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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 127 records · Page 7

Dynamic characteristics of a high-speed rotor with radial and axial foil-bearing supports

An asymmetric rotor (19N; 4.3 lb), supported radially and axially by compliant bearings is subjected to severe excitation by rotating unbalance in the 'pitching' mode at speeds to 50,000 rpm. The resilient, air-lubricated bearings provide very effective damping, so that regions of resonance and instability can be traversed with amplitudes and limit-trajectories within acceptable bounds. A novel journal bearing is introduced, in which a resilient support is furnished by the outer turn of the coiled foil-element bent to form an open polygon. The experimental apparatus and procedure are described, and the response of the rotor and flexible support system are documented by oscilloscope records of motion.

Licht, L.↗

Summary of aerothermal test results from the first flight of the Pegasus air-launched space booster

Temperature measurements were obtained on the Pegasus booster from launch through Mach 8.0. The majority of sensors were thin-foil temperature gages installed near the surface within the vehicle's ablating thermal protection system. These gages were distributed on the wing surfaces and on the wing-body fairing or fillet. Temperature time histories from these installations are presented. In addition, thermocouples were installed on the surface of nonablating plugs located on the fairing. These sensors were more responsive to changes in flight conditions than the foil gages and allowed a derivation of convective heat flux. A heating rate magnification of 2 was found in the vicinity of the wing shock interaction.

Noffz, Gregory K.↗

High temperature insulation materials for reradiative thermal protection systems

Results are presented of a two year program to evaluate packaged thermal insulations for use under a metallic radiative TPS of a shuttle orbiter vehicle. Evaluations demonstrated their survival for up to 100 mission reuse cycles under shuttle acoustic and thermal loads with peak temperatures of 1000 F, 1800 F, 2000 F, 2200 F and 2500 F. The specimens were composed of low density refractory fiber felts, packaged in thin gage metal foils. In addition, studies were conducted on the venting requirements of the packages, salt spray resistance of the metal foils, and the thermal conductivity of many of the insulations as a function of temperature and ambient air pressure. Data is also presented on the radiant energy transport through insulations, and back-scattering coefficients were experimentally determined as a function of source temperature.

Hughes, T. A.↗

Process Development of the Vaporizing Foil Actuator Welding Technique

The industrial focus on continuous improvement for products is leading design engineers to consider multi-material design concepts more frequently. The design concepts use the advantages of each material while simultaneously minimizing the drawbacks. It also allows for the overall weight of the products to be reduced. Some traditional joining methods, though, struggle to join dissimilar material combinations. A technique known as vaporizing foil actuator welding, which was developed around ten years ago, is a solid-state joining method that has the potential to overcome the barriers to dissimilar material joining. The biggest drawbacks of vaporizing foil actuator welding are that it is still exclusively used in laboratory settings and early in the technology development process. As such, there is not enough confidence in the process for it to be transitioned to manufacturing environments yet. This work begins by analyzing the current state of the technology and identifying a roadmap to achieve a transition to manufacturing. The analysis found that increased confidence in the technology requires sample to sample repeatability to be improved. Beyond that, the process also needs to be fully automated before it can be considered as a viable technique for mass production. In order to further develop the technique, a fully automated work cell was constructed. By removing the human element from the process, this cell helped identify iii the aspects which contribute to process variability. The positioning of the vaporizing foil actuator was identified as the most important factor in process stability. A small set of samples were made in the automated cell with the addition of one component epoxy adhesive around the perimeter of the weld. These samples showed improved process repeatability compared with the samples made without adhesive. This indicates that small amounts of adhesive may be critical in using the process in industrial settings. Additionally, work was performed with manual positioning and adhesive dispensing. This work found that a hybrid joint behaves like traditional weld bonding, where the addition of adhesive makes the joint stronger than if either of the two joining methods were used on their own. To realize this performance with vaporizing foil actuator welding, though, the adhesive needs to be protected from burning during the rapid compression of air during the impact process.

