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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

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NASA NTRS1993

Thermal-mechanical behavior of high precision composite mirrors

Composite mirror panels were designed, constructed, analyzed, and tested in the framework of a NASA precision segmented reflector task. The deformations of the reflector surface during the exposure to space enviroments were predicted using a finite element model. The composite mirror panels have graphite-epoxy or graphite-cyanate facesheets, separated by an aluminum or a composite honeycomb core. It is pointed out that in order to carry out detailed modeling of composite mirrors with high accuracy, it is necessary to have temperature dependent properties of the materials involved and the type and magnitude of manufacturing errors and material nonuniformities. The structural modeling and analysis efforts addressed the impact of key design and materials parameters on the performance of mirrors.

Kuo, C. P.↗

DOE OSTI2024

AGR-5/6/7 CAPSULE 1 THERMAL MODEL WITH OFFSET GAS GAPS

Fuel compact temperatures are a crucial factor in assessing the irradiation performance of tristructural isotropic (TRISO) fuel particles. In the absence of direct measurement, fuel compact temperatures were calculated using a 3 D finite-element thermal model that was subject to simulation uncertainty. The most dominant factor in the uncertainty of calculated fuel temperatures is the gas gap uncertainty caused by the graphite holder nub-to-capsule clearance. This thermal model was revised to examine the most probable graphite offset position for Capsule 1 for four different days during the irradiation. In the analysis, the offset distance and azimuthal direction at both the top and bottom of the holder were varied. The best-fit offset was estimated based on the minimum root mean square error (RMSE) of the residuals (measured minus calculated thermocouple [TC] temperatures) for the operational TCs in Capsule 1. Near the end of the irradiation, when the graphite had shrunk and the gas gaps had grown, a peak temperature was found with maximum offset along the TC lines, with nickel introducing a potential mechanism for fuel particle failures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1991

Nonlinear static and dynamic finite element analysis of an eccentrically loaded graphite-epoxy beam

The Dynamic Crash Analysis of Structures (DYCAT) and NIKE3D nonlinear finite element codes were used to model the static and implulsive response of an eccentrically loaded graphite-epoxy beam. A 48-ply unidirectional composite beam was tested under an eccentric axial compressive load until failure. This loading configuration was chosen to highlight the capabilities of two finite element codes for modeling a highly nonlinear, large deflection structural problem which has an exact solution. These codes are currently used to perform dynamic analyses of aircraft structures under impact loads to study crashworthiness and energy absorbing capabilities. Both beam and plate element models were developed to compare with the experimental data using the DYCAST and NIKE3D codes.

Fasanella, Edwin L.↗

DOE OSTI2025

Utilization of Carbon Supply Chain Wastes and Byproducts to Manufacture Graphite for Energy Storage Applications

This project explored how coal and waste coal can be transformed into high-value graphite used in batteries for electric vehicles and power grids. A manufacturing technique that converts coal into carbon foam and subsequently graphite was developed and refined to improve the thermal and mechanical properties of the resulting materials. Cost-effectiveness and environmental impacts were also evaluated. Coal-derived graphite, especially when processed at high temperatures, was shown to perform comparably to commercial graphite in battery tests. Advanced computer simulations were used to model battery behavior and predict long-term performance, demonstrating that coal-based graphite has the potential to support electric vehicle deployment while reducing reliance on imported materials. This work offers a promising pathway for cleaner energy storage solutions and creates economic opportunities for coal-reliant communities by generating new uses for mining byproducts.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

AGR-5/6/7 Thermal Model with Non-uniform Gas Gaps

The daily as-run thermal analysis for the Advanced Gas Reactor (AGR)-5/6/7 experiment was documented in ECAR-5633 (Hawkes 2021). A finite element model was created for the entire test train, which consisted of five capsules. The fuel compacts, graphite holders, stainless-steel capsule walls, and all other major components were individually modeled, including all thermocouples (TCs). Daily heat rates for each compact and component in the model were input from daily as-run physics analyses. Daily gas compositions for each capsule were also input. The thermal conductivity of the compacts and graphite holders varied with fast neutron fluence. Gas mixture thermal conductivity was implemented using experimentally attained values from the literature. Fluence and temperature-dependent thermal conductivity was used for the graphite components and the fuel compacts. Radiation heat transfer was implemented. The model was tuned in an attempt to match the TC readings during the first cycle by adjusting the Neolube (graphite lubricant) thickness.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Microreactor Core Transportation Cask Model Description for Criticality Safety Validation Basis Assessment (Rev. 2)

