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Battery development and testing at ESA

The principal activities of the Energy Storage Section of the Space Research and Technology Center (ESTEC) of the European Space Agency are presented. Nickel-hydrogen and fuel cell systems development are reported. The European Space Battery Test Center (ESBTC) facilities are briefly described along with the current test programs and results obtained.

Verniolle, Jean↗

Propellant Technologies: A Persuasive Wave of Future Propulsion Benefits

Rocket propellant and propulsion technology improvements can be used to reduce the development time and operational costs of new space vehicle programs. Advanced propellant technologies can make the space vehicles safer, more operable, and higher performing. Five technology areas are described: Monopropellants, Alternative Hydrocarbons, Gelled Hydrogen, Metallized Gelled Propellants, and High Energy Density Materials. These propellants' benefits for future vehicles are outlined using mission study results and the technologies are briefly discussed.

Palaszewski, Bryan↗

Innovative Airbreathing Propulsion Concepts for Access to Space

This paper will present technologies and concepts for novel aeropropulsion systems. These technologies will enhance the safety of operations, reduce life cycle costs, and contribute to reduced costs of air travel and access to space. One of the goals of the NASA program is to reduce the carbon-dioxide emissions of aircraft engines. Engine concepts that use highly efficient fuel cell/electric drive technologies in hydrogen-fueled engines will be presented in the proposed paper. Carbon-dioxide emissions will be eliminated by replacing hydrocarbon fuel with hydrogen, and reduce NOx emissions through better combustion process control. A revolutionary exoskeletal engine concept, in which the engine drum is rotated, will be shown. This concept has the potential to allow a propulsion system that can be used for subsonic through hypersonic flight. Dual fan concepts that have ultra-high bypass ratios, low noise, and low drag will be presented. Flow-controlled turbofans and control-configured turbofans also will be discussed. To increase efficiency, a system of microengines distributed along lifting surfaces and on the fuselage is being investigated. This concept will be presented in the paper. Small propulsion systems for affordable, safe personal transportation vehicles will be discussed. These low-oil/oilless systems use technologies that enable significant cost and weight reductions. Pulse detonation engine-based hybrid-cycle and combined-cycle propulsion systems for aviation and space access will be presented.

Whitlow, Jr., Woodrow↗

Noninvasive, near infrared spectroscopic-measured muscle pH and PO2 indicate tissue perfusion for cardiac surgical patients undergoing cardiopulmonary bypass

OBJECTIVE: To determine whether near infrared spectroscopic measurement of tissue pH and Po2 has sufficient accuracy to assess variation in tissue perfusion resulting from changes in blood pressure and metabolic demand during cardiopulmonary bypass. DESIGN: Prospective clinical study. SETTING: Academic medical center. SUBJECTS: Eighteen elective cardiac surgical patients. INTERVENTION: Cardiac surgery under cardiopulmonary bypass. MEASUREMENTS AND MAIN RESULTS: A near infrared spectroscopic fiber optic probe was placed over the hypothenar eminence. Reference Po2 and pH sensors were inserted in the abductor digiti minimi (V). Data were collected every 30 secs during surgery and for 6 hrs following cardiopulmonary bypass. Calibration equations developed from one third of the data were used with the remaining data to investigate sensitivity of the near infrared spectroscopic measurement to physiologic changes resulting from cardiopulmonary bypass. Near infrared spectroscopic and reference pH and Po2 measurements were compared for each subject using standard error of prediction. Near infrared spectroscopic pH and Po2 at baseline were compared with values during cardiopulmonary bypass just before rewarming commenced (hypotensive, hypothermic), after rewarming (hypotensive, normothermic) just before discontinuation of cardiopulmonary bypass, and at 6 hrs following cardiopulmonary bypass (normotensive, normothermic) using mixed-model analysis of variance. Near infrared spectroscopic pH and Po2 were well correlated with the invasive measurement of pH (R2 =.84) and Po2 (R 2 =.66) with an average standard error of prediction of 0.022 +/- 0.008 pH units and 6 +/- 3 mm Hg, respectively. The average difference between the invasive and near infrared spectroscopic measurement was near zero for both the pH and Po2 measurements. Near infrared spectroscopic Po2 significantly decreased 50% on initiation of cardiopulmonary bypass and remained depressed throughout the bypass and monitored intensive care period. Near infrared spectroscopic pH decreased significantly during cardiopulmonary bypass, decreased significantly during rewarming, and remained depressed 6 hrs after cardiopulmonary bypass. Diabetic patients responded differently than nondiabetic subjects to cardiopulmonary bypass, with lower muscle pH values (p =.02). CONCLUSIONS: Near infrared spectroscopic-measured muscle pH and Po2 are sensitive to changes in tissue perfusion during cardiopulmonary bypass.

