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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

Analysis of the Spread Across Liquid-5 (SAL-5) Experiment Failure to Fill Properly During Flight

When a pool of flammable liquid is ignited, the flame spread rate can vary widely depending on the initial fuel temperature, pool geometry, ambient atmospheric conditions, and gravitational level. There is substantial decades-old debate in the scientific literature about the role of gravity in these phenomena. The objective of the research was to measure ignition and flame spread across liquid pools in both normal and microgravity with and without forced airflow, and to obtain detailed thermal and velocity field data for comparison to a predictive numerical model that is concurrently being developed. To that end, an experiment known as Spread Across Liquids 5 (SAL 5) was designed to be conducted in a low-gravity environment on a sounding rocket. Unfortunately, during the sounding rocket flight the fuel tray for the experiment failed to fill properly prior to ignition. The primary cause of the failure to fill properly is the geometry of the fuel tray; that is, the presence of the gaps on the side walls and the sharp edge around the thermocouple through-holes. The contamination resulting from the cleaning process is a strong secondary factor which would have prevented proper, timely filling had the primary cause not been present.

Allen, Jeffrey Stuart↗

Transient natural and surface-tension-driven convection in a two-layer gas-and-liquid enclosure with nonuniform radiative transfer

A numerical study has been made of transient heat transfer and fluid flow in a cylindrical enclosure containing a two-layer gas-and-liquid system. The geometric configuration and the boundary conditions of the problem are relevant to the analysis of the preignition processes during the fire accident situation involving a pool of liquid fuel in the vicinity of an ignition source. It is demonstrated that the effects of the natural and thermocapillary convection, radiative transfer, thermal inertia and conduction of the walls bounding the enclosure, as well as, the magnitude of the gravity field play important roles in the development of the temperature and velocity fields in the container.

Abramzon, B.↗

Ignition Delay Associated with a Strained Strip

Ignition processes associated with two adjacent fuel-oxidizer interferences bounding a strained fuel strip are explored here using single-step activation energy asymptotics. Calculations are made for constant as well as temporally decaying strain fields. There possible models of ignition are determined: one in which the two interfaces ignite independently as diffusion flames; one in which the two interfaces ignite dependently and in which ignition occurs to form a single , premixed flame at very high strain rates before ignition is completely prevented. In contrast to a single, isolated interface in which ignition can be prevented by overmatching heat production with heat convection due to strain, ignition of a strained fuel strip can also be prevented if the finite extend of fuel is diluted by oxidizer more quickly than heat production can cause a positive feedback thermal runaway. These behaviors are dependent on the relative sizes of timescales associated with species and heat diffusion, with convection due to strain, and with the chemical reaction. The result here indicate that adjacent, strained species interfaces may ignite quite differently in nature from ignition of a single, strained intrface and that their interdependence should be considered as the interfaces are brought closer together in complex strain fields. Critical strain rates leading to complete ignition delay are found to be considerably smaller for the fuel strip than those for single interfaces as the fuel strip is made thin in comparison to diffusion and chemical length scales.

Gerk, T. J.↗

Hydrogen flash in stars.

The initial adiabat of the gas in a flat rotating disk is estimated in several ways. A star which can be represented by a polytrope of index 1.5 is considered. The central conditions are determined through specification of the total mass and the adiabatic constant. The values for the temperature and the density of the center are much higher than now exist at the center of the sun. It is possible that the ignition of hydrogen-burning reactions at the center of the disk can be accompanied by a thermal runaway.

Perri, F.↗

Self-sterilizing canister

Canister, originally conceived for remote sterilization of spacecraft packages, could be used terrestrially to handle samples in biologically hazardous environments. Multiwalled canister includes inner layer of pyrotechnic powder. For sterilization, electrically activated squib ignites powder, raising temperature of outer surface of canister to 230 degrees centigrade for several minutes. Thermal-buffer inner layer prevents inside temperature for exceeding 100 degrees centigrade to protect contents from damage. Samples in field hospitals and other emergency situations could also be handled by equipment.

Yang, L. C.↗

Alternative aircraft fuels

The efficient utilization of fossil fuels by future jet aircraft may necessitate the broadening of current aviation turbine fuel specifications. The most significant changes in specifications would be an increased aromatics content and a higher final boiling point in order to minimize refinery energy consumption and costs. These changes would increase the freezing point and might lower the thermal stability of the fuel, and could cause increased pollutant emissions, increased combustor liner temperatures, and poorer ignition characteristics. The effects that broadened specification fuels may have on present-day jet aircraft and engine components and the technology required to use fuels with broadened specifications are discussed.

