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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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NASA NTRS2010

Economical Fabrication of Thick-Section Ceramic Matrix Composites

A method was developed for producing thick-section [>2 in. (approx.5 cm)], continuous fiber-reinforced ceramic matrix composites (CMCs). Ultramet-modified fiber interface coating and melt infiltration processing, developed previously for thin-section components, were used for the fabrication of CMCs that were an order of magnitude greater in thickness [up to 2.5 in. (approx.6.4 cm)]. Melt processing first involves infiltration of a fiber preform with the desired interface coating, and then with carbon to partially densify the preform. A molten refractory metal is then infiltrated and reacts with the excess carbon to form the carbide matrix without damaging the fiber reinforcement. Infiltration occurs from the inside out as the molten metal fills virtually all the available void space. Densification to <5 vol% porosity is a one-step process requiring no intermediate machining steps. The melt infiltration method requires no external pressure. This prevents over-infiltration of the outer surface plies, which can lead to excessive residual porosity in the center of the part. However, processing of thick-section components required modification of the conventional process conditions, and the means by which the large amount of molten metal is introduced into the fiber preform. Modification of the low-temperature, ultraviolet-enhanced chemical vapor deposition process used to apply interface coatings to the fiber preform was also required to accommodate the high preform thickness. The thick-section CMC processing developed in this work proved to be invaluable for component development, fabrication, and testing in two complementary efforts. In a project for the Army, involving SiC/SiC blisk development, nominally 0.8 in. thick x 8 in. diameter (approx. 2 cm thick x 20 cm diameter) components were successfully infiltrated. Blisk hubs were machined using diamond-embedded cutting tools and successfully spin-tested. Good ply uniformity and extremely low residual porosity (<2 percent) were achieved, the latter being far lower than that achieved with SiC matrix composites fabricated via CVI or PIP. The pyrolytic carbon/zirconium nitride interface coating optimized in this work for use on carbon fibers was incorporated in the SiC/SiC composites and yielded a >41 ksi (approx. 283 MPa) flexural strength.

Babcock, Jason↗
NASA NTRS1985

A review of fracture mechanics life technology

Current lifetime prediction technology for structural components subjected to cyclic loads was reviewed. The central objectives of the project were to report the current state of and recommend future development of fracture mechanics-based analytical tools for modeling and forecasting subcritical fatigue crack growth in structures. Of special interest to NASA was the ability to apply these tools to practical engineering problems and the developmental steps necessary to bring vital technologies to this stage. A survey of published literature and numerous discussions with experts in the field of fracture mechanics life technology were conducted. One of the key points made is that fracture mechanics analyses of crack growth often involve consideration of fatigue and fracture under extreme conditions. Therefore, inaccuracies in predicting component lifetime will be dominated by inaccuracies in environment and fatigue crack growth relations, stress intensity factor solutions, and methods used to model given loads and stresses. Suggestions made for reducing these inaccuracies include: development of improved models of subcritical crack growth, research efforts aimed at better characterizing residual and assembly stresses that can be introduced during fabrication, and more widespread and uniform use of the best existing methods.

Thomas, J. M.↗
NASA NTRS1986

A review of fracture mechanics life technology

Lifetime prediction technology for structural components subjected to cyclic loads is examined. The central objectives of the project are: (1) to report the current state of the art, and (2) recommend future development of fracture mechanics-based analytical tools for modeling subcritical fatigue crack growth in structures. Of special interest is the ability to apply these tools to practical engineering problems and the developmental steps necessary to bring vital technologies to this stage. The authors conducted a survey of published literature and numerous discussions with experts in the field of fracture mechanics life technology. One of the key points made is that fracture mechanics analyses of crack growth often involve consideration of fatigue and fracture under extreme conditions. Therefore, inaccuracies in predicting component lifetime will be dominated by inaccuracies in environment and fatigue crack growth relations, stress intensity factor solutions, and methods used to model given loads and stresses. Suggestions made for reducing these inaccuracies include development of improved models of subcritical crack growth, research efforts aimed at better characterizing residual and assembly stresses that can be introduced during fabrication, and more widespread and uniform use of the best existing methods.