36 MATERIALS SCIENCE↗

Contamination monitoring of the OSIRIS-REx ISO5 asteroid sample cleanroom

The OSIRIS-REx mission to asteroid Bennu successfully collected hundreds of grams of asteroid regolith in October 2020 [1]. The spacecraft departed Bennu in May 2021 for Earth return and will release the sample canister to be recovered in Utah in September 2023 [2]. Samples will be transported to the curation facility at NASA Johnson Space Center, where an ISO5 equivalent cleanroom has been designed in 2017 and completed in 2021. Aspects of the design and material selection for the cleanroom and its supporting facilities (air handling system, cleanroom floors and walls, filters, paints, etc.) were optimized to minimize effects of organic and inorganic contaminants and offgassing [3]. Since its completion, the lab has been carefully monitored to understand and establish a baseline with respect to multiple environmental aspects – measurement of particle counts, deploying Si wafer witness plates for organic and inorganic contaminants, deploying aluminum foils for a focus on organics with JSC in-house expertise, gas samples, and regular microbial and fungal measurements on selected surfaces and air samples in the cleanroom. This contribution will report on nearly one year of monitoring and highlight several specific aspects that have led to a better understanding of the new cleanroom environment.

carbonaceous asteroid↗

Use of piezoelectric foil for flow diagnostics

A laboratory investigation was conducted to characterize two piezoelectric-film sensor configurations, a rigidly mounted sensor and a sensor mounted over an air cavity. The sensors are evaluated for sensitivity and frequency response, and methods to optimize data are presented. The cavity-mounted sensor exhibited a superior frequency response and was more sensitive to normal pressure fluctuations and less sensitive to vibrations through the structure. Both configurations were sensitive to large-scale structural vibrations. Flight-test data are shown for cavity-mounted sensors, illustrating practical aspects to consider when designing sensors for application in such harsh environments. The relation of the data to skin friction and maximum shear stress, transition detection, and turbulent viscous layers is derived through analysis of the flight data.

Carraway, Debra L.↗

Analytic Modeling of the Hydrodynamic, Thermal, and Structural Behavior of Foil Thrust Bearings

A simulation and modeling effort is conducted on gas foil thrust bearings. A foil bearing is a self acting hydrodynamic device capable of separating stationary and rotating components of rotating machinery by a film of air or other gaseous lubricant. Although simple in appearance these bearings have proven to be complicated devices in analysis. They are sensitive to fluid structure interaction, use a compressible gas as a lubricant, may not be in the fully continuum range of fluid mechanics, and operate in the range where viscous heat generation is significant. These factors provide a challenge to the simulation and modeling task. The Reynolds equation with the addition of Knudsen number effects due to thin film thicknesses is used to simulate the hydrodynamics. The energy equation is manipulated to simulate the temperature field of the lubricant film and combined with the ideal gas relationship, provides density field input to the Reynolds equation. Heat transfer between the lubricant and the surroundings is also modeled. The structural deformations of the bearing are modeled with a single partial differential equation. The equation models the top foil as a thin, bending dominated membrane whose deflections are governed by the biharmonic equation. A linear superposition of hydrodynamic load and compliant foundation reaction is included. The stiffness of the compliant foundation is modeled as a distributed stiffness that supports the top foil. The system of governing equations is solved numerically by a computer program written in the Mathematica computing environment. Representative calculations and comparisons with experimental results are included for a generation I gas foil thrust bearing.

Bruckner, Robert J.↗

Advanced Gas Turbine (AGT) powertrain system development for automotive applications

Topics covered include the AGT 101 engine test; compressor design modification; cold air turbine testing; Mod 1 alloy turbine rotor fabrication; combustion aspects; regenerator development; and thermal screening tests for ceramic materials. The foil gas bearings, rotor dynamics, and AGT controls and accessories are also considered.

