is an apparatus and method for wire splicing using an explosive joining process. The apparatus consists of a prebend, U-shaped strap of metal that slides over prepositioned wires. A standoff means separates the wires from the strap before joining. An adhesive means holds two ribbon explosives in position centered over the U-shaped strap. A detonating means connects to the ribbon explosives. The process involves spreading strands of each wire to be joined into a flat plane. The process then requires alternating each strand in alignment to form a mesh-like arrangement with an overlapped area. The strap slides over the strands of the wires. and the standoff means is positioned between the two surfaces. The detonating means then initiates the ribbon explosives that drive the strap to accomplish a high velocity. angular collision between the mating surfaces. This collision creates surface melts and collision bonding resulting in electron-sharing linkups.

Bement, Laurence J.↗
NASA NTRS1982

Vacuum tight quartz ampoule for Bridgman growth of crystals with interface demarcation

A growth ampoule for protecting the furnace lining and to prevent a change in the composition of the melt during growth of Pb-T-Te or Ge semiconductors doped with Ga is described. Mo foil is inserted into a quartz tube and sealed at the ends. A vacuum pumping system collapses the tube onto the foil. Spotwelded Mo wires lead in two directions from the collapsed section through quartz capillaries, one of which is also collapsed, on the wire, which provides a contact point for seeded growth of the semiconductor. The ampoule has been used for Bridgeman growth of crystals using a hot zone of 1150 C, with a temperature gradient of 240 C/m, and with current pulses up to 40 A/sq cm.

Crouch, R. K.↗
NASA NTRS2004

Lunar Contour Crafting: A Novel Technique for ISRU-Based Habitat Development

As the nation prepares to return to the Moon, it is apparent that the viability of long duration visits with appropriate radiation shielding/crew protection, hinges on the development of Lunar structures, preferably in advance of a manned landing, and preferably utilizing in-situ resources. Contour Crafting is a USC-patented technique for automated development of terrestrial concrete-based structures. The process is relatively fast, completely automated, and supports the incorporation of various infrastructure elements such as plumbing and electrical wiring. This paper will present a conceptual design of a Lunar Contour Crafting system designed to autonomously fabricate integrated structures on the Lunar surface using high-strength concrete based on Lunar regolith, including glass reinforcement rods or fibers fabricated from melted regolith. Design concepts will be presented, as well as results of initial tests aimed at concrete and glass production using Lunar regolith simulant. Key issues and concerns will be presented, along with design concepts for an LCC testbed to be developed at MSFC's Prototype Development Laboratory (PDL).

Khoshnevis, Behrokh↗
NASA NTRS2015

Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗
NASA NTRS1981

Analysis of SPAR 8 single-axis levitation experiment

The melting and resolidification of SPAR 8 payload melting and resolidification of a glass specimen from the in a containerless condition and the retrieval and examination of the specimen from the. The absence of container contact was assured by use of a single-axis acoustic levitation system. However, the sample contacted a wire cage after being held without container contact by the acoustic field for only approximately 87 seconds. At this time, the sample was still molten and, therefore, flowed aroung the wire and continued to adhere to it. An analysis of why the sample did not remain levitated free of container contact is presented. The experiment is described, and experimental observations are discussed and analyzed.

Rush, J. E.↗
NASA NTRS1993

Improvement of persistent magnetic field trapping in bulk Y-Ba-Cu-O superconductors

For type-II superconductors, magnetic field can be trapped due to persistent internal supercurrent. Quasi-persistent magnetic fields near 2 T at 60 K (and 1.4 T at 77 K) have been measured in minimagnets made of proton-irradiated melt-textured Y-Ba-Cu-O (MT-Y123) samples. Using the trapping effect, high-field permanent magnets with dipole, quadrupole, or more complicated configurations can be made of existing MT-Y123 material, thus bypassing the need for high-temperature superconductor (HTS) wires. A phenomenological current model has been developed to account for the trapped field intensity and profile in HTS samples. This model is also a guide to select directions of materials development to further improve field trapping properties. General properties such as magnetic field intensities, spatial distributions, stabilities, and temperature dependence of trapped field are discussed.

Chen, In-Gann↗
NASA NTRSDate not supplied

Metal Extraction Lunar Technology from Carbothermal Reduction (MELT-CR)

Large metallic infrastructure components on the Moon are currently cost prohibitive due to the expense of transporting mass to the lunar surface. Astrobotic has quoted upwards of $1.2 million dollars per kilogram of payload to the surface. Advantageously, however, aluminum is present in great quantities as aluminum silicates on the lunar surface. And because aluminum is ductile, highly conductive, and amendable for advanced manufacturing processes such as wire fed directed energy deposition (DED), if it can be refined from regolith, its utilization can enable cost-effective, on-surface manufacturing of metallic infrastructure. The goal of project is to develop the core processes and technologies to extract aluminum from Lunar regolith and refine it into wire feedstock from a carbothermic reduction process.