Non-NASA Center↗

Kinetic and mechanistic analysis of nonenzymatic, template-directed oligoribonucleotide ligation

The role of divalent cations in the mechanism of pyrophosphate-activated, template-directed oligoribonucleotide ligation has been investigated. The dependence of the reaction rate on Mg2+ concentration suggests a kinetic scheme in which a Mg2+ ion must bind before ligation can proceed. Mn2+, Ca2+, Sr2+, and Ba2+ can also catalyze the reaction. Although Pb2+ and Zn2+ do not catalyze the reaction in the absence of other divalent ions, they significantly modulate the reaction rate when added in the presence of Mg2+, with Pb2+ stimulating the reaction (up to 65-fold) and Zn2+ inhibiting the reaction. The logarithm of the ligation rate increases linearly, with slope of 0.95, as a function of pH, indicating that the reaction involves a single critical deprotonation step. The ligation rates observed with the different divalent metal ion catalysts (Mn2+ > Mg2+ > Ca2+ > Sr2+ = Ba2+) vary inversely with the pKa values of their bound water molecules. The pH profile and these relative ligation rates suggest a mechanism in which a metal-bound hydroxide ion located near the ligation junction promotes catalysis, most likely by deprotonation of the hydroxl nucleophile. The effects of changing either the leaving group or the attacking hydroxyl, together with the large delta S(++) value for oligonucleotide ligation (about -20 eu), are consistent with an associative transition state.

Non-NASA Center↗

Advanced Turbulence Modeling Concepts

The ZCET program developed at NASA Glenn Research Center is to study hydrogen/air injection concepts for aircraft gas turbine engines that meet conventional gas turbine performance levels and provide low levels of harmful NOx emissions. A CFD study for ZCET program has been successfully carried out. It uses the most recently enhanced National combustion code (NCC) to perform CFD simulations for two configurations of hydrogen fuel injectors (GRC- and Sandia-injector). The results can be used to assist experimental studies to provide quick mixing, low emission and high performance fuel injector designs. The work started with the configuration of the single-hole injector. The computational models were taken from the experimental designs. For example, the GRC single-hole injector consists of one air tube (0.78 inches long and 0.265 inches in diameter) and two hydrogen tubes (0.3 inches long and 0.0226 inches in diameter opposed at 180 degree). The hydrogen tubes are located 0.3 inches upstream from the exit of the air element (the inlet location for the combustor). To do the simulation, the single-hole injector is connected to a combustor model (8.16 inches long and 0.5 inches in diameter). The inlet conditions for air and hydrogen elements are defined according to actual experimental designs. Two crossing jets of hydrogen/air are simulated in detail in the injector. The cold flow, reacting flow, flame temperature, combustor pressure and possible flashback phenomena are studied. Two grid resolutions of the numerical model have been adopted. The first computational grid contains 0.52 million elements, the second one contains over 1.3 million elements. The CFD results have shown only about 5% difference between the two grid resolutions. Therefore, the CFD result obtained from the model of 1.3-million grid resolution can be considered as a grid independent numerical solution. Turbulence models built in NCC are consolidated and well tested. They can handle both coarse and fine grids near the wall. They can model the effect of anisotropy of turbulent stresses and the effect of swirling. The chemical reactions of Magnusson model and ILDM method were both used in this study.

