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DOE OSTI2021

Development of a Castable High Strength Secondary Aluminum Alloy from Recycled Wrought Aluminum Scrap

A new process for recycling scrap AA7075 aerospace alloys directly into a high strength castable secondary alloy is demonstrated. The process involves enhancing the castability of the utilized primary wrought aluminum scrap feedstock by scrap alloy chemistry optimization and zirconium additions in order to mitigate the inherent hot tearing tendency of 7075 alloys. By utilizing the new process, the hot tearing index of scrap AA7075 was reduced from 26 to 4. Defect-free castings were obtained in pilot-scale castings trials. The developed secondary 7075 alloy also satisfied preset target mechanical properties with strength levels exceeding 250 MPa and elongation levels higher than 3%. The validity of the new approach and its readiness for transition to commercial practice was demonstrated by casting cylinder heads directly from the modified 7075 scrap.

36 MATERIALS SCIENCE↗

NASA NTRS2013

Time-Filtered Navier-Stokes Approach and Emulation of Turbulence-Chemistry Interaction

This paper describes the time-filtered Navier-Stokes approach capable of capturing unsteady flow structures important for turbulent mixing and an accompanying subgrid model directly accounting for the major processes in turbulence-chemistry interaction. They have been applied to the computation of two-phase turbulent combustion occurring in a single-element lean-direct-injection combustor. Some of the preliminary results from this computational effort are presented in this paper.

Liu, Nan-Suey↗

DOE OSTI2019

Decomposition of Select Volatile Organic Compounds by Caustic Hydrolysis for Effluent Management Facility (Rev. 0)

Hydrolysis is a proposed treatment method for organic constituents at the Effluent Management Facility during the Direct-Feed Low-Activity Waste process at the Waste Treatment and Immobilization Plant. Four compounds, acetonitrile, acrylonitrile, acetone, and methylene chloride, comprise a significant portion of the organic constituents identified in the Waste Treatment and Immobilization Plant Effluent Composition Estimate. In support of the Direct-Feed Low-Activity Waste process, the Washington River Protection Solutions Organic Studies Group at the 222-S Laboratory completed a laboratory test of caustic hydrolysis reactions of these four compounds.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Secondary ion mass spectrometry for superconducting radiofrequency cavity materials

Historically, many advances in superconducting radio frequency (SRF) cavities destined for use in advanced particle accelerators have come empirically, through the iterative procedure of modifying processing and then performance testing. However, material structure is directly responsible for performance. Understanding, the link between processing, structure, and performance will streamline and accelerate the research process. In order to connect processing, structure, and performance, accurate and robust materials characterization methods are needed. Here in this paper, one such method, SIMS, is discussed with focus on analysis of SRF materials. In addition, several examples are presented, showing how SIMS is being used to further understanding of materials based SRF technologies.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

${S}^5$: The destruction of a bright dwarf galaxy as revealed by the chemistry of the Indus stellar stream

The recently discovered Indus stellar stream exhibits a diverse chemical signature compared to what is found for most other streams due to the abundances of two outlier stars, Indus$\_$0 and Indus$\_$13. Indus$\_$13, exhibits an extreme enhancement in rapid neutron-capture ($r$-)process elements with $\mathrm{[Eu/Fe]} = +1.81$. It thus provides direct evidence of the accreted nature of $r$-process enhanced stars. In this paper we present a detailed chemical analysis of the neutron-capture elements in Indus$\_$13, revealing the star to be slightly actinide poor. The other outlier, Indus$\_0$, displays a globular cluster-like signature with high N, Na, and Al abundances, while the rest of the Indus stars show abundances compatible with a dwarf galaxy origin. Hence, Indus$\_0$ provides the first chemical evidence of a fully disrupted dwarf containing a globular cluster. We use the chemical signature of the Indus stars to discuss the nature of the stream progenitor which was likely a chemically evolved system, with a mass somewhere in the range from Ursa Minor to Fornax.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS1996

GPS Multipath Fade Measurements to Determine L-Band Ground Reflectivity Properties

In personal satellite communications, especially when the line-of-sight is clear, ground specular reflected signals along with direct signals are received by low gain, almost omni-directional subscriber antennas. A six-channel, C/A code processing, GPS receiver with an almost omni-directional patch antenna was used to take measurements over three types of ground to characterize 1.575 GHz specular ground reflections and ground dielectric properties. Fade measurements were taken over grass, asphalt, and lake water surfaces by placing the antenna in a vertical position at a fixed height from the ground. Electrical characteristics (conductivity and dielectric constant) of these surfaces (grass, asphalt, lake water) were obtained by matching computer simulations to the experimental results.

