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Report describes investigation of containerless processing of glass, conducted in preparation of gravity-free processing experiments on board Space Shuttle. 105 candidate glass materials screened. Large number of oxide proportions studied and ternary phase diagram of glass formation developed as result.
Liquid distributed more evenly in evaporator section. Improved heat pipe contains an artery and wick rolled from stainless-steel screen of 180 mesh (openings about 80 micrometers). Screen material helps to prevent dryout in evaporator section by conducting liquid through hotspots and to vaporchannel wall. Insert reduces incidence of dryout at hotspots or during intervals of general thermal overload.
This study was conducted to evaluate the repeatability of the ambient LO2 mechanical impact test used by NASA to screen materials for oxygen service (NHB 8060.1B Test 12 Part 1, which is based on the ASTM method). Four materials were tested: Teflon, Vespel SP-21, Viton A, and nylon 6/6. Each test material was subjected to several series of tests that were conducted at different impact energy levels. The results show that the variability from series to series in the reaction threshold energy level is within the precision statement of the ASTM method. However, this precision is considerably broader than the reaction threshold implied by the NHB 8060.1B test criteria.
The influence of material volume on the transverse tensile strength of AS4/3501-6 graphite epoxy composites was investigated. Tensile tests of 90 degree laminates with 3 different widths and 5 different thicknesses were conducted. A finite element analysis was performed to determine the influence of the grip on the stress distribution in the coupons and explain the tendency for the distribution of failure locations to be skewed toward the grip. Specimens were instrumented with strain gages and extensometers to insure good alignment and to measure failure strains. Data indicated that matrix dominated strength properties varied with the volume of material that was stressed, with the strength decreasing as volume increased. Transverse strength data were used in a volumetric scaling law based on Weibull statistics to predict the strength of 90 degree laminates loaded in three point bending. Comparisons were also made between transverse strength measurements and out-of-plane interlaminar tensile strength measurements from curved beam bending tests. The significance of observed scale effects on the use of tests for material screening, quality assurance, and design allowables is discussed.
Sliding durability studies of candidate ceramic fibers were conducted in hydrogen to support the high temperature seal development program at NASA LeRC. Pin-on-disk tests were used to measure the friction and durability of a tow or bundle of ceramic fibers in sliding against a superalloy disk. This procedure was used previously to test candidate fibers in an air environment. The fibers based upon mullite (Al2O3-SiO2) chemistry (Nextel 550, 440, and 312) exhibited better durability in hydrogen than in air. HPZ, a complex silicon carboxynitride fiber which showed good durabilty in air, however, showed a significant loss of durability in hot hydrogen. These results are consistent with recent thermodynamic and experimental studies of ceramic compatibility with hydrogen at elevated temperatures. These research results indicate that only oxide fibers display good durability in both air and hydrogen environments. Also, simple, low cost testing in air can provide an adequate data base for initial seal material screening and selection, especially for oxide fiber candidates. The findings of this research provide critical input to the seal design team.
One of the performance goals for NASA's enterprise of Human Exploration and Development of Space (HEDS) is to develop methods, data bases, and validating tests for material flammability characterization, hazard reduction, and fire detection/suppression strategies for spacecraft and extraterrestrial habitats. This work addresses these needs by applying the fundamental knowledge gained from low stretch experiments to the development of a normal gravity low stretch material flammability test method. The concept of the apparatus being developed uses the low stretch geometry to simulate the conditions of the extraterrestrial environment through proper scaling of the sample dimensions to reduce the buoyant stretch in normal gravity. The apparatus uses controlled forced-air flow to augment the low stretch to levels which simulate Lunar or Martian gravity levels. In addition, the effect of imposed radiant heat flux on material flammability can be studied with the cone heater. After breadboard testing, the apparatus will be integrated into NASA's White Sands Test Facility's Atmosphere-Controlled Cone Calorimeter for evaluation as a new materials screening test method.