Shih, Tsan-Hsing↗

Solid oxidized fuel cells seals leakage setup and testing

As the world s reserves of fossil fuels are depleted, the U.S. Government, as well as other countries and private industries, is researching solutions for obtaining power, answers that would be more efficient and environmentally friendly. For a long time engineers have been trying to obtain the benefits of clean electric power without heavy batteries or pollution-producing engines. While some of the inventions proved to be effective (i.e. solar panels or windmills) their applications are limited due to dependency on the energy source (i.e. sun or wind). Currently, as energy concerns increase, research is being carried out on the development of a Solid Oxide Fuel Cell (SOFC). The United States government is taking a proactive role in expanding the technology through the Solid State Energy Conversion Alliance (SECA) Program, which is coordinated by the Department of Energy. into an electrical energy. This occurs by the means of natural tendency of oxygen and hydrogen to chemically react. While controlling the process, it is possible to harvest the energy given off by the reaction. SOFCs use currently available fossil fuels and convert a variety of those fuels with very high efficiency (about 40% more efficient than modem thermal power plants). At the same time they are almost entirely nonpolluting and due to their size they can be placed in remote areas. The main fields where the application of the fuel cells appears to be the most useful for are stationary energy sources, transportation, and military applications. structure and materials must be resolved. All the components must be operational in harsh environments including temperatures reaching 800 C and cyclic thermal- mechanical loading. Under these conditions, the main concern is the requirement for hermetic seals to: (1) prevent mixing of the fuel and oxidant within the stack, (2) prevent parasitic leakage of the fuel from the stack, (3) prevent contamination of the anode by air leaking into the stack, (4) electrically isolate the individual cells within the stack, and (5) mechanically bond the cell components. The sealing challenges are aggravated by the need to maintain hermetic boundaries between the different flow paths within the fuel cell throughout cycled operation. Within the timeframe of my tenure, the main objective is to assist in building a state-of-art test facility.

Bastrzyk, Marta B.↗

Two-Phase Convection Heat Transfer Correlations for Liquid Hydrogen Pipe Chilldown

Recently, heat transfer correlations based on liquid nitrogen (LN2) and liquid hydrogen (LH2) pipe quenching data were developed to improve the predictive accuracy of lumped node codes like SINDA/FLUINT and the Generalized Fluid System Simulation Program (GFSSP). After implementing these correlations into both programs, updated model runs showed strong improvement in LN2 pipe chilldown modeling but only modest improvement in LH2 modeling. Due to large differences in thermal and fluid properties between the two fluids, results indicated a need to develop a separate set of LH2-only correlations to improve the accuracy of the simulations. This paper presents a new set of two-phase convection heat transfer correlations based on LH2 pipe quenching data. A correlation to predict the bulk vapor temperature was developed after analysis showed that high amounts of thermal nonequilibrium of the liquid and vapor phases occurred during film boiling of LH2. Implemented in a numerical model, the new correlations achieve a mean absolute error of 19.5 K in the predicted wall temperature when compared to recent LH2 pipe chilldown data, an improvement of 40% over recent GFSSP predictions. This correlation set can be implemented in simulations of the transient LH2 chilldown process. Such simulations are useful for predicting the chilldown time and boil-off mass of LH2 for applications such as the transfer of LH2 from a ground storage tank to the rocket vehicle propellant tank, or through a rocket engine feedline during engine startup.

critical heat flux↗

Space Exploration Applications for Development of High Capacity Cryocoolers

Long term storage of cryogens is necessary to enable NASAs long duration crewed missions to both the lunar and Martian surfaces. Such missions require in-space transport systems such as Nuclear Thermal Propulsion (NTP), and descent/ascent vehicles for transportation to and from the lunar and Martian surfaces. NTP systems and Lunar/Martian landers utilize cryogenic fluids to minimize architectural volume and mass. To further enhance the capability of these cryogenic systems, the Agency is putting emphasis on reusability, which requires the NTP and ascent/descent elements be replenished on-orbit via tankers or propellant depots, or on the lunar or Martian surface using liquefied in-situ produced propellants. NTP is one of the leading propulsion option for human Mars missions and requires liquid hydrogen to be stored on-orbit for over four years. For such a long duration mission, near “Zero Boil-Off” (ZBO) must be achieved which requires an optimized suite of passive Cryogenic Fluid Management technologies and active cooling (cryocoolers). Tens of Watts of 20K cooling is required to achieve ZBO conditions for NTP, however two-stage cooling using both 20K and 90K systems can lead to a significant reduction in both active cooling mass and power. The use of in-situ resources for lunar and Martian missions will require 150 Watts of 90K cooling for oxygen liquefaction and 300 Watts of 20K cooling for hydrogen liquefaction (lunar only). Descent/Ascent vehicles, propellant depots, and tankers will also require the use of cryocoolers to achieve ZBO conditions. To support these programs, NASA is developing high capacity 20K and 90K reverse turbo-Brayton cycle cryocoolers which offer a scalable, high efficiency, low vibration solution.