Besuner, P. M.↗
NASA NTRS1999

Interaction of Burning Metal Particles

Physical characteristics of the combustion of metal particle groups have been addressed in this research. The combustion behavior and interaction effects of multiple metal particles has been studied using a microgravity environment, which presents a unique opportunity to create an "aerosol" consisting of relatively large particles, i.e., 50-300 m diameter. Combustion behavior of such an aerosol could be examined using methods adopted from well-developed single particle combustion research. The experiment included fluidizing relatively large (order of 100 m diameter) uniform metal particles under microgravity and igniting such an "aerosol" using a hot wire igniter. The flame propagation and details of individual particle combustion and particle interaction have been studied using a high speed movie and video-imaging with cameras coupled with microscope lenses to resolve individual particles. Interference filters were used to separate characteristic metal and metal oxide radiation bands from the thermal black body radiation. Recorded flame images were digitized and various image processing techniques including flame position tracking, color separation, and pixel by pixel image comparison were employed to understand the processes occurring in the burning aerosol. The development of individual particle flames, merging or separation, and extinguishment as well as induced particle motion have been analyzed to identify the mechanisms governing these processes. Size distribution, morphology, and elemental compositions of combustion products were characterized and used to link the observed in this project aerosol combustion phenomena with the recently expanded mechanism of single metal particle combustion.

Dreizin, Edward L.↗
NASA NTRS1966

Orbital tube flare for tubing connectors

Marshall engineering personnel have developed and are now refining a new and unique method of mechanically flaring tubing. The system eliminates the use of the conventional split backing die which is used with most tube-flaring equipment. The Marshall-developed tool is adapted for use on standard Leonard 3-CP-HD flaring machines. The stationary split backing die is replaced in function with a die ring, whose i.d.-surface rolls or orbits around the o.d. of the tube flare zone. An i.d.-flaring cone moves axially and forces the metal against the rolling die to form the flare. Major advantages of this system are the elimination of flash, or split die marks, on the back angle of the flare, and improved flare-surface finishes, permitting more uniform sealing characteristics and improvements of the total geometric configuration of the flare as required by the MSFC specification MC-146. The Orbital Adapter system of tooling is currently being used to manufacture flared tube hardware for the Saturn V S-IO space launch vehicle at MSFC, for the Agena space launch vehicle (used for the Gemini project) at Lockheed, Sunnyvale, for LEM checkout equipment for Grumman, and for the Saturn S-IV-B space launch vehicle by Douglas Aircraft Company. Several other aerospace firms are evaluating the system for possible incorporation on their tube flaring requirements. Marshall engineers are now concentrating their efforts on refining and reducing the total cost of the overall system.

Tubing↗
NASA NTRS1990

A general-purpose development environment for intelligent computer-aided training systems

Space station training will be a major task, requiring the creation of large numbers of simulation-based training systems for crew, flight controllers, and ground-based support personnel. Given the long duration of space station missions and the large number of activities supported by the space station, the extension of space shuttle training methods to space station training may prove to be impractical. The application of artificial intelligence technology to simulation training can provide the ability to deliver individualized training to large numbers of personnel in a distributed workstation environment. The principal objective of this project is the creation of a software development environment which can be used to build intelligent training systems for procedural tasks associated with the operation of the space station. Current NASA Johnson Space Center projects and joint projects with other NASA operational centers will result in specific training systems for existing space shuttle crew, ground support personnel, and flight controller tasks. Concurrently with the creation of these systems, a general-purpose development environment for intelligent computer-aided training systems will be built. Such an environment would permit the rapid production, delivery, and evolution of training systems for space station crew, flight controllers, and other support personnel. The widespread use of such systems will serve to preserve task and training expertise, support the training of many personnel in a distributed manner, and ensure the uniformity and verifiability of training experiences. As a result, significant reductions in training costs can be realized while safety and the probability of mission success can be enhanced.

Savely, Robert T.↗
NASA NTRS2010

26th Space Simulation Conference Proceedings. Environmental Testing: The Path Forward