Source record↗

Aerothermal test results from the second flight of the Pegasus booster

A survey of temperature, heat-flux, and pressure measurements was obtained at speeds through Mach 8.0 on the second flight of the Pegasus air-launched space booster system. All sensors were distributed on the wing-body fairing or fillet. Sensors included thin foil-gauge thermocouples installed near the surface within the thermal protection system. Thermocouples were also installed on the surface of nonablating plugs. The resulting temperature time history allowed derivation of convective heat flux. In addition, commercially available calorimeters were installed on the fillet at selected locations. Calorimeters exhibited a larger change in measured heat flux than collocated nonablating plugs in response to particular events. Similar proportional variations in heat flux across different regions of the fillet were detected by both the calorimeters and nonablating plugs. Pressure ports were installed on some nonablating plugs to explore the effects of port protrusion and high-frequency noise on pressure requirements. The effect of port protrusion on static-pressure measurements was found to decrease with increasing Mach number. High-frequency noise suppression was found to be desirable but not required on any future flight.

Noffz, Gregory K.↗

Friction and Wear Characteristics of Candidate Foil Bearing Materials from 25 C to 800 C

The friction and wear behavior of unlubricated metal/metal sliding couples was investigated to screen potential candidates for high temperature foil bearings. The tribo-tests were run in an induction-heated high temperature pin-on-disk tribometer in an air atmosphere at a load of 4.9 N and at a sliding velocity of 1 m/s. The friction and wear properties of several nickel based alloys (Rene'41, Inconel X-750, Inconel 713C), iron based alloys (MA956 and Inconel 909) and a ceramic (Al2O3) were tested at 25, 500, and 800 C. In general, at elevated temperatures the alloys oxidized and formed a tenacious and lubricous oxide surface film or layer. At 800 C, Inconel X-750 versus Rene'41 had the lowest friction coefficient (0.27) and at 500 C, Inconel X-750 versus Inconel 909 the lowest pin wear (2.84 x 10(exp -6)cu mm/N-m). Gouging and severe wear of the softer material occurred whenever a significant difference in hardness existed between the pin and disk specimens.

DellaCorte, C.↗

Hermetic edge sealing of photovoltaic modules

The feasibility of using an electrostatic bonding (ESB) and ultrasonic welding process to produce hermetic edge seals on terrestrial solar cell modules was investigated. The fabrication sequence is to attach an aluminum foil "gasket' to the perimeter of a glass sheet. A cell circuit is next encapsulated inside the gasket, and its aluminum foil back cover is seam welded ultrasonically to the gasket. An ESB process for sealing aluminum to glass was developed in an ambient air atmosphere, which eliminates the requirement for a vacuum or pressure vessel. An ultrasonic seam welding process was also developed which did not degrade the quality of the ESB seal. Good quality welds with minimal deformation were produced. The effectiveness of the above described sealing techniques was tested by constructing 400 sq cm (8 x 8 s64 sq in) sample modules, and then subjecting them to nondestructive fine and gross leak tests. The gross leak tests identified several different causes of leaks which were then eliminated by modifying the assembly process.

Nowlan, M. J.↗

Diffusion Bonding of Silicon Carbide for a Micro-Electro-Mechanical Systems Lean Direct Injector

Robust approaches for joining silicon carbide (SiC) to silicon carbide sub-elements have been developed for a micro-electro-mechanical systems lean direct injector (MEMS LDI) application. The objective is to join SiC sub-elements to form a leak-free injector that has complex internal passages for the flow and mixing of fuel and air. Previous bonding technology relied upon silicate glass interlayers that were not uniform or leak free. In a newly developed joining approach, titanium foils and physically vapor deposited titanium coatings were used to form diffusion bonds between SiC materials during hot pressing. Microscopy results show the formation of well adhered diffusion bonds. Initial tests show that the bond strength is much higher than required for the component system. Benefits of the joining technology are fabrication of leak free joints with high temperature and mechanical capability.