cryocooler↗

An Overview of the NASA Aerospace Flight Battery Systems Program

The NASA Aerospace Flight Battery Systems Program is an agency-wide effort aimed at ensuring the quality, safety, reliability and performance of flight battery systems for NASA applications. The program provides for the validation of primary and secondary cell and battery level technology advances to ensure their availability and readiness for use in NASA missions. It serves to bridge the gap between the development of technology advances and the realization and incorporation of these advances into mission applications. The program is led by the Glenn Research Center and involves funded task activities at each of the NASA mission centers and JPL. The overall products are safe, reliable, high quality batteries for mission applications. The products are defined along three product lines: 1. Battery Systems Technology - Elements of this task area cover the systems aspects of battery operation and generally apply across chemistries. This includes the development of guidelines documents, the establishment and maintenance of a central battery database that serves a central repository for battery characterization and verification test data from tests performed under the support of this program, the NASA Battery Workshop, and general test facility support. 2. Secondary Battery Technology - l h s task area focuses on the validation of battery technology for nickel-cadmium, nickel-hydrogen, nickel-metal-hydride and lithium-ion secondary battery systems. Standardized test regimes are used to validate the quality of a cell lot or cell design for flight applications. In this area, efforts are now concentrated on the validation and verification of lithium-ion battery technology for aerospace applications. 3. Primary Battery Technology - The safety and reliability aspects for primary lithium battery systems that are used in manned operations on the Shuttle and International Space Station are addressed in the primary battery technology task area. An overview of the task areas supported under this program will be presented.

Manzo, Michelle A.↗

Turning things downside up: Adsorbate induced water flipping on Pt(111)

We have examined the adsorption of the weakly bound species N{sub 2}, O{sub 2}, CO, and Kr on the (√(37)×√(37))R25.3{sup ∘} water monolayer on Pt(111) using a combination of molecular beam dosing, infrared reflection absorption spectroscopy, and temperature programmed desorption. In contrast to multilayer crystalline ice, the adsorbate-free water monolayer is characterized by a lack of dangling OH bonds protruding into the vacuum (H-up). Instead, the non-hydrogen-bonded OH groups are oriented downward (H-down) to maximize their interaction with the underlying Pt(111) substrate. Adsorption of Kr and O{sub 2} have little effect on the structure and vibrational spectrum of the “√(37)” water monolayer while adsorption of both N{sub 2}, and CO are effective in “flipping” H-down water molecules into an H-up configuration. This “flipping” occurs readily upon adsorption at temperatures as low as 20 K and the water monolayer transforms back to the H-down, “√(37)” structure upon adsorbate desorption above 35 K, indicating small energy differences and barriers between the H-down and H-up configurations. The results suggest that converting water in the first layer from H-down to H-up is mediated by the electrostatic interactions between the water and the adsorbates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Laboratory for Laser Energetics Targets Inertial Confinement Fusion

The University of Rochester’s Laboratory for Laser Energetics is targeting laser-driven inertial confinement fusion, as part of National Nuclear Security Administration’s Stockpile Stewardship Program and in the quest for clean sources of energy. The Laboratory for Laser Energetics (LLE) is home to two extremely powerful lasers—OMEGA and OMEGA EP—and researchers are using them to explore laser-driven inertial confinement fusion (ICF). ICF involves compressing a small amount of fuel consisting of hydrogen isotopes, deuterium (D), and tritium (T), and heating it to temperatures greater than the center of stars. “When these conditions are reached, the fuel undergoes fusion—releasing enormous energy that can be used for research relevant to the National Nuclear Security Administration’s (NNSA) Stockpile Stewardship Program (SSP) and to drive carbon-free power plants,” explains Valeri Goncharov, distinguished scientist and director of the Theory Division at LLE. LLE was established at the University of Rochester in 1970 and is the largest U.S. Department of Energy university-based research program in the nation, supported by the National Nuclear Security Administration as part of its Stockpile Stewardship Program (SSP). “As a center for exploring the interaction of intense radiation with matter, LLE is a unique national resource for research and education in science and technology,” says Goncharov. “Our current research includes exploring fusion for the SSP program and as a future source of energy, developing new laser and materials technologies, and pursuing a better understanding of high-energy-density phenomena.”