Topics covered include: A Multifunctional Space Environment Simulation Facility for Accelerated Spacecraft Materials Testing; Exposure of Spacecraft Surface Coatings in a Simulated GEO Radiation Environment; Gravity-Offloading System for Large-Displacement Ground Testing of Spacecraft Mechanisms; Microscopic Shutters Controlled by cRIO in Sounding Rocket; Application of a Physics-Based Stabilization Criterion to Flight System Thermal Testing; Upgrade of a Thermal Vacuum Chamber for 20 Kelvin Operations; A New Approach to Improve the Uniformity of Solar Simulator; A Perfect Space Simulation Storm; A Planetary Environmental Simulator/Test Facility; Collimation Mirror Segment Refurbishment inside ESA s Large Space; Space Simulation of the CBERS 3 and 4 Satellite Thermal Model in the New Brazilian 6x8m Thermal Vacuum Chamber; The Certification of Environmental Chambers for Testing Flight Hardware; Space Systems Environmental Test Facility Database (SSETFD), Website Development Status; Wallops Flight Facility: Current and Future Test Capabilities for Suborbital and Orbital Projects; Force Limited Vibration Testing of JWST NIRSpec Instrument Using Strain Gages; Investigation of Acoustic Field Uniformity in Direct Field Acoustic Testing; Recent Developments in Direct Field Acoustic Testing; Assembly, Integration and Test Centre in Malaysia: Integration between Building Construction Works and Equipment Installation; Complex Ground Support Equipment for Satellite Thermal Vacuum Test; Effect of Charging Electron Exposure on 1064nm Transmission through Bare Sapphire Optics and SiO2 over HfO2 AR-Coated Sapphire Optics; Environmental Testing Activities and Capabilities for Turkish Space Industry; Integrated Circuit Reliability Simulation in Space Environments; Micrometeoroid Impacts and Optical Scatter in Space Environment; Overcoming Unintended Consequences of Ambient Pressure Thermal Cycling Environmental Tests; Performance and Functionality Improvements to Next Generation Thermal Vacuum Control System; Robotic Lunar Lander Development Project: Three-Dimensional Dynamic Stability Testing and Analysis; Thermal Physical Properties of Thermal Coatings for Spacecraft in Wide Range of Environmental Conditions: Experimental and Theoretical Study; Molecular Contamination Generated in Thermal Vacuum Chambers; Preventing Cross Contamination of Hardware in Thermal Vacuum Chambers; Towards Validation of Particulate Transport Code; Updated Trends in Materials' Outgassing Technology; Electrical Power and Data Acquisition Setup for the CBER 3 and 4 Satellite TBT; Method of Obtaining High Resolution Intrinsic Wire Boom Damping Parameters for Multi-Body Dynamics Simulations; and Thermal Vacuum Testing with Scalable Software Developed In-House.

Packard, Edward A.↗
NASA NTRSDate not supplied

Predicting the Seawater Chemistry of an Ocean World Using Machine Learning on Isotopic Measurements of Volatile CO2

Introduction: Given the long time intervals required for data transmission to and from ocean worlds targets, low bandwidth for data transmission, time required for data processing and analysis, and potentially extreme radiation environments (e.g., Europa), it is clear that ocean worlds missions will need more autonomous flight instruments and software in order to achieve established science goals. Protracted time intervals for data analysis (e.g., Europa Lander) strongly motivates the development of rapid, consistent and streamlined methods for interpreting data from flight mass spectrometers to e.g., determine how mass spectra from a plume or surface liquid/ice relates to the surface/subsurface. Since mass spectrometry also has the potential to correctly identify biosignatures[1], it is imperative that such methods for interpreting data are consistent and accurate. We used 848 isotope ratio mass spectra from laboratory analyses of CO2 that interacted with ocean worlds-relevant seawaters as a ‘training’ dataset for ‘unsupervised’ machine learning. In unsupervised learning, characteristics of the data are not labeled or linked, and any similarities found only result from the neural network. CO2 isotopologues analyzed for this dataset mimic the remote measurements of CO2 by a flight mass spectrometer, and are detailed in Theiling [2]. From this dataset, we used measured features of the spectra, such as retention time, intensity, and (isotopologue) mass ratios as inputs for our autoencoder neural network. Our neural network was trained to find similarities in these and other spectral features for seawaters of a particular composition and amount of initial CO2. Successful training then created an output of these similarities for various seawaters, which included MgSO4, Na2SO4, NaCl, MgCl2, KCl, and NaHCO3, and combinations of these salts. We then applied dimensionality reduction techniques such as Principal Component Analysis (PCA), T-Distributed Stochastic Neighbor Embedding (TSNE), and Uniform Manifold Approximation and Projection (UMAP) to demonstrate latent data features as a two-dimensional projection in a unitless, high-dimensional space. In this projection, a data point represents the combined effect of spectral features such as intensity, retention time, and isotope ratio. Our initial UMAP demonstrates data clustering (organization of the data by the neural network) based on the amount of CO2 that had initially interacted with each seawater. Further training using more ‘supervised’ learning techniques demonstrate strong clustering of preliminary data based on initial CO2 concentration, seawater chemical composition, and ionic strength (salinity). Our preliminary work therefore suggests that machine learning has the potential to identify compositional variants of an ocean world seawater based on mass spectra from volatile CO2 measurements. Acknowledgments: This work was funded through a Strategic Task Group at NASA Goddard Space Flight Center. The training dataset was collected through funding from the Oklahoma Space Grant Consortium. References: [1] Pappalardo, R. et al. (2013) Astrobiology, 13, 740–773. [2] Theiling (2020) Icarus, 114216.