Longwell, J. P.↗

Flame Spread Along Free Edges of Thermally Thin Samples in Microgravity

The effects of imposed flow velocity on flame spread along open edges of a thermally thin cellulosic sample in microgravity are studied experimentally and theoretically. In this study, the sample is ignited locally at the middle of the 4 cm wide sample and subsequent flame spread reaches both open edges of the sample. The following flame behaviors are observed in the experiments and predicted by the numerical calculation; in order of increased imposed flow velocity: (1) ignition but subsequent flame spread is not attained, (2) flame spreads upstream (opposed mode) without any downstream flame, and (3) the upstream flame and two separate downstream flames traveling along the two open edges (concurrent mode). Generally, the upstream and downstream edge flame spread rates are faster than the central flame spread rate for an imposed flow velocity of up to 5 cm/s. This is due to greater oxygen supply from the outer free stream to the edge flames than the central flames, For the upstream edge flame, the greater oxygen supply results in a flame spread rate that is nearly independent of, or decreases gradually, with the imposed flow velocity. The spread rate of the downstream edge, however, increases significantly with the imposed flow velocity.

Mell, W. E.↗

Flame Spread Along Free Edges of Thermally Thin Samples in Microgravity

The effects of imposed flow velocity on flame spread along open edges of a thermally thin cellulosic sample in microgravity were studied experimentally and theoretically. In this study, the sample was ignited locally at the middle of the 4 cm wide sample, and subsequent flame spread reached both open edges of the sample along the direction of the flow. The following flame behaviors were observed in the experiments and predicted by the numerical calculation, in order of increased imposed flow velocity: (1) ignition but subsequent flame spread was not attained, (2) flame spread upstream (opposed mode) without any downstream flame, and (3) the upstream flame and two separate downstream flames traveled along the two open edges (concurrent mode). Generally, the upstream and downstream edge flame spread rates were faster than the central flame spread rate for an imposed flow velocity of up to 5 cm/s. This was due to greater oxygen supply from the outer free stream to the edge flames and more efficient heat transfer from the edge flames to the sample surface than the central flames. For the upstream edge flame, flame spread rate was nearly independent of, or decreased gradually with, the imposed flow velocity. The spread rate of the downstream edge, however, increased significantly with the imposed flow velocity.

MICROGRAVITY↗

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗

Cathode & Electromagnet Qualification Status and Power Processing Unit Development Update for the Ascendant Sub-kW Transcelestial Electric Propulsion System

A review of the component-level flight qualification efforts and power processing unit development status of the Ascendant Sub-kW Transcelestial Electric Propulsion System (ASTRAEUS) program is presented. Component-level qualification efforts were undertaken for the system’s ultra-compact heaterless LaB6 hollow cathode and electromagnets, both of which employ designs bespoke to ASTRAEUS, as they represent the highest failure risks for the thruster. Through parallel long-duration wear and ignition tests, the ASTRAEUS cathode demonstrated invariant discharge performance over more than 5000 h of operation at its maximum operating current of 4 A and demonstrated more than 25,000 ignition cycles. The ASTRAEUS electromagnets completed their environmental qualification through a demonstration of more than 1200 deep thermal cycles with no indication of coil degradation (the test articles previously completed qualification-level vibration and shock testing). ASTRAEUS’s prototype power processing unit has demonstrated more than 92% total power conversion efficiency and class-leading power density & specific power density of 4.5 W/cm3 & 1670 W/kg, respectively. The various power converters found in the ASTRAEUS power processing unit are reviewed with a focus on the methods by which such high performance was achieved.

Conversano, Ryan W.↗

Status of Hollow Cathode Heater Development for the Space Station Plasma Contactor

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Heater tests included testing of the heater unit alone and plasma contactor and ion thruster testing. To date, eight heaters have been or are being processed through heater unit testing, two through plasma contactor testing and three through ion thruster testing, all using direct current power supplies. Comparisons of data from heater unit performance tests before cyclic testing, plasma contactor tests, and ion thruster tests at the ignition input current level show the average deviation of input power and tube temperature near the cathode tip to be +/-0.9 W and +/- 21 C, respectively. Heater unit testing included cyclic testing to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Four additional heaters successfully completed 6300, 6300, 700, and 700 cycles. Heater unit testing is currently ongoing for three heaters which have to date accumulated greater than 7250, greater than 5500, and greater than 5500 cycles, respectively.

Soulas, George C.↗

Proactive Wildfire Management: A Remote Sensing and Multimodal CNN-MLP Architecture for Ignition Risk Forecasting

As the frequency and intensity of wildfires increase, with fire seasons now starting earlier and ending later than they have over the past decades, current monitoring systems, such as lookout towers and satellites, are hindered by cloud cover, low-resolution imagery, and static data gaps that fail to track vegetation moisture levels fast enough to catch rapid pre-ignition changes. This report proposes a Machine Learning-enabled Wildfire Ignition Prediction framework that combines satellite monitoring with dynamic and high-resolution remote sensing from Unmanned Aerial Vehicle (UAV) swarms. The method would use multispectral and thermal data from the Landsat program to create a baseline for vegetation health, calculating a two-band Enhanced Vegetation Index (EVI2) and the moisture content of the vegetation. These inputs will later be fused with microscale UAV weather data, including thermal hotspots found through thick canopies, hyperspectral chemical signatures of pre-visual combustion, and local weather streams. The multispectral satellite, multispectral Light Detection and Ranging (LiDAR), and thermal data would then be processed through a Convolutional Neural Network (CNN), alongside a Multilayer Perceptron (MLP) for the micro-weather telemetry. The outputs of these networks would be fused into a single feature representation and passed through a final prediction network to generate real-time ignition risk scores and hotspot alerts. Model performance would be assessed using standard classification metrics, including a Receiver Operating Characteristic - Area Under the Curve (ROC AUC) and F1 score. This system would allow first responders to identify high-risk zones and intervene before ignition occurs, improving emergency response time compared to current approaches.

machine learning↗

Hollow cathode heater development for the Space Station plasma contactor

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater design. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Three heaters have been tested to date using direct current power supplies. Performance testing was conducted to determine input current and power requirements for achieving activation and ignition temperatures, single unit operational repeatability, and unit-to-unit operational repeatability. Comparisons of performance testing data at the ignition input current level for the three heaters show the unit-to-unit repeatability of input power and tube temperature near the cathode tip to be within 3.5 W and 44 degrees C, respectively. Cyclic testing was then conducted to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Two additional heaters were subsequently fabricated and have completed 3178 cycles to date in an on-going test.

Soulas, George C.↗

Evaluation of dissociated and steam-reformed methanol as automotive engine fuels

Dissociated and steam reformed methanol were evaluated as automotive engine fuels. Advantages and disadvantages in using methanol in the reformed rather than liquid state were discussed. Engine dynamometer tests were conducted with a four cylinder, 2.3 liter, spark ignition automotive engine to determine performance and emission characteristics operating on simulated dissociated and steam reformed methanol (2H2 + CO and 3H2 + CO2 respectively), and liquid methanol. Results are presented for engine performance and emissions as functions of equivalence ratio, at various throttle settings and engine speeds. Operation on dissociated and steam reformed methanol was characterized by flashback (violent propagation of a flame into the intake manifold) which limited operation to lower power output than was obtainable using liquid methanol. It was concluded that: an automobile could not be operated solely on dissociated or steam reformed methanol over the entire required power range - a supplementary fuel system or power source would be necessary to attain higher powers; the use of reformed mechanol, compared to liquid methanol, may result in a small improvement in thermal efficiency in the low power range; dissociated methanol is a better fuel than steam reformed methanol for use in a spark ignition engine; and use of dissociated or steam reformed methanol may result in lower exhaust emissions compared to liquid methanol.

Lalk, T. R.↗

Near-limit flame structures at low Lewis number

The characteristics of premixed gas flames in mixtures with low Lewis numbers near flammability limits were studied experimentally using a low-gravity environment to reduce buoyant convection. The behavior of such flames was found to be dominated by diffusive-thermal instabilities. For sufficiently reactive mixtures, cellular structures resulting from these instabilities were observed and found to spawn new cells in regular patterns. For less reactive mixtures, cells formed shortly after ignition but did not spawn new cells; instead these cells evolved into a flame structure composed of stationary, apparently stable spherical flamelets. Experimental observations are found to be in qualitative agreement with elementary analytical models based on the interaction of heat release due to chemical reaction, differential diffusion of thermal energy and mass, flame front curvature, and volumetric heat losses due to gas and/or soot radiation.

Ronney, Paul D.↗

Combustion efficiency determined from wall pressure and temperature measurement in a Mach 2 combustor

A study of transverse hydrogen injection behind a rearward facing step in a Mach 2 airflow was conducted to determine the combustion efficiency and the combustor/inlet interactions at the low temperature lean-mixture operational end of a scramjet combustor model. The fuel was injected at sonic conditions into the electrically heated airstream, which was maintained at 850 K or below. The static pressure delivered at the entrance of the combustor ranged between 0.25 to 0.5 atm. Injector configurations included single and staged injectors placed at 3 or 3-and-7 step-heights downstream of the step, respectively, with injector diameters of 1, 1.5, and 2 mm. Ignition was achieved by initially unstarting the test section. The constant area combustor and the low initial temperatures caused thermal choking and upstream interaction to occur at very low equivalence ratios. Typically, most of the fuel was burned in the recirculation region behind the step and around the jets. The effects of initial conditions (temperature and pressure), fuel-to-air dynamic pressure ratio, and boundaries (thermal vs adiabatic) are presented.

Segal, Corin↗