As fossil fuel resources continue to deplete, research for alternate power sources continues to develop. One of these alternate technologies is fuel cells. They are a practical fuel source able to provide significant amounts of power for applications from laptops to automobiles and their only byproduct is water. However, although this technology is over a century old and NASA has been working with it since the early 1960 s there is still room for improvement. The research I am involved in at NASA's Glenn Research Center is focusing on what is called a regenerative fuel cell system. The unique characteristic of this type of system is that it used an outside power source to create electrolysis of the water it produces and it then reuses the hydrogen and oxygen to continue producing power. The advantage of this type of system is that, for example, on space missions it can use solar power to recharge its gas supplies between periods when the object being orbited blocks out the sun. This particular system however is far from completion. This is because of the many components that are required to make up a fuel cell that need to be tested individually. The specific part of the system that is being worked on this summer of 2004 is the cooling system. The fuel cell stack, that is the part that actually creates the power, also produces a lot of heat. When not properly cooled, it has been known to cause fires which, needless to say are not conducive to the type of power that is trying to be created. In order to cool the fuel cell stack in this system we are developing a heat pipe cooling system. One of the main components of a heat pipe cooling system is what is known as the evaporator, and that is what happens to be the part of the system we are developing this summer. In most heat pipe systems the evaporator is a tube in which the working fluid is cooled and then re-circulated through the system to absorb more heat energy from the fuel cell stack. For this system, instead of a tube, the evaporator is made up of a stack-up of screen material and absorbent membranes inside a stainless steel shell and held together by a film adhesive and epoxy. There is an initial design for this flat plate evaporator, however is has not yet been made. The components of the stack-up are known, so all testing is focused on how it will all go together. This includes finding an appropriate epoxy to make the evaporator conductive all the way through and finding a way to hold the required tight tolerances as the stainless steel outer shell is put together. By doing the tests on smaller samples of the stack-ups and then testing the fill size component, the final flat plate evaporator will reach its final design so that research can continue on other parts of the regenerative fue1 cell system, and another step in the improvement of fue1 cell technology can be made.
Recent quartz crystal microbalance measurements made in the Marshall Space Flight Center, Photo-Deposition Facility, for several materials, recorded a significant loss of deposited contaminants when the deposition surface of the microbalance was illuminated by a deuterium lamp. These measurements differ from observations made by other investigators in which the rate of deposition increased significantly when the deposition surface was illuminated with vacuum ultraviolet radiation. These observations suggest that the accelerated deposition of molecular contaminants on optically sensitive surfaces is dependant upon the contaminant being deposited and must be addressed during the materials selection process by common material screening techniques.
Bird strike events in commercial airliners are a fairly common occurrence. According to data collected by the US Department of Agriculture, over 80,000 bird strikes were reported in the period 1990-2007 in the US alone [1]. As a result, bird ingestion is an important factor in aero engine design and FAA certification. When it comes to bird impacts on engine fan blades, the FAA requires full-scale bird ingestion tests on an engine running at full speed to pass certification requirements. These rotating tests are complex and very expensive. To reduce development costs associated with new materials for fan blades, it is desirable to develop more cost effective testing procedures than full-scale rotating engine tests for material evaluation. An impact test on a non-rotating single blade that captures most of the salient physics of the rotating test would go a long way towards enabling large numbers of evaluative material screening tests. NASA Glenn Research Center has been working to identify a static blade test procedure that would be effective at reproducing similar results as seen in rotating tests. The current effort compares analytical simulations of a bird strike on various nonrotating blades to a bird strike simulation on a rotating blade as a baseline case. Several different concepts for simulating the rotating loads on a non-rotating blade were analyzed with little success in duplicating the deformation results seen in the rotating case. The rotating blade behaves as if it were stiffer than the non-rotating blade resulting in less plastic deformation from a given bird impact. The key factor limiting the success of the non-rotating blade simulations is thought to be the effect of gyroscopics. Prior to this effort, it was anticipated the difficulty would be in matching the pre-stress in the blade due to centrifugal forces Additional work is needed to verify this assertion, and to determine if a static test procedure can simulate the gyroscopic effects in a suitable manner. This paper describes the various non-rotating concepts analyzed, and demonstrates the effect believed to be gyroscopic in nature on the results.