Europa↗
NASA NTRS1992

SO2 on Venus: A final cross-calibration with Pioneer Venus

In our previous report, we noted that we had successfully completed all of the IUE observations which were proposed. A total of 7 Venus spectra were obtained. In the present reporting period, essentially all of the associated data reduction and analysis activities were completed, and Drs. Stern, Barker, and Na met to collaborate on data interpretation. The model atmosphere used in this analysis is similar to the one used in the analysis of the Pioneer Venus observations (Esposito, et al. 1979, 1988) and the previous IUE observations (Na, et al. 1990). In this model, sulfuric acid aerosols with a radius of about 1 micron are mixed uniformly with Rayleigh scattering gases throughout the cloud layer. There are two wavelength-independent absorbers. First, the aerosols are assumed to have a single scattering albedo of 0.98, and second a pure absorbing layer with an optical depth of 0.2 is added at an altitude of 75 mbar. The variable parameters in this model are the mixing ratios of SO2 at the cloud top (40 mbar level), and the scale height of SO2 at the same altitude. Model spectra were calculated using a radiative transfer code utilizing a Markov Chain method. Each model calculation takes into account the multiple scattering and the vertical inhomogeneity of the atmosphere. We reported those initial results at the 1992 meeting of the AAS Division of Planetary Sciences (Barker, Stern, and Na 1992) The important finding we have reached is that the 1991 IUE observations indicate that the long-term decline in Venus SO2 abundance has either halted or reversed. Our simultaneous groundbased measurements made on the McDonald Observatory 2.7 m corroborate this result. We are now preparing a paper describing these IUE results for publication in Icarus. With the IUE results reduced, we are also beginning a project to compare the 1991 IUE results to Pioneer Venus UV spectra made on the same dates.

Stern, S. Alan↗
NASA NTRS1996

Study of the Radiative Properties of Inhomogeneous Stratocumulus Clouds

Clouds play an important role in the radiation budget of the atmosphere. A good understanding of how clouds interact with solar radiation is necessary when considering their effects in both general circulation models and climate models. This study examined the radiative properties of clouds in both an inhomogeneous cloud system, and a simplified cloud system through the use of a Monte Carlo model. The purpose was to become more familiar with the radiative properties of clouds, especially absorption, and to investigate the excess absorption of solar radiation from observations over that calculated from theory. The first cloud system indicated that the absorptance actually decreased as the cloud's inhomogeneity increased, and that cloud forcing does not indicate any changes. The simplified cloud system looked at two different cases of absorption of solar radiation in the cloud. The absorptances calculated from the Monte Carlo is compared to a correction method for calculating absorptances and found that the method can over or underestimate absorptances at cloud edges. Also the cloud edge effects due to solar radiation points to a possibility of overestimating the retrieved optical depth at the edge, and indicates a possible way to correct for it. The effective cloud fraction (Ne) for a long time has been calculated from a cloud's reflectance. From the reflectance it has been observed that the N, for most cloud geometries is greater than the actual cloud fraction (Nc) making a cloud appear wider than it is optically. Recent studies we have performed used a Monte Carlo model to calculate the N, of a cloud using not only the reflectance but also the absorptance. The derived Ne's from the absorptance in some of the Monte Carlo runs did not give the same results as derived from the reflectance. This study also examined the inhomogeneity of clouds to find a relationship between larger and smaller scales, or wavelengths, of the cloud. Both Fourier transforms and wavelet transforms were used to analyze the liquid water content of marine stratocumulus clouds taken during the ASTEX project. From the analysis it was found that the energy in the cloud is not uniformly distributed but is greater at the larger scales than at the smaller scales. This was determined by examining the slope of the power spectrum, and by comparing the variability at two scales from a wavelet analysis.