Kavak, Adnan↗

NASA NTRS2000

Quasi-Steady Acceleration Direction Indicator in Three Dimensions

Many materials processing and fluids physics experiments conducted in a microgravity environment require knowledge of the orientation of the low-frequency acceleration vector. This need becomes especially acute for space experiments such as directional solidification of a molten semiconductor, which is extremely sensitive to orientation and may involve tens of hours of operations of a materials furnace. These low-frequency acceleration data have been measured for many Shuttle missions with the Orbital Acceleration Research Experiment. Previous attempts at using fluid chambers for acceleration measurements have met with limited success due to pointing and vehicle attitude complications. An acceleration direction indicator is described, which is comprised of two orthogonal short cylinders of fluid, each with a small bubble. The motion and the position of the bubble within the chamber will indicate the direction of the acceleration experienced at the sensor location. The direction of the acceleration vector may then be calculated from these data. The frequency response of such an instrument may be tailored for particular experiments with the proper selection of fluid and gas parameters, surface type, and geometry. A three-dimensional system for sensing and displaying the low-frequency acceleration direction via an innovative technique described in this paper has advantages in terms of size, mass, and power compared with electronic instrumentation systems.

DeLombard, Richard↗

NASA NTRS2012

NASA Advanced Explorations Systems: Concepts for Logistics to Living

The NASA Advanced Exploration Systems (AES) Logistics Reduction and Repurposing (LRR) project strives to enable a largely mission-independent cradle-to-grave-to-cradle approach to minimize logistics contributions to total mission architecture mass. The goals are to engineer logistics materials, common crew consumables, and container configurations to meet the following five basic goals: 1. Minimize intrinsic logistics mass and improve ground logistics flexibility. 2. Allow logistics components to be directly repurposed for on-orbit non-logistics functions (e.g., crew cabin outfitting) thereby indirectly reducing mass/volume. 3. Compact and process logistics that have not been directly repurposed to generate useful on-orbit components and/or compounds (e.g., radiation shielding, propellant, other usable chemical constituents). 4. Enable long-term stable storage and disposal of logistics end products that cannot be reused or repurposed (e.g., compaction for volume reduction, odor control, and maintenance of crew cabin hygienic conditions). 5. Allow vehicles in different mission phases to share logistics resources. This paper addresses the work being done to meet the second goal, the direct repurposing of logistics components to meet other on-orbit needs, through a strategy termed Logistics to Living (L2L). L2L has several areas but can be defined as repurposing or converting logistical items (bags, containers, foam, components, etc.) into useful crew items or life support augmentation on-orbit after they have provided their primary logistics function. The intent is that by repurposing items, dedicated crew items do not have to be launched and overall launch mass is decreased. For non-LEO missions, the vehicle interior volume will be relatively fixed so L2L will enable this volume to be used more effectively through reuse and rearrangement of logistical components. Past work in the area of L2L has already conceptually developed several potential technologies [Howe, Howard 2010]. Several of the L2L concepts that have shown the most potential in the past are based on NASA cargo transfer bags (CTBs) or their equivalents which are currently used to transfer cargo to and from the ISS. A high percentage of all logistics supplies are packaging mass and for a 6-month mission a crew of four might need over 100 CTBs. These CTBs are used for on-orbit transfer and storage but eventually becomes waste after use since down mass is very limited. The work being done in L2L also considering innovative interior habitat construction that integrate the CTBs into the walls of future habitats. The direct integration could provide multiple functions: launch packaging, stowage, radiation protection, water processing, life support augmentation, as well as structure. Reuse of these CTBs would reduce the amount of waste generated and also significantly reduce future up mass requirements for exploration missions. Also discussed here is the L2L water wall , an innovative reuse of an unfolded CTB as a passive water treatment system utilizing forward osmosis. The bags have been modified to have an inner membrane liner that allows them to purify wastewater. They may also provide a structural water-wall element that can be used to provide radiation protection and as a structural divider. Integration of the components into vehicle/habitat architecture and consideration of operations concepts and human factors will be discussed. In the future these bags could be designed to treat wastewater, concentrated brines, and solid wastes, and to dewater solid wastes and produce a bio-stabilized construction element. This paper will describe the follow-on work done in design, fabrication and demonstrations of various L2L concepts, including advanced CTBs for reuse/repurposing, internal outfitting studies and the CTB-based forward osmosis water wall.