Criticality safety analyses are completed on transportation casks used for microreactor whole core shipment to provide examples of models and analyses to industry, regulators, and nuclear community at large to be used in verification and validation analyses of similar applications. The microreactors considered are based on a Gas-Cooled Microreactor (GCMR) and a Heat-Pipe Microreactor (HPMR), both utilize HALEU fuel in the form of TRISO particles and various other design options considered in industry microreactor designs. Variant design options of GCMR and HPMR were also investigated to provide a wider application range for each technology. Criticality safety analyses for the GCMR and HPMR packages were performed using the CSAS6 sequence of SCALE 6.3.2 with the ENDF/B-VII.1-based continuous energy neutron libraries. Different scenarios were investigated, including normal operation and water flooded conditions to represent nominal and hypothetical accident scenarios. Sensitivity and similarity analyses are also performed using the TSUNAMI sequence of SCALE 6.3.2, and the similarity analysis uses all the experiments from the ICSBEP Handbook with High Enriched Uranium (HEU), Intermediate and mixed Enriched Uranium (IEU) and Low Enriched Uranium (LEU) systems. Many ICSBEP experiments were found marginally similar, with similarity index (ck) values greater than 0.8, to the GCMR and HPMR cask models, especially in flooded conditions that may be more constraining due to reduced reactivity margins. Some experiments using TRISO fuel particles and graphite moderator, including the recent THETA and Deimos experiments from LANL, together with some IRPhEP experiments, were also used for the similarity analyses. These TRISO-fueled and graphite moderated experiments behaved similarly to the GCMR models, with maximum ck value greater than 0.9, but they are less similar to the HPMR models. This observation indicates that additional critical experiments might be needed to further validate the criticality safety models, especially for heat-pipe based microreactor transport packages and for non-flooded transportation configurations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1990

Eddy current inspection of graphite fiber components

The recognition of defects in materials properties still presents a number of problems for nondestructive testing in aerospace systems. This project attempts to utilize current capabilities in eddy current instrumentation, artificial intelligence, and robotics in order to provide insight into defining geometrical aspects of flaws in composite materials which are capable of being evaluated using eddy current inspection techniques. The unique capabilities of E-probes and horseshoe probes for inspecting probes for inspecting graphite fiber materials were evaluated and appear to hold great promise once the technology development matures. The initial results are described of modeling eddy current interactions with certain flaws in graphite fiber samples.

Workman, G. L.↗

DOE OSTI2024

Oxidation of Silicon Carbide with Atomic Oxygen through the Passive-to-Active Transition

The inelastic and reactive scattering dynamics of O( 3 P) atoms on a 6H-silicon carbide (SiC) surface were investigated as a function of temperature with a molecular beam-surface scattering technique that employed a rotatable mass spectrometer detector. One set of experiments used a pulsed hyperthermal beam that produced ~8 km s –1 O atoms, and another set of experiments used a continuous beam that contained O atoms with a nominal velocity of ~2 km s –1 . When exposed to the relatively low-flux, pulsed hyperthermal O-atom beam, a passive oxide layer on the SiC that formed at lower temperatures decomposed as the temperature increased above 1673 K. Instead of entering an active oxidation regime, a graphitic layer formed on the surface and largely protected the underlying SiC from incoming O atoms. Investigation of the oxide decomposition without O-atom bombardment revealed volatile Si and SiO products at the moment that the oxide decomposed, implying that Si sublimation occurs concurrently with oxide decomposition. In the experiment with the continuous (higher flux) O-atom beam, volatile SiO and CO products were observed after the passive oxide decomposed, indicating that active oxidation was reached. Finally, the results of this study provide evidence for the importance of Si sublimation within the active oxidation regime. Above the passive-to-active transition temperature, Si sublimation is an ongoing process, and continuous active oxidation will only occur if sufficient oxygen reacts with the surface to produce SiO more quickly than a graphitic layer can form. Thus, accurate models of SiC ablation by atomic oxygen must account for multiple competing mechanisms that depend on the surface temperature and incident O-atom flux.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1986

Dynamic response and stability of a composite prop-fan model

Results are presented for blade response and stability during wind tunnel tests of a 62.2 cm diameter model of a prop-fan, advanced turboprop, with swept graphite/epoxy composite blades. Measurements of dynamic response were made with the rotor mounted on an isolated nacelle, with varying tilt for nonuniform inflow, at flow speeds from 0.36 to 0.9 Mach number. The blade displayed no instabilities over the operating range tested, up to 0.9 Mach number and 10,000 RPM. Measurements are compared with those for other prop-fan models of both solid metal and graphite composite construction. The swept composite blade had less response than an unswept composite blade. Composite blades had more response than metal blades. Measurements are compared with theoretically based predictions. The 1-P blade response was significantly overpredicted using unimproved methods and somewhat overpredicted using improved methods. Unexpectedly high 2-P strain levels were measured and suggest the presence of nonlinear effects on blade response.