ISRU↗
NASA NTRS2014

Behavior of Particle Depots in Molten Silicon During Float-Zone Growth in Strong Static Magnetic Fields

In the photovoltaics industry, the largest market share is represented by solar cells made from multicrystalline silicon, which is grown by directional solidification. During the growth process, the silicon melt is in contact with the silicon nitride coated crucible walls and the furnace atmosphere which contains carbon monoxide. The dissolution of the crucible coating, the carbon bearing gas, and the carbon already present in the feedstock, lead to the precipitation of silicon carbide, and silicon nitride, at later stages of the growth process. The precipitation of Si3N4 and SiC particles of up to several hundred micrometers in diameter leads to severe problems during the wire sawing process for wafering the ingots. Furthermore the growth of the silicon grains can be negatively influenced by the presence of particles, which act as nucleation sources and lead to a grit structure of small grains and are sources for dislocations. If doped with Nitrogen from the dissolved crucible coating, SiC is a semi conductive material, and can act as a shunt, short circuiting parts of the solar cell. For these reasons, the incorporation of such particles needs to be avoided. In this contribution we performed model experiments in which the transport of intentionally added SiC particles and their interaction with the solid-liquid interface during float zone growth of silicon in strong steady magnetic fields was investigated. SiC particles of 7μm and 60μm size are placed in single crystal silicon [100] and [111] rods of 8mm diameter. This is achieved by drilling a hole of 2mm diameter, filling in the particles and closing the hole by melting the surface of the rod until a film of silicon covers the hole. The samples are processed under a vacuum of 1x10(exp -5) mbar or better, to prevent gas inclusions. An oxide layer to suppress Marangoni convection is applied by wet oxidation. Experiments without and with static magnetic field are carried out to investigate the influence of melt convection on the distribution of particles and their incorporation into the crystal. The field strengths applied by a superconducting magnet are 1T, 3T, 4.5T, and 5T. The increase in field strength dampens the melt flow, and so this study provides comparative data to the crystal growth experiment to be carried out onboard the sounding rocket mission TEXUS 51, where purely diffusive growth condition will be achieved under microgravity conditions.

Jauss, T.↗
NASA NTRS1981

Computer program for pulsed thermocouples with corrections for radiation effects

A pulsed thermocouple was used for measuring gas temperatures above the melting point of common thermocouples. This was done by allowing the thermocouple to heat until it approaches its melting point and then turning on the protective cooling gas. This method required a computer to extrapolate the thermocouple data to the higher gas temperatures. A method that includes the effect of radiation in the extrapolation is described. Computations of gas temperature are provided, along with the estimate of the final thermocouple wire temperature. Results from tests on high temperature combustor research rigs are presented.

Will, H. A.↗
NASA NTRS2018

Conductivity of a Copper-Carbon Covetic Composite

NASA is currently engaged in the development of highly electrically conductive wire for space and aviation power and propulsion applications. Higher levels of electrical conductivity and lower densities compared to copper and aluminum are needed to improve the efficiency of commercial aviation and space flight. Carbon, in various forms, is being considered as a component in composites to increase conductivity and decrease density in Cu and Al. One form of carbon that is currently receiving much interest is known as covectic. The technology currently known as covetics was first introduced by Shugart and Scherer whose patents claimed "Carbon can be incorporated into any of these metals by melting the metal, mixing the carbon into the molten metal and, while mixing, applying a current of sufficient amperage to the molten mixture such that the carbon becomes incorporated into the metal, thereby forming a single phase metal-carbon material." It is reported that in this process a conversion reaction occurs with the carbon forming covalent bonds with the host metal, and that covetic processing enables higher carbon solubility and improvements in properties. Although there is a growing body of work supporting covetic materials, it is still a very new and somewhat controversial field. Composition, density, and electrical conductivity measurements of a covetically processed alloy ingot of Cu and C, with a nominal composition of Cu-0.4wt.% C, were made. A pure Cu ingot was similarly processed for comparison. Sections of these ingots were worked into wire and tested. Only small amounts of C could be detected in the Cu-0.4wt.% C ingot, and trace amounts (0.006 wt.%) in the wire. All wires had densities very close to the full density of pure Cu, indicating a high level of Cu purity and low void fraction. Finally, the electrical conductivity of the Cu-0.4wt.% C wires were 9% lower than the samples similarly processed but without C additions. The wires made without C additions had conductivities approximately equal to pure Cu. The low conductivity of the Cu-0.4wt.% C material is believed to be due to: (1) a structure of interfaces in the wire created by collapsed voids lined with elemental C, (2) impurities, such as Fe in the Cu, which came from the added C, and (3) a small volume fraction of voids.

Degroh, Henry C.↗
NASA NTRS1997

Test Report - Fault Current Through Graphite Filament Reinforced Plastic

Tests were performed to determine the damage to samples of composite material when a current carrying wire is shorted to the surface of the composite material, and to determine whether enough current can flow through the material to blow a fuse before damage can occur. Fault current tests were performed on samples of graphite epoxy materials. Samples consisted of six layers of IM7 graphite fiber mat in Hercules 8552 epoxy resin. A variable power supply provided up to 35 amps of current. The high voltage side of the power supply was attached to a wire at the end of a hinged arm, and the low side was attached to the edge of the sample. To test joints, the return was connected to the edge of one sample, and the high side was shorted to the top of the other sample. Tests show that when current exceeds approximately 5 amps, the graphite glows, and the epoxy melts out at the shorted contact. At higher current levels the epoxy burns. At voltages above 15 volts the epoxy outer coat is easily broken, and fire, flame, and a rise in current occur suddenly. When joints are introduced, resistance is increased, and the maximum current resulting from a short circuit to the graphite epoxy is reduced. This condition can easily result in fault current lower than the circuit breaker limit and higher than the 5 amp ignition level. The shorting contact and the joint become hot spots with melting epoxy, smoke, and fire.

Evans, R. W.↗