Halbig, Michael C.↗

NASA PS400: A New Temperature Solid Lubricant Coating for High Temperature Wear Applications

A new solid lubricant coating, NASA PS400, has been developed for high temperature tribological applications. This plasma sprayed coating is a variant of the patented PS304 coating and has been formulated to provide higher density, smoother surface finish and better dimensional stability than PS304. PS400 is comprised of a nickel-molybdenum binder that provides strength, creep resistance and extreme oxidative and dimensional stability. Chromium oxide, silver and barium-calcium fluoride eutectic are added to the binder to form PS400.Tribological properties were evaluated with a pin-on-disk test rig in sliding contact to 650 C. Coating material samples were exposed to air, argon and vacuum at 760 C followed by cross section microscopic analysis to assess microstructure stability. Oil-Free microturbine engine hot section foil bearing tests were undertaken to assess PS400 s suitability for hot foil gas bearing applications. The preliminary results indicate that PS400 exhibits tribological characteristics comparable to the PS304 coating but with enhanced creep resistance and dimensional stability suitable for demanding, dynamic applications.

DellaCorte, C.↗

Isothermal and nonisothermal fatigue behavior of a metal matrix composite

The isothermal and nonisothermal fatigue resistance of a metal matrix composite (MMC) consisting of Ti-15V-3Cr-3Al-3Sn (Ti-15-3) matrix reinforced by 33 vol pct continuous SiC fibers was investigated. The fibers were nominally oriented parallel to the specimen axis. Isothermal fatigue tests were performed in air at 300 and 550 C. The MMC had good isothermal fatigue resistance at low cyclic stress, with fatigue cracks initiating from fiber-matrix interfaces and foil laminations. At high cyclic stresses, stress relaxation in the matrix reduced isothermal composite fatigue resistance at 550 C. Nonisothermal fatigue loading substantially degraded composite fatigue resistnce. This degradation was produced by a thermomechanical fatigue damage mechanism associated with the fiber-matrix interfaces.

Gabb, T. P.↗

Development of copper thiolate organometallic compound as thermal sensitive coating for energy storage system safety

Safety and reliability are primary concerns for the deployment of lithium-ion batteries, especially in electric vehicles (EV) and larger-scale energy storage systems (ESS). Current technology in battery management systems (BMS) includes cell voltage monitoring and positioning temperature sensors in selected locations. For a system with hundreds to thousands of individual batteries, single-point temperature monitoring is inadequate to detect hot spots and cell overheating, which could lead to thermal runaway. Here, we have developed a temperature-sensitive copper-thiol compound that can be directly coated onto battery pouch foils to enable early detection of thermal runaway. Upon reaching specific temperatures, this compound releases a sulfur-containing detectable gas, which can be identified using chemically specific gas sensors to trigger an early warning signal. Such a signal propagate through air offers broad signal coverage and enables a more comprehensive approach to large-area temperature monitoring. The Cu-ethanethiol coating is designed to release volatile gases when the substrate surface temperature exceeds 70 °C, with continuous outgassing as the temperature increases. The compound is composed of Cu, S, Cl, hydrocarbons and trace amounts of oxygen. Upon heating, the oxidation state of Cu(I) transitions to Cu (II), accompanied by gas release. Thermogravimetric analysis coupled with mass spectrometry correlated well with the onset of gas release temperature and emission of sulfur-containing volatile gases. Additionally, an acrylic overcoat is applied to enhance the adhesion of the thermally sensitive compound film to the battery pouch foil. This coating is expected to offer an additional safety layer for ESS, alerting possible thermal runaway events before a failure occurs, thereby allowing sufficient time to implement a mitigation plan.