Batey, Michael↗
NASA NTRS2017

Embracing Open Source for NASA's Earth Science Data Systems

The overarching purpose of NASAs Earth Science program is to develop a scientific understanding of Earth as a system. Scientific knowledge is most robust and actionable when resulting from transparent, traceable, and reproducible methods. Reproducibility includes open access to the data as well as the software used to arrive at results. Additionally, software that is custom-developed for NASA should be open to the greatest degree possible, to enable re-use across Federal agencies, reduce overall costs to the government, remove barriers to innovation, and promote consistency through the use of uniform standards. Finally, Open Source Software (OSS) practices facilitate collaboration between agencies and the private sector. To best meet these ends, NASAs Earth Science Division promotes the full and open sharing of not only all data, metadata, products, information, documentation, models, images, and research results but also the source code used to generate, manipulate and analyze them. This talk focuses on the challenges to open sourcing NASA developed software within ESD and the growing pains associated with establishing policies running the gamut of tracking issues, properly documenting build processes, engaging the open source community, maintaining internal compliance, and accepting contributions from external sources. This talk also covers the adoption of existing open source technologies and standards to enhance our custom solutions and our contributions back to the community. Finally, we will be introducing the most recent OSS contributions from NASA Earth Science program and promoting these projects for wider community review and adoption.

Earth Science↗
NASA NTRS1993

A Regional Analysis of Cloudy Mean Spherical Albedo over the Marine Stratocumulus Region and the Tropical Atlantic Ocean

Since clouds are the largest variable in Earth's radiation budget, it is critical to determine both the spatial and temporal characteristics of their radiative properties. This study examines the relationships between cloud properties and cloud fraction in order to supplement grid scale parameterizations. The satellite data used in this study is from three hourly ISCCP (International Satellite Cloud Climatology Project) and monthly ERBE (Earth Radiation Budget Experiment) data on a 2.50 x 2.50 latitude-longitude grid. Mean cloud spherical albedo, the mean optical depth distribution and cloud fraction are examined and compared off the coast of California and the mid-tropical Atlantic for July 1987 and 1988. Individual grid boxes and spatial averages over several grid boxes are correlated to Coakleys (1991) theory of reflection for uniform and broken layered cloud and to Kedem, et al.(1990) findings that rainfall volume and fractional area of rain in convective systems is linear. Kedem's hypothesis can be expressed in terms of cloud properties. That is, the total volume of liquid in a box is a linear function of cloud fraction. Results for the marine stratocumulus regime indicate that albedo is often invariant for cloud fractions of 20% to 80%. Coakley's satellite model of small and large clouds with cores (1 km) and edges (100 in) is consistent with this observation. The cores maintain high liquid water concentrations and large droplets while the edges contain low liquid water concentrations and small droplets. Large clouds are just a collection of cores. The mean optical depth (TAU) distributions support the above observation with TAU values of 3.55 to 9.38 favored across all cloud fractions. From these results, a method based upon Kedem, et al. theory is proposed to separate the cloud fraction and liquid water path (LWP) calculations in a general circulation model (GCM). In terms of spatial averaging, a linear relationship between albedo and cloud fraction is observed. For tropical locations outside the Intertropical Convergence Zone (ITCZ), results of cloud fraction and albedo spatial averaging followed that of the stratus boxes containing few overcast scenes. Both the ideas of Coakley and Kedem, et al. apply. Within the ITCZ, the grid boxes tended to have the same statistical properties as stratus boxes containing many overcast scenes. Because different dynamical forcing mechanisms are present, it is difficult to devise a method for determining subgrid scale variations. Neither of the theories proposed by Kedem, et al. or Coakley works well for the boxes with numerous overcast scenes.

Ginger, Kathryn M.↗
NASA NTRS1993

A regional analysis of cloudy mean spherical albedo over the marine stratocumulus region and the tropical Atlantic Ocean

Since clouds are the largest variable in Earth's radiation budget, it is critical to determine both the spatial and temporal characteristics of their radiative properties. The relationships between cloud properties and cloud fraction are studied in order to supplement grid scale parameterizations. The satellite data used is from three hourly ISCCP (International Satellite Cloud Climatology Project) and monthly ERBE (Earth Radiation Budget Experiment) data on a 2.5 deg x 2.5 deg latitude-longitude grid. Mean cloud spherical albedo, the mean optical depth distribution, and cloud fraction are examined and compared off the coast of California and the mid-tropical Atlantic for July 1987 and 1988. Individual grid boxes and spatial averages over several grid boxes are correlated to Coakley's theory of reflection for uniform and broken layered cloud and to Kedem, et al.'s findings that rainfall volume and fractional area of rain in convective systems is linear. Kedem's hypothesis can be expressed in terms of cloud properties. That is, the total volume of liquid in a box is a linear function of cloud fraction. Results for the marine stratocumulus regime indicate that albedo is often invariant for cloud fractions of 20% to 80%. Coakley's satellite model of small and large clouds with cores (1 km) and edges (100 m) is consistent with this observation. The cores maintain high liquid water concentrations and large droplets while the edges contain low liquid water concentrations and small droplets. Large clouds are just a collection of cores. The mean optical depth (TAU) distributions support the above observation with TAU values of 3.55 to 9.38 favored across all cloud fractions. From these results, a method based upon Kedem, et al's theory is proposed to separate the cloud fraction and liquid water path (LWP) calculations in a general circulation model (GCM). In terms of spatial averaging, a linear relationship between albedo and cloud fraction is observed. For tropical locations outside the Intertropical Convergence Zone (ITCZ), results of cloud fraction and albedo spatial averaging followed that of the stratus boxes containing few overcast scenes. Both the ideas of Coakley and Kedem, et al. apply. Within the ITCZ, the grid boxes tended to have the same statistical properties as stratus boxes containing many overcast scenes. Because different dynamical forcing mechanisms are present, it is difficult to devise a method for determining subgrid scale variations. Neither of the theories proposed by Kedem, et al. or Coakley works well for the boxes with numerous overcast scenes.