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Oil-free centrifugal hydrogen compression technology demonstration

One of the key elements in realizing a mature market for hydrogen vehicles is the deployment of a safe and efficient hydrogen production and delivery infrastructure on a scale that can compete economically with current fuels. The challenge, however, is that hydrogen, being the lightest and smallest of gases with a lower viscosity and density than natural gas, readily migrates through small spaces and is difficult to compresses efficiently. While efficient and cost effective compression technology is crucial to effective pipeline delivery of hydrogen, the compression methods used currently rely on oil lubricated positive displacement (PD) machines. PD compression technology is very costly, has poor reliability and durability, especially for components subjected to wear (e.g., valves, rider bands and piston rings) and contaminates hydrogen with lubricating fluid. Even so called “oil-free” machines use oil lubricants that migrate into and contaminate the gas path. Due to the poor reliability of PD compressors, current hydrogen producers often install duplicate units in order to maintain on-line times of 98-99%. Such machine redundancy adds substantially to system capital costs. As such, DOE deemed that low capital cost, reliable, efficient and oil-free advanced compressor technologies are needed. MiTi’s solution is a completely oil-free, multi-stage, high-speed, centrifugal compressor designed for flow capacity of 500,000 kg/day with a discharge pressure of 1200 psig. The design employs oil-free compliant foil bearings and seals to allow for very high operating speeds, totally contamination free operation, long life and reliability. This design meets the DOE’s performance targets and achieves an extremely aggressive, specific power metric of 0.48 kW-hr/kg and provides significant improvements in reliability/durability, energy efficiency, sealing and freedom from contamination. The multi-stage compressor system concept has been validated through full scale performance testing of a single stage with helium similitude gas at full speed in accordance with ASME PTC-10. The experimental results indicated that aerodynamic performance, with respect to compressor discharge pressure, flow, power and efficiency exceeded theoretical prediction. Dynamic testing of a simulated multistage centrifugal compressor was also completed under a parallel program to validate the integrity and viability of the system concept. The results give strong confidence in the feasibility of the multi-stage design for use in hydrogen gas transportation and delivery from production locations to point of use.

08 HYDROGEN↗

Systems Engineering Provides Successful High Temperature Steam Electrolysis Project

This paper describes two Systems Engineering Studies completed at the Idaho National Laboratory (INL) to support development of the High Temperature Stream Electrolysis (HTSE) process. HTSE produces hydrogen from water using nuclear power and was selected by the Department of Energy (DOE) for integration with the Next Generation Nuclear Plant (NGNP). The first study was a reliability, availability and maintainability (RAM) analysis to identify critical areas for technology development based on available information regarding expected component performance. An HTSE process baseline flowsheet at commercial scale was used as a basis. The NGNP project also established a process and capability to perform future RAM analyses. The analysis identified which components had the greatest impact on HTSE process availability and indicated that the HTSE process could achieve over 90% availability. The second study developed a series of life-cycle cost estimates for the various scale-ups required to demonstrate the HTSE process. Both studies were useful in identifying near- and long-term efforts necessary for successful HTSE process deployment. The size of demonstrations to support scale-up was refined, which is essential to estimate near- and long-term cost and schedule. The life-cycle funding profile, with high-level allocations, was identified as the program transitions from experiment scale R&D to engineering scale demonstration.