Early warning systems↗

The GLACE-2 Experiment

A major motivation for the study of the coupled land-atmosphere system is the idea that soil moisture anomalies may affect future meteorological variables through their effects on future surface energy and water budgets. If true, the accurate initialization of soil moisture in a subseasonal or seasonal forecast system may improve forecast skill, making the forecast products more valuable to society. The Global Land-Atmosphere Coupling Experiment (GLACE-2) project is examining, with a wide variety of models, the degree to which subseasonal (out to two months) precipitation and air temperature forecasts improve through the realistic initialization of soil moisture. For the first time ever, a global consensus should emerge regarding the value of land initialization for forecasts, perhaps motivating national forecast centers to make full use of land moisture initialization in their operations. Participants in GLACE-2 perform two series of forecasts, each consisting of 100 2-month forecast ensembles (10 members per ensemble) covering ten boreal spring and summer start-dates in each of the years 1986-1995. Series 1 utilizes realistic land surface state initialization, provided through a decadal offline simulation using realistic meteorological forcing, as provided by the Global Soil Wetness Project - Phase 2 (GSWP-2), a research activity of the Global Land-Atmosphere System Study (GLASS) of GEWEX. Series 2 is identical to Series 1 in every way except for the fact that it does not benefit from realistic land state initialization. Through the comparison of Series 1 and 2, we isolate the impact of land initialization on the forecasts. Optional extensions to these base runs include forecasts covering additional years, using alternative meteorological forcing for the land initialization. To date, GLACE-2 has garnered participation from eleven modeling groups, covering 13 atmospheric models. Analysis of available results is already well underway, both at the individual modeling institutions and at the NASA Goddard Space Flight Center, which is coordinating the project. Analysis focuses on two elements of the forecast problem: (i) the quantification of model-specific "predictability" (i.e., the degree to which simulated atmospheric chaos will foil a forecast, even under the assumption of"perfect" model physics, initialization data, and validation data) and its decay with time; and (ii) the quantification of forecast skill, determined through a comparison of predicted precipitation and air temperature against observations. Indeed, the specific contribution of land initialization to both these elements is isolated through a comparison of the Series 1 and 2 forecasts. We examine the two elements at four different forecast leads: 1-15, 16-30, 31-45, and 46-60 days. Statistics-based approaches for enhancing skill (essentially using observational statistics to reduce the impact of the models' climatic biases) are also tested. In the present talk, we provide an update of progress in GLACE-2, featuring quantifications of predictability and forecast skill for a number of the participating models and providing a "first look" at the desired consensus view of land impacts on subseasonal forecasts.

Koster, Randal↗

Performance of the high speed anechoic wind tunnel at Lyon University

The characteristics of the feed duct, the wind tunnel, and the experiments run in the convergent-divergent anechoic wind tunnel at Lyon University are described. The wind tunnel was designed to eliminate noise from the entrance of air or from flow interactions with the tunnel walls so that noise caused by the flow-test structure interactions can be studied. The channel contains 1 x 1 x 0.2 m glass and metal foil baffles spaced 0.2 m apart. The flow is forced by a 350 kW fan in the primary circuit, and a 110 kW blower in the secondary circuit. The primary circuit features a factor of four throat reductions, followed by a 1.6 reduction before the test section. Upstream and downstream sensors permit monitoring of the anechoic effectiveness of the channel. Other sensors allow modeling of the flow structures in the tunnel. The tunnel was used to examine turbulent boundary layers in flows up to 140 m/sec, tubulence-excited vibrations in walls, and the effects of laminar and turbulent flows on the appearance and locations of noise sources.

Sunyach, M.↗

Oil-Free Rotor Support Technologies for Long Life, Closed Cycle Brayton Turbines

The goal of this study is to provide technological support to ensure successful life and operation of a 50-300 kW dynamic power conversion system specifically with response to the rotor support system. By utilizing technical expertise in tribology, bearings, rotordynamic, solid lubricant coatings and extensive test facilities, valuable input for mission success is provided. A discussion of the history of closed cycle Brayton turboalternators (TA) will be included. This includes the 2 kW Mini-Brayton Rotating Unit (Mini-BRU), the 10kW Brayton Rotating Unit (BRU) and the 125 kW turboalternator-compressor (TAC) designed in mid 1970's. Also included is the development of air-cycle machines and terrestrial oil-free gas turbine power systems in the form of microturbines, specifically Capstone microturbines. A short discussion of the self-acting compliant surface hydrodynamic fluid film bearings, or foil bearings, will follow, including a short history of the load capacity advances, the NASA coatings advancements as well as design model advances. Successes in terrestrial based machines will be noted and NASA tribology and bearing research test facilities will be described. Finally, implementation of a four step integration process will be included in the discussion.

Lucero, John M.↗