Bird strike events in commercial airliners are a fairly common occurrence. According to data collected by the US Department of Agriculture, over 80,000 bird strikes were reported in the period 1990 to 2007 in the US alone (Ref. 1). As a result, bird ingestion is an important factor in aero engine design and FAA certification. When it comes to bird impacts on engine fan blades, the FAA requires full-scale bird ingestion tests on an engine running at full speed to pass certification requirements. These rotating tests are complex and very expensive. To reduce development costs associated with new materials for fan blades, it is desirable to develop more cost effective testing procedures than full-scale rotating engine tests for material evaluation. An impact test on a nonrotating single blade that captures most of the salient physics of the rotating test would go a long way towards enabling large numbers of evaluative material screening tests. NASA Glenn Research Center has been working to identify a static blade test procedure that would be effective at reproducing similar results as seen in rotating tests. The current effort compares analytical simulations of a bird strike on various non-rotating blades to a bird strike simulation on a rotating blade as a baseline case. Several different concepts for simulating the rotating loads on a non-rotating blade were analyzed with little success in duplicating the deformation results seen in the rotating case. The rotating blade behaves as if it were stiffer than the non-rotating blade resulting in less plastic deformation from a given bird impact. The key factor limiting the success of the non-rotating blade simulations is thought to be the effect of gyroscopics. Prior to this effort, it was anticipated the difficulty would be in matching the prestress in the blade due to centrifugal forces Additional work is needed to verify this assertion, and to determine if a static test procedure can simulate the gyroscopic effects in a suitable manner. This paper describes the various non-rotating concepts analyzed, and demonstrates the effect believed to be gyroscopic in nature on the results
The Electron Microscopy Abrasion Analysis of Candidate Fabrics for Planetary Space Suit Protective Overgarment Application is in support of the Abrasion Resistance Materials Screening Test. The fundamental assumption made for the SEM abrasion analysis was that woven fabrics to be used as the outermost layer of the protective overgarment in the design of the future, planetary space suits perform best when new. It is the goal of this study to determine which of the candidate fabrics was abraded the least in the tumble test. The sample that was abraded the least will be identified at the end of the report as the primary candidate fabric for further investigation. In addition, this analysis will determine if the abrasion seen by the laboratory tumbled samples is representative of actual EVA Apollo abrasion.
As NASA plans to return people to the Moon for extended durations, we present an experiment concept to understand fire and material flammability there. A small combustion chamber would be used to conduct the first-ever combustion tests on another world. Multiple fuel samples are to be individually burned in Lunar gravity, with cameras and other sensors recording flame characteristics. The main hypothesis is that some materials burning in Lunar-g are more flammable than on Earth. The reason is that buoyant flow has two counteracting effects on material flammability. Increasing gravity level permits more fresh oxygen to be supplied to the flame, but if the buoyant speed is too high, combustion chemistry and increased cooling hinder combustion. This has important implications for the current 1-g material screening method used by NASA. Oxygen limits for upward and downward spread on the Moon will be compared to 1-g values. Earth-based partial gravity facilities (drop towers, aircraft, and sounding rockets) will be used to refine the experiment and provide some limited-duration data. Measured flame characteristics in 1-g and Lunar-g will be compared to a detailed model. These will refine pressure-gravity scaling relations that will then be applied to other g-levels. The work directly addresses knowledge gaps in flammability and crew safety as defined in several NASA strategic documents.
In order to maintain cleanliness during preparations for JWST’s OTIS (Optical Telescope Element-Integrated Science Instrument Module) Cryogenic Thermal Vacuum Test, a cleanroom was built that attached directly to the 60-year-old Chamber A. The cleanroom and chamber were outfitted with independent environmental control systems each providing ISO Class 71 air cleanliness. To maintain balanced, positive pressure in both the cleanroom and chamber volumes, a special control protocol was developed and successfully implemented. Dual back-up environmental control units (one each for the chamber and cleanroom) were installed just outside the building to provide environmental control redundancy due to a single source chilled water supply and weather threats. In addition, lack of a dedicated cleanroom airlock facilitating clean ingress and egress made it necessary to perform additional cleaning and packaging, as well as augment the uncontrolled truck lock space with small clean tents for pre-cleaning. Special procedures were developed to allow ingress of extra-large support equipment required for load testing of the cleanroom crane, installation of optical equipment in Chamber A and accommodation of the OTIS shipping container. A thorough bake-out and cleaning of Chamber A was also necessary to reduce volatiles from the shroud’s black thermal paint and to reduce particle fallout. Acrylic adhesive fracture discovered during early cryo-testing represented a significant challenge that was successfully mitigated prior to OTIS testing. A dedicated team of Contamination Control (CC) Technicians was specifically trained to clean support equipment and screen materials entering the cleanroom and chamber to ensure cleanliness and vacuum compatibility.
In order to maintain cleanliness during preparations for JWST’s OTIS (Optical Telescope Element-Integrated Science Instrument Module) Cryogenic Thermal Vacuum Test, a cleanroom was built that attached directly to the 60-year-old Chamber A. The cleanroom and chamber were outfitted with independent environmental control systems each providing ISO Class 71 air cleanliness. To maintain balanced, positive pressure in both the cleanroom and chamber volumes, a special control protocol was developed and successfully implemented. Dual back-up environmental control units (one each for the chamber and cleanroom) were installed just outside the building to provide environmental control redundancy due to a single source chilled water supply and weather threats. In addition, lack of a dedicated cleanroom airlock facilitating clean ingress and egress made it necessary to perform additional cleaning and packaging, as well as augment the uncontrolled truck lock space with small clean tents for pre-cleaning. Special procedures were developed to allow ingress of extra-large support equipment required for load testing of the cleanroom crane, installation of optical equipment in Chamber A and accommodation of the OTIS shipping container. A thorough bake-out and cleaning of Chamber A was also necessary to reduce volatiles from the shroud’s black thermal paint and to reduce particle fallout. Acrylic adhesive fracture discovered during early cryo-testing represented a significant challenge that was successfully mitigated prior to OTIS testing. A dedicated team of Contamination Control (CC) Technicians was specifically trained to clean support equipment and screen materials entering the cleanroom and chamber to ensure cleanliness and vacuum compatibility.