08 HYDROGEN↗

Fiscalini Farms Biomass Energy Project

In this final report describes and documents research that was conducted by the Ecological Engineering Research Program (EERP) at the University of the Pacific (Stockton, CA) under subcontract to Fiscalini Farms LP for work under the Assistance Agreement DE-EE0001895 'Measurement and Evaluation of a Dairy Anaerobic Digestion/Power Generation System' from the United States Department of Energy, National Energy Technology Laboratory. Fiscalini Farms is operating a 710 kW biomass-energy power plant that uses bio-methane, generated from plant biomass, cheese whey, and cattle manure via mesophilic anaerobic digestion, to produce electricity using an internal combustion engine. The primary objectives of the project were to document baseline conditions for the anaerobic digester and the combined heat and power (CHP) system used for the dairy-based biomass-energy production. The baseline condition of the plant was evaluated in the context of regulatory and economic constraints. In this final report, the operation of the plant between start-up in 2009 and operation in 2010 are documented and an interpretation of the technical data is provided. An economic analysis of the biomass energy system was previously completed (Appendix A) and the results from that study are discussed briefly in this report. Results from the start-up and first year of operation indicate that mesophilic anaerobic digestion of agricultural biomass, combined with an internal combustion engine, is a reliable source of alternative electrical production. A major advantage of biomass energy facilities located on dairy farms appears to be their inherent stability and ability to produce a consistent, 24 hour supply of electricity. However, technical analysis indicated that the Fiscalini Farms system was operating below capacity and that economic sustainability would be improved by increasing loading of feedstocks to the digester. Additional operational modifications, such as increased utilization of waste heat and better documentation of potential of carbon credits, would also improve the economic outlook. Analysis of baseline operational conditions indicated that a reduction in methane emissions and other greenhouse gas savings resulted from implementation of the project. The project results indicate that using anaerobic digestion to produce bio-methane from agricultural biomass is a promising source of electricity, but that significant challenges need to be addressed before dairy-based biomass energy production can be fully integrated into an alternative energy economy. The biomass energy facility was found to be operating undercapacity. Economic analysis indicated a positive economic sustainability, even at the reduced power production levels demonstrated during the baseline period. However, increasing methane generation capacity (via the importation of biomass codigestate) will be critical for increasing electricity output and improving the long-term economic sustainability of the operation. Dairy-based biomass energy plants are operating under strict environmental regulations applicable to both power-production and confined animal facilities and novel approached are being applied to maintain minimal environmental impacts. The use of selective catalytic reduction (SCR) for nitrous oxide control and a biological hydrogen sulfide control system were tested at this facility. Results from this study suggest that biomass energy systems can be compliant with reasonable scientifically based air and water pollution control regulations. The most significant challenge for the development of biomass energy as a viable component of power production on a regional scale is likely to be the availability of energy-rich organic feedstocks. Additionally, there needs to be further development of regional expertise in digester and power plant operations. At the Fiscalini facility, power production was limited by the availability of biomass for methane generation, not the designed system capacity. During the baseline study period, feedstocks included manure, sudan grass silage, and refused-feed. The ability of the dairy to produce silage in excess of on-site feed requirements limited power production. The availability of biomass energy crops and alternative feedstocks, such as agricultural and food wastes, will be a major determinant to the economic and environmental sustainability of biomass based electricity production.

03 NATURAL GAS↗

Abradable Sealing Materials for Emerging IGCC-Based Turbine Systems (Final Report)