Shull, Sarah A.↗

NASA NTRS1996

Contamination control engineering design guidelines for the aerospace community

Thermal control surfaces, solar arrays, and optical devices may be adversely affected by a small quantity of molecular and/or particulate contamination. What is rarely discussed is how one: (1) quantifies the level of contamination that must be maintained in order for the system to function properly, and (2) enforces contamination control to ensure compliance with requirements. This document is designed to address these specific issues and is intended to serve as a handbook on contamination control for the reader, illustrating process and methodology while providing direction to more detailed references when needed. The effects of molecular contamination on reflecting and transmitting surfaces are examined and quantified in accordance with MIL STD 1246C. The generation, transportation, and deposition of molecular contamination is reviewed and specific examples are worked to illustrate the process a design engineer can use to estimate end of life cleanliness levels required by solar arrays, thermal control surfaces, and optical surfaces. A similar process is used to describe the effect of particulate contamination as related to percent area coverage (PAC) and bi-directional reflectance distribution function (BRDF). Relationships between PAC and surface cleanliness, which include the effects of submicron sized particles, are developed and BRDF is related to specific sensor design parameters such as Point Source Transmittance (PST). The pros and cons of various methods of preventing, monitoring, and cleaning surfaces are examined and discussed.

Tribble, A. C.↗

NASA NTRS2002

An Aeroacoustic Study of a Leading Edge Slat Configuration

Aeroacoustic evaluations of high-lift devices have been carried out in the Quiet Flow Facility of the NASA Langley Research Center. The present paper describes detailed flow and acoustic measurements that have been made in order to better understand the noise generated from airflow over a wing leading edge slat configuration, and to possibly predict and reduce this noise source. The acoustic database is obtained by a moveable Small Aperture Directional Array of microphones designed to electronically steer to different portions of models under study. The slat is shown to be a uniform distributed noise source. The data was processed such that spectra and directivity were determined with respect to a one-foot span of slat. The spectra are normalized in various fashions to demonstrate slat noise character. In order to equate portions of the spectra to different slat noise components, trailing edge noise predictions using measured slat boundary layer parameters as inputs are compared to the measured slat noise spectra.

Mendoza, J. M.↗

NASA NTRS1973

Methods of measurement for semiconductor materials, process control, and devices

This progress report describes NBS activities directed toward the development of methods of measurement for semiconductor materials, process control, and devices. Significant accomplishments during this reporting period include design of a plan to provide standard silicon wafers for four-probe resistivity measurements for the industry, publication of a summary report on the photoconductive decay method for measuring carrier lifetime, publication of a comprehensive review of the field of wire bond fabrication and testing, and successful completion of organizational activity leading to the establishment of a new group on quality and hardness assurance in ASTM Committee F-1 on Electronics. Work is continuing on measurement of resistivity of semiconductor crystals; characterization of generation-recombination-trapping centers in silicon; study of gold-doped silicon; development of the infrared response technique; evaluation of wire bonds and die attachment; and measurement of thermal properties of semiconductor devices, delay time and related carrier transport properties in junction devices, and noise properties of microwave diodes.

Bullis, W. M.↗

NASA NTRS1985

Blowing Polymer Bubbles in an Acoustic Levitator

In new manufacturing process, small gas-filled polymer shells made by injecting gas directly into acoustically levitated prepolymer drops. New process allows sufficient time for precise control of shell geometry. Applications foreseen in fabrication of deuterium/tritium-filled fusion targets and in pharmaceutical coatings. New process also useful in glass blowing and blow molding.

Lee, M. C.↗

NASA NTRS2000

Roles Played by Electrostatic Waves in Producing Radio Emissions

Processes in which electromagnetic radiation is produced directly or indirectly via intermediate waves are reviewed. It is shown that strict theoretical constraints exist for electrons to produce nonthermal levels of radiation directly by the Cerenkov or cyclotron resonances. In contrast, indirect emission processes in which intermediary plasma waves are converted into radiation are often favored on general and specific grounds. Four classes of mechanisms involving the conversion of electrostatic waves into radiation are linear mode conversion, hybrid linear/nonlinear mechanisms, nonlinear wave-wave and wave-particle processes, and radiation from localized wave packets. These processes are reviewed theoretically and observational evidence summarized for their occurrence. Strong evidence exists that specific nonlinear wave processes and mode conversion can explain quantitatively phenomena involving type III solar radio bursts and ionospheric emissions. On the other hand, no convincing evidence exists that magnetospheric continuum radiation is produced by mode conversion instead of nonlinear wave processes. Further research on these processes is needed.