Density functional theory based defect thermodynamic modeling was performed to determine the effect of humidity and H2/O2 gas pressure on various defect chemistry and transport properties of perovskite and fluorite oxides for solid-oxide and proton-conducting-oxide cell applications, with inclusion of the electronic-conducting oxides (as electrodes) and insulating oxides (as electrolytes). Automatic defect generation workflow and first-principles charged defect analysis were implemented on NETL Joule supercomputer for modeling defect equilibria and transport properties of insulating oxides as electrolytes in SOCs and proton-conducting ceramic cells. A GNU Octave defect model subroutines were developed to facilitate defect modeling of electronic conducting oxides in a wide range of operating conditions guided by modeling and experiments. The model includes the hydride defect formation reaction under reducing conditions and allows to incorporate nonstoichiometry effects on the defect thermodynamic parameters. The developed model serves as a platform to facilitate fundamental understanding of the defect thermodynamics in SOC oxide materials and can be used as a novel tool in computational materials screening for SOC and other energy applications.
Currently, 80% of the global final energy consumption occurs in form of fuels and only 20% as electricity. On the other hand, renewable energy additions come almost exclusively in the form of electricity (dominantly photovoltaics and wind). Thus, a successful energy transition will require enormous growth in renewables, sufficient to convert excess electricity into fuels, as well as the development of non-electricity based solar fuel technologies. As much as photovoltaic capacities have grown over the past 20 years, it is far from clear that current technologies and materials are up to the task to grow from here by yet another factor 100 until 2050. Therefore, sustained research efforts on emerging inorganic semiconductors for solar electricity and fuels are essential for facing the double challenge of climate change and energy security. Computational materials science can make important contributions, guiding and supporting research activities through both materials search and discovery and through detailed studies that help to develop a mechanistic understanding of materials performance and bottlenecks. This presentation will highlight three recent computational projects with relevance for photovoltaics and solar fuels (1) Defect graph neural networks (dGNN) for materials discovery in solar thermochemical hydrogen (STCH) [1]. The dGNN approach facilitates broad and fast materials screening for defect properties. (2) Modeling highly off-stoichiometric systems by evaluating the free energy of defect interaction [2]. This approach allows quantitative prediction of H2 production in complex STCH oxides. (3) First-principles atomic structure prediction for interfaces [3]. This work showed how an atomically thin CdCl2 interlayer phase enables in principle ideal electron transport across the incommensurate SnO2/CdTe interface. [1] M.D. Witman, A. Goyal, T. Ogitsu, A.H. McDaniel, S. Lany, Nat. Comput. Sci. (2023). https://doi.org/10.1038/s43588-023-00495-2. [2] A. Goyal, M.D. Sanders, R.P. O'Hayre, S. Lany, PRX Energy 3, 013008 (2024). https://doi.org/10.1103/PRXEnergy.3.013008. [3] A. Sharan, M. Nardone, D. Krasikov, N. Singh, S. Lany, Appl. Phys. Rev. 9, 041411 (2022). https://doi.org/10.1063/5.0104008.
The Durable Module Materials Consortium's overarching goal is to understand photovoltaic (PV) module degradation and enable high-energy-yield modules with a 50-year lifespan. One of DuraMAT's milestones this year was to identify cases where the whole of DuraMAT really mattered and made an impact that was greater than the sum of the project results. We identified five key results that demonstrate progress toward enabling 50-year modules for a resilient PV industry: 1) Resilient PV Systems; 2) Proactive Materials Screening; 3) Understanding Wear-Out; 4) Identifying Which Cracks Matter; and 5) Software Tools and Data Resources This annual report summarizes these key results, as well as reviewing our other ongoing work in fiscal year 2024.
Machine learning can be used to screen millions of compounds and unearth relationships between electronic structure, chemistry, thermodynamic stability, formability and band gap. We know how to calculate thermodynamic stability and calculate approximate band gap, but it is very complicated to estimate synthesizability.