Ginger, Kathryn M.↗
NASA NTRS2009

Constructing LDPC Codes from Loop-Free Encoding Modules

A method of constructing certain low-density parity-check (LDPC) codes by use of relatively simple loop-free coding modules has been developed. The subclasses of LDPC codes to which the method applies includes accumulate-repeat-accumulate (ARA) codes, accumulate-repeat-check-accumulate codes, and the codes described in Accumulate-Repeat-Accumulate-Accumulate Codes (NPO-41305), NASA Tech Briefs, Vol. 31, No. 9 (September 2007), page 90. All of the affected codes can be characterized as serial/parallel (hybrid) concatenations of such relatively simple modules as accumulators, repetition codes, differentiators, and punctured single-parity check codes. These are error-correcting codes suitable for use in a variety of wireless data-communication systems that include noisy channels. These codes can also be characterized as hybrid turbolike codes that have projected graph or protograph representations (for example see figure); these characteristics make it possible to design high-speed iterative decoders that utilize belief-propagation algorithms. The present method comprises two related submethods for constructing LDPC codes from simple loop-free modules with circulant permutations. The first submethod is an iterative encoding method based on the erasure-decoding algorithm. The computations required by this method are well organized because they involve a parity-check matrix having a block-circulant structure. The second submethod involves the use of block-circulant generator matrices. The encoders of this method are very similar to those of recursive convolutional codes. Some encoders according to this second submethod have been implemented in a small field-programmable gate array that operates at a speed of 100 megasymbols per second. By use of density evolution (a computational- simulation technique for analyzing performances of LDPC codes), it has been shown through some examples that as the block size goes to infinity, low iterative decoding thresholds close to channel capacity limits can be achieved for the codes of the type in question having low maximum variable node degrees. The decoding thresholds in these examples are lower than those of the best-known unstructured irregular LDPC codes constrained to have the same maximum node degrees. Furthermore, the present method enables the construction of codes of any desired rate with thresholds that stay uniformly close to their respective channel capacity thresholds.

Divsalar, Dariush↗
DOE OSTI2025

FCET Solid Oxide Fuel Cell Testing and Development (CRADA 526) (Final Report)

Pacific Northwest National Laboratory (PNNL) tested electrolyte coatings from Fuel Cell Enabling Technologies, Inc. (FCET) for use in solid oxide fuel cells (SOFCs). The key technology held by FCET is a process to deposit thin layers of oxide materials, less than 1 μm in thickness. The range of possible materials that can be deposited with their method is broad, but this project focused on the gadolinium-doped ceria (GDC) and yttria-stabilized zirconia (YSZ) electrolytes for SOFCs. Thin, gas tight electrolyte membranes have been a long-sought target in SOFC research. The thinner the electrolyte, the lower the cell resistance, and the higher performance of the cell (or the lower the operating temperature). A YSZ thickness of 1 μm would be a step change from the state-of-the-art, tape-cast electrolytes (~10 μm). An in-house prototype SOFC stack from FCET was first tested. The sealing geometry of the prototype stack was determined to be problematic, and testing shifted to button cells. Anode-supported solid oxide electrolysis cell (SOEC) button cells without an electrolyte layer were produced at PNNL and sent to FCET for coating with electrolyte. Three cells were tested with a gadolinium-doped ceria (GDC) electrolyte applied via spin coating. GDC was chosen for its conductivity at lower temperatures than YSZ. All three cells failed during initial reduction under hydrogen at 600°C. Testing then shifted to YSZ, which is the standard SOFC electrolyte. Several button cells were coated with YSZ and examined with scanning electron microscopy (SEM). A promising coating of ~1 mm thickness was observed under SEM. A similarly coated button cell was tested and failed similarly to previous tests during reduction at 600°C. The YSZ coating appeared dense and uniform in SEM analysis. The roughness of the underlying Ni/YSZ anode is on the order of 1 μm, and that may have compromised the gas-tightness of the coating. Further development is warranted to understand and refine the coating process. Thin YSZ applied via this spin-coating technique could be used as a low-cost, drop-in replacement in large-scale SOFC manufacturing processes, improving cell performance and lowering the cost per watt of SOFCs.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2002