Cairns, Iver H.↗

DOE OSTI2023

Experimental investigation of a reverse osmosis desalination system directly powered by wave energy

Powering desalination processes with renewable energy is a promising solution to address the global issue of water shortage with minimum carbon footprint and environmental impact. Here, we experimentally investigate a sustainable reverse osmosis (RO) desalination system directly powered by wave energy. In this system, seawater is pressurized and pumped to a RO desalination module via a piston pump directly driven by an oscillating surge wave energy converter (OSWEC). An accumulator is adopted on the feed inlet to mitigate the pressure fluctuations under time-varying ocean conditions. Meanwhile, a needle valve on the brine outlet is used to adjust the system pressure and water recovery. A 1:10 scaled model was designed, fabricated, and tested in a wave tank based on the Froude scaling law. Further, the optimal specific water productivity (SWP) obtained in the tank tests with 3.5 g/L feed salinity was 2.23m 3 /kWh, indicating a full-scale specific water productivity of 0.22m 3 /kWh for 35g/L seawater salinity. The influence of needle valve tuning on the specific water productivity was experimentally investigated and analyzed. Under a specific operational condition, tuning this valve improved specific water productivity by about 17% and reduced the system pressure by 24%, thereby avoiding extreme pressure and improving the system’s capability. This pilot study demonstrates that ocean wave energy is a promising source to sustainably power reverse osmosis desalination and provide freshwater water for coastal regions.

16 TIDAL AND WAVE POWER↗

DOE OSTI2022

In-situ imaging of nucleation and growth of superlattices from nanoscale colloidal nanoparticles

Nanoparticle-based superlattices have attracted extensive research efforts due to their versatile composition and packing-dependent optical, magnetic, electronic, catalytic, mechanical properties. Yet the experimental understanding of the thermodynamics and pathways of the crystallization processes for these systems, which govern their ultimate morphology, size, and packing structure, has for long remained underexplored. Here, this minireview highlights recent integration of liquid-phase transmission electron microscopy, which allows for real-space, real-time direct imaging of the crystallization processes at the single-particle level, with simulation and the conceptual framework established by pioneers such as Dr. A. A. Chernov. Different aspects of superlattice formation were revealed by direct imaging for the first time, such as the existence of prenucleation precursor in nonclassical crystallization, surface energy-dependent growth, and coalescence, allowing for the charting of phase coordinates and thermodynamic quantities at the nanoscale. We discuss the similarities and differences of crystal growth behaviors in atomic and nanoparticle systems, as well as engineering opportunities to fashion, shape, and achieve quality control in superlattice formation from nanoparticles, for next-generation optical and mechanical metamaterials.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Development and Evaluation of a Mobile Plant to Prepare Natural Gas for Use in Foam Fracturing Treatments

Hydraulic fracturing treatments are used to produce oil and gas reserves that would otherwise not be accessible using traditional production techniques. Fracturing treatments require a significant amount of water, which has an associated environmental impact. In recent work funded by the Department of Energy (DOE), an alternative fracturing process has been investigated that uses natural gas as the primary fracturing fluid. In the investigated method, a high-pressure foam of natural gas and water is used for fracturing, a method than could reduce water usage by as much as 80% (by volume). A significant portion of the work focused on identifying and optimizing a mobile processing facility that can be used to pressurize natural gas sourced from adjacent wells or nearby gas processing plants. This paper discusses some of the evaluated processes capable of producing a high-pressure (10,000 psia) flow of natural gas from a low-pressure source (500 psia). The processes include five refrigeration cycles producing liquefied natural gas as well as a cycle that directly compresses the gas. The identified processes are compared based on their specific energy as calculated from a thermodynamic analysis. Additionally, the processes are compared based on the estimated equipment footprint and the process safety. Details of the thermodynamic analyses used to compare the cycles are provided. This paper also discusses the current state of the art of foam fracturing methods and reviews the advantages of these techniques.

Beck, Griffin↗

DOE OSTI2021

Diagnostic and predictive capabilities of the TCR digital platform

The Transformational Challenge Reactor program is leveraging additive manufacturing technologies to fabricate the nuclear components required to assemble a microreactor core. Compared with traditional manufacturing processes, additive manufacturing allows for direct observation of