Reducing the gap between rotating and stationary parts in gas turbine engines, and mitigating gas leakage via these paths, can significantly increase the performance and attendant efficiency. One approach to reducing such gaps is to deploy abradable coatings on the stationary shroud components as seals, to reduce the blade-tip clearances under operational conditions. Abradable coatings must be able to withstand high temperature oxidation, thermal cycling, and erosion, while providing optimal controlled abrasion and associated shape retention. Existing abradable seals utilized in power generation turbines have generally been optimized for use with natural gas-fired systems; however, preliminary testing of syngas and high-hydrogen-content (HHC) fired turbines has shown that the stability of hot-section materials (and presumably abradable sealing materials) may be substantially altered due to characteristic changes in the combustion by-products (partial pressures of water vapor, etc.) as well as characteristic impurities and particulate matter entrained in the fuel. The primary focus of this research program has been to develop a mechanistic understanding of how the altered combustion environments modify the thermo-mechanical stability and performance of the sealing materials, including the requisite abradable sealing behavior. A key component of the research program carried out has been an exploration of mechanisms underpinning observed degradation processes, and an assessment of connections to the combustion environments and characteristic non-combustible constituents. The ultimate goal of the project has been to advance the goals of the Advanced Turbine Program by developing materials design protocols leading to turbine hot-section components with improved resistance to service lifetime degradation under advanced fuels exposures. This research program has evaluated the performance and degradation of ceramic abradable seals used in the high-temperature turbine sections of gas turbine engines. The focus has been two-fold: (1) to understand performance of such materials in relation to the turbines operating on coal-derived syngas and high hydrogen content (HHC) fuels, ultimately seeking an improved understanding of factors that control performance and durability of abradable seal materials for these combustion environments (and play into materials design protocols); and (2) to evaluate the potential of alternative materials as abradable seals for the higher temperatures expected with IGCC and HHC fueled turbine systems. In particular, we carried out an initial assessment of multi-layered systems of existing abradable seal materials (YSZ) and other ceramics. The research program also investigated several classes of abradable coatings under simulated exposures to syngas-based combustion environments, evaluating the relevant wear behavior, hardness, stability under cyclic oxidation, and general thermo-mechanical behavior. The research also attempted to develop alternatives to carrying out full-scale combustion-based abradability test rig exposures to evaluate materials system performance. The research has been focused on correlating the measured thermo-mechanical behavior, and controlled abrasive wear, with the intrinsic properties of the multilayer coatings and processing-controlled microstructural features that have shown attractive machinability characteristics based on weak interfacial bonding between the constituent phases at elevate temperatures (while maintaining thermochemical stability). This program has resulted in an improved mechanistic understanding of factors governing performance of high temperature abradable seals, and degradation mechanisms unique to IGCC-based power generation turbine systems and the realization of coal-derived syngas and HHC-based combustion environments – ultimately with the goal of developing a knowledge base upon which the design of coatings that retain optimal sealing characteristics and are more resistant to the observed wear/attack mechanisms, important aspects of advancing the goals of the DOE Advanced Turbine Program.

36 MATERIALS SCIENCE↗

Environmental Impact Statement for the Space Shuttle Program

Test firings and launches will release air pollutants causing a temporary localized small degradation in air quality near the tests or launch site. Areas adjacent to the site will also be subjected to moderate sound levels of predominantly low frequencies for short durations. During the launch phase, hydrogen chloride will be introduced into the stratosphere causing a small decrease in ozone. Temporary perturbations to the ionosphere will occur during orbital maneuvers and entry will have no significant effect on communication or radio wave propagation. As the Orbiter descends, a low magnitude sonic beam will be produced along the groundtrack with maximum overpressures occurring near the landing site. The overpressures will be infrequent, will vary in location and are of sufficiently low energy to be considered a momentary annoyance, if noticed at all. Major alternatives considered are discontinuation or postponement of the program, use of alternate propellants and neutralization of the ground cloud.

Malkin, M. S.↗

Integrated Solar Upper Stage Technical Support

NASA Lewis Research Center is participating in the Integrated Solar Upper Stage (ISUS) program. This program is a ground-based demonstration of an upper stage concept that will be used to generate both solar propulsion and solar power. Solar energy collected by a primary concentrator is directed into the aperture of a secondary concentrator and further concentrated into the aperture of a heat receiver. The energy stored in the receiver-absorber-converter is used to heat hydrogen gas to provide propulsion during the orbital transfer portion of the mission. During the balance of the mission, electric power is generated by thermionic diodes. Several materials issues were addressed as part of the technical support portion of the ISUS program, including: 1) Evaluation of primary concentrator coupons; 2) Evaluation of secondary concentrator coupons; 3) Evaluation of receiver-absorber-converter coupons; 4) Evaluation of in-test witness coupons. Two different types of primary concentrator coupons were evaluated from two different contractors-replicated coupons made from graphite-epoxy composite and coupons made from microsheet glass. Specular reflectivity measurements identified the replicated graphite-epoxy composite coupons as the primary concentrator material of choice. Several different secondary concentrator materials were evaluated, including a variety of silver and rhodium reflectors. The specular reflectivity of these materials was evaluated under vacuum at temperatures up to 800 C. The optical properties of several coupons of rhenium on graphite were evaluated to predict the thermal performance of the receiver-absorber-converter. Finally, during the ground test demonstration, witness coupons placed in strategic locations throughout the thermal vacuum facility were evaluated for contaminants. All testing for the ISUS program was completed successfully in 1997. Investigations related to materials issues have proven helpful in understanding the operation of the test article, leading to a potential ISUS flight test in 2002.

Jaworske, Donald A.↗