Techniques Optimized for Reducing Instabilities in Advanced Nickel-Base Superalloys for Turbine Blades

The High-Speed Research (HSR) Airfoil Alloy program developed fourth-generation single-crystal superalloys with up to an 85 F increase in creep rupture capability over current production airfoil alloys. Recent results have been generated at the NASA Glenn Research Center on these fourth-generation alloys, but in coated form, for subsonic turbine blade applications under NASA's Ultra-Efficient Engine Technology (UEET) Program. One goal for UEET is to optimize the airfoil alloy/thermal barrier coating system for 3100 F turbine inlet temperatures. The state-of-the art turbine blade airfoil system consists of a superalloy single crystal that provides the basic mechanical performance of the airfoil. A thermal barrier coating is used to reduce the temperature of the base superalloy, and a bondcoat is deposited between the base material and the thermal barrier coating. The bondcoat improves the oxidation and corrosion resistance of the base superalloy and improves the spallation resistance of the thermal barrier coating. A commercial platinum aluminide bondcoat was applied to the HSR-developed alloys, and a diffusion zone developed as a result of interaction between the bondcoat and the superalloy. Optimized strength is obtained for superalloys when the refractory element content is high and the limits of microstructural stability are approached or exceeded slightly. For fourthgeneration alloys, instability leads to the formation of topologically close packed (TCP) phases, which form internally in the superalloy, and a secondary reaction zone (SRZ), which forms under the diffusion zone. There was a concern that excessive quantities of either TCP or SRZ might decrease the mechanical properties of the superalloy, with SRZ thought to be particularly detrimental and its formation unpredictable. Thus, an SRZreduction effort was initiated in the NASA UEET Program so that methods developed during the HSR project could be optimized further to reduce or eliminate the SRZ. An SRZ is a three-phase constituent composed of TCP and stringers of gamma phase in a matrix of gamma prime. An incoherent grain boundary separates the SRZ from the gammagamma prime microstructure of the superalloy. The SRZ is believed to form as a result of local chemistry changes in the superalloy due to the application of the diffusion aluminide bondcoat. Locally high surface stresses also appear to promote the formation of the SRZ. Thus, techniques that change the local alloy chemistry or reduce surface stresses have been examined for their effectiveness in reducing SRZ. These SRZ-reduction steps are performed on the test specimen or the turbine blade before the bondcoat is applied. Stressrelief heat treatments developed at NASA Glenn have been demonstrated to reduce significantly the amount of SRZ that develops during subsequent high-temperature exposures. Stress-relief heat treatments reduce surface stresses by recrystallizing a thin surface layer of the superalloy. However, in alloys with very high propensities to form SRZ, stress relief heat treatments alone do not eliminate SRZ entirely. Thus, techniques that modify the local chemistry under the bondcoat have been emphasized and optimized successfully at Glenn. One such technique is carburization, which changes the local chemistry by forming submicron carbides near the surface of the superalloy. Detailed characterizations have demonstrated that the depth and uniform distribution of these carbides are enhanced when a stress relief treatment and an appropriate surface preparation are employed in advance of the carburization treatment. Even in alloys that have the propensity to develop a continuous SRZ layer beneath the diffusion zone, the SRZ has been completely eliminated or reduced to low, manageable levels when this combination of techniques is utilized. Now that the techniques to mitigate SRZ have been established at Glenn, TCP phase formation is being emphasized in ongoing work under the UEET Program. The limitsf stability of the fourth-generation alloys with respect to TCP phase formation are currently being defined along with high-temperature creep rupture properties. In addition, a regression model is being developed at Glenn for the prediction of the presence of TCP phase in the microstructure and SRZ under the diffusion zone. The model is based on a design-of-experiments methodology with emphasis on the potential synergistic effects of alloying elements.

MacKay, Rebecca A.↗
NASA NTRS1995

Windowed and Wavelet Analysis of Marine Stratocumulus Cloud Inhomogeneity

To improve radiative transfer calculations for inhomogeneous clouds, a consistent means of modeling inhomogeneity is needed. One current method of modeling cloud inhomogeneity is through the use of fractal parameters. This method is based on the supposition that cloud inhomogeneity over a large range of scales is related. An analysis technique named wavelet analysis provides a means of studying the multiscale nature of cloud inhomogeneity. In this paper, the authors discuss the analysis and modeling of cloud inhomogeneity through the use of wavelet analysis. Wavelet analysis as well as other windowed analysis techniques are used to study liquid water path (LWP) measurements obtained during the marine stratocumulus phase of the First ISCCP (International Satellite Cloud Climatology Project) Regional Experiment. Statistics obtained using analysis windows, which are translated to span the LWP dataset, are used to study the local (small scale) properties of the cloud field as well as their time dependence. The LWP data are transformed onto an orthogonal wavelet basis that represents the data as a number of times series. Each of these time series lies within a frequency band and has a mean frequency that is half the frequency of the previous band. Wavelet analysis combined with translated analysis windows reveals that the local standard deviation of each frequency band is correlated with the local standard deviation of the other frequency bands. The ratio between the standard deviation of adjacent frequency bands is 0.9 and remains constant with respect to time. This ratio defined as the variance coupling parameter is applicable to all of the frequency bands studied and appears to be related to the slope of the data's power spectrum. Similar analyses are performed on two cloud inhomogeneity models, which use fractal-based concepts to introduce inhomogeneity into a uniform cloud field. The bounded cascade model does this by iteratively redistributing LWP at each scale using the value of the local mean. This model is reformulated into a wavelet multiresolution framework, thereby presenting a number of variants of the bounded cascade model. One variant introduced in this paper is the 'variance coupled model,' which redistributes LWP using the local standard deviation and the variance coupling parameter. While the bounded cascade model provides an elegant two- parameter model for generating cloud inhomogeneity, the multiresolution framework provides more flexibility at the expense of model complexity. Comparisons are made with the results from the LWP data analysis to demonstrate both the strengths and weaknesses of these models.

Gollmer, Steven M.↗
NASA NTRS1995

Aerodynamic sound of flow past an airfoil

The long term objective of this project is to develop a computational method for predicting the noise of turbulence-airfoil interactions, particularly at the trailing edge. We seek to obtain the energy-containing features of the turbulent boundary layers and the near-wake using Navier-Stokes Simulation (LES or DNS), and then to calculate the far-field acoustic characteristics by means of acoustic analogy theories, using the simulation data as acoustic source functions. Two distinct types of noise can be emitted from airfoil trailing edges. The first, a tonal or narrowband sound caused by vortex shedding, is normally associated with blunt trailing edges, high angles of attack, or laminar flow airfoils. The second source is of broadband nature arising from the aeroacoustic scattering of turbulent eddies by the trailing edge. Due to its importance to airframe noise, rotor and propeller noise, etc., trailing edge noise has been the subject of extensive theoretical (e.g. Crighton & Leppington 1971; Howe 1978) as well as experimental investigations (e.g. Brooks & Hodgson 1981; Blake & Gershfeld 1988). A number of challenges exist concerning acoustic analogy based noise computations. These include the elimination of spurious sound caused by vortices crossing permeable computational boundaries in the wake, the treatment of noncompact source regions, and the accurate description of wave reflection by the solid surface and scattering near the edge. In addition, accurate turbulence statistics in the flow field are required for the evaluation of acoustic source functions. Major efforts to date have been focused on the first two challenges. To this end, a paradigm problem of laminar vortex shedding, generated by a two dimensional, uniform stream past a NACA0012 airfoil, is used to address the relevant numerical issues. Under the low Mach number approximation, the near-field flow quantities are obtained by solving the incompressible Navier-Stokes equations numerically at chord Reynolds number of 104. The far-field noise is computed using Curle's extension to the Lighthill analogy (Curle 1955). An effective method for separating the physical noise source from spurious boundary contributions is developed. This allows an accurate evaluation of the Reynolds stress volume quadrupoles, in addition to the more readily computable surface dipoles due to the unsteady lift and drag. The effect of noncompact source distribution on the far-field sound is assessed using an efficient integration scheme for the Curle integral, with full account of retarded-time variations. The numerical results confirm in quantitative terms that the far-field sound is dominated by the surface pressure dipoles at low Mach number. The techniques developed are applicable to a wide range of flows, including jets and mixing layers, where the Reynolds stress quadrupoles play a prominent or even dominant role in the overall sound generation.

Wang, Meng↗