Smith, A. F.↗

NASA NTRS1990

Impact damage in composite laminates

A low-velocity impact-damage model for quasi-symmetric graphite-fiber composite plates is presented. The distribution of damage in each layer of the plate was calculated by employing Di Sciuva's composite laminate theory together with Hashin's failure criterion for fiber-reinforced composites. The dynamic deformation of the target plate was represented by the lower vibrational modes of the plate. The principle of virtual work was applied in the formulation of the problem. In the analysis, the material was regarded as 'damaged' when its designed strength was reduced by the failure of its constituents. The constituent failures consisted of matrix crackings, fiber breakages, and delamination between layers. According to damage modes, the moduli of material in the damaged zone were reduced according to the failure criteria. The interaction between layers and its role in damage propagation were also studied.

Wang, Chung-Yue↗

NASA NTRS2001

New Interstellar Dust Models Consistent with Interstellar Extinction, Emission and Abundances Constraints

We present new interstellar dust models that are consistent with both, the FUV to near-IR extinction and infrared (IR) emission measurements from the diffuse interstellar medium. The models are characterized by different dust compositions and abundances. The problem we solve consists of determining the size distribution of the various dust components of the model. This problem is a typical ill-posed inversion problem which we solve using the regularization approach. We reproduce the Li Draine (2001, ApJ, 554, 778) results, however their model requires an excessive amount of interstellar silicon (48 ppM of hydrogen compared to the 36 ppM available for an ISM of solar composition) to be locked up in dust. We found that dust models consisting of PAHs, amorphous silicate, graphite, and composite grains made up from silicates, organic refractory, and water ice, provide an improved fit to the extinction and IR emission measurements, while still requiring a subsolar amount of silicon to be in the dust. This research was supported by NASA Astrophysical Theory Program NRA 99-OSS-01.

Zubko, V.↗

NASA NTRS2017

Hybrid-PIC Simulation of Backsputtered Carbon Transport in the Near-Field Plume of a Hall Thruster

Magnetic shielding has eliminated boron nitride erosion as the life limiting mechanism in a Hall thruster but has resulted in erosion of the front magnetic field pole pieces. Recent experiments show that the erosion of graphite pole covers, which are added to protect the magnetic field pole pieces, causes carbon to redeposit on other surfaces, such as boron nitride discharge channel and cathode keeper surfaces. As a part of the risk-reduction activities for AEPS thruster development, this study models transport of backsputtered carbon from the graphite front pole covers and vacuum facility walls. Fluxes, energy distributions, and redeposition rates of backsputtered carbon on the anode, discharge channel, and graphite cathode keeper surfaces are predicted.

Choi, Maria↗

NASA NTRS2014

Afterbody Heat Flux Measurements in the NASA Ames HFFAF Ballistic Range

In order to measure afterbody heat fluxes over a model in the ballistic range, the required modifications to a proven technique for measuring forebody heat fluxes are described. This involves the use of an extended helium gas plume to remove the glowing wake and the use of special high conductivity, high temperature capable graphite-filled plastic for the afterbody. The models and test conditions are described. Data in the form of plots of the surface temperature of the models are presented. Finally, experimental and computational fluid dynamic (CFD) heat flux data for forebody and afterbody heat fluxes are presented and compared. Data are presented for a 45 degree sphere-cone (with a projecting rear stud) at 2.70 km/s and for a sphere at 4.76 km/s. Both models were launched into 76 Torr of CO2 gas. The experimental forebody heat fluxes were within 1.5% of the CFD values. The experimental afterbody heat fluxes were within 1% of the CFD values for the sphere, but only 51% of the CFD values for the sphere-cone.

Bogdanoff, David W.↗

DOE OSTI2025

Studies of the influence of heat pipe model and coupling strategy in heat pipe microreactor simulations using Sockeye

This work demonstrates various modeling approaches for thermally coupling heat pipes to a graphite monolithic block in a microreactor context, accounting for the presence of a gap. We show that heat pipe model selection has a significant impact on the transient behavior of a three-dimensional coupled microreactor assembly problem by comparing results obtained using different heat pipe models from the heat pipe code Sockeye. Additionally, we show that the choice of coupling strategy has significant consequences for both accuracy and performance. Furthermore, we found that our heat flux transfer strategy exhibited greater accuracy than our temperature transfer strategy, even when comparing a loose coupling of the heat flux transfer strategy to a tight coupling of the temperature transfer strategy. Although this research uses only theoretical test problems, it provides important insights in modeling thermal fluids phenomena in heat pipe microreactors.

Direwolf↗

NASA NTRS2018

Hybrid-Particle-In-Cell Simulation of Backsputtered Carbon Transport in the Near-Field Plume of a Hall Thruster

Magnetic shielding has eliminated boron nitride erosion as the life limiting mechanism in a Hall thruster but has resulted in erosion of the front magnetic field pole pieces. Recent experiments show that the erosion of graphite pole covers, which are added to protect the magnetic field pole pieces, causes carbon to redeposit on other surfaces, such as boron nitride discharge channel and cathode keeper surfaces. As a part of the risk-reduction activities for Advanced Electric Propulsion System thruster development, this study models transport of backsputtered carbon from the graphite front pole covers and vacuum facility walls. Fluxes, energy distributions, and redeposition rates of backsputtered carbon on the anode, discharge channel, and graphite cathode keeper surfaces are predicted.

Choi, Maria↗

DOE OSTI2025

Estimation of extreme temperatures in direct solar methane pyrolysis within a porous medium

Porous media have wide application in renewable energy conversion processes, such as solar-thermal fuels production and decarbonization. Heat transport mechanisms within porous media can be highly complex, particularly under extreme conditions encountered in concentrated solar thermal reactors in which direct measurement of temperature is challenging. Here, we implement and report an inverse heat conduction model to estimate the temperature distribution throughout a porous substrate domain in a direct solar methane pyrolysis process. By solving a two-dimensional heat transfer problem and applying an inverse optimization algorithm, we estimate the quasi-steady state spatial temperature distribution in a fibrous porous carbon substrate. The results are validated indirectly by experimentally measured graphite deposition and a simplified reaction kinetic model.

finite difference method↗

NASA NTRS1980

Preliminary design of composite wing-box structures for global damage tolerance

A procedure is presented that incorporates the influence of potential global damage conditions into the design process for minimum-mass wing-box structures. The procedure is based on mathematical-programming optimization techniques. Material-strength, minimum-gage, and panel-buckling constraints are introduced by penalty functions, and Newton's method with approximate second derivatives of the penalty terms is used as the search algorithm to obtain minimum-mass designs. A potential global damage condition is represented by a structural model with the damaged components removed. Example minimum-mass designs are obtained that simultaneously satisfy the constraints of the damaged and undamaged configurations of both graphite-epoxy and aluminum wing-box structural models. These examples are designed with and without the influence of potential damage conditions, and results indicate that for equal mass cases the residual strength of a damaged structure is higher when the influence of potential damage is properly included in the design from the outset. Results of these examples also identify the minimum structural mass increase required to increase residual strength levels.

Starnes, J. H., Jr.↗

NASA NTRS2004

Interstellar Dust Models Consistent with Extinction, Emission, and Abundance Constraints

We present new interstellar dust models which have been derived by simultaneously fitting the far ultraviolet to near infrared extinction, the diffuse infrared emission, and, unlike previous models, the elemental abundances in dust for the diffuse interstellar medium. We found that dust models consisting of a mixture of spherical graphite and silicate grains, polycyclic aromatic hydrocarbon (PAH) molecules, in addition to porous composite particles containing silicate, organic refractory, and water ice, provide an improved .t to the UV-to-infrared extinction and infrared emission measurements, while consuming the amounts of elements well within the uncertainties of adopted interstellar abundances, including B star abundances. These models are a signi.cant improvement over the recent Li & Draine (2001, ApJ, 554, 778) model which requires an excessive amount of silicon to be locked up in dust: 48 ppm (atoms per million of H atoms), considerably more than the solar abundance of 34 ppm or the B star abundance of 19 ppm.

Zubko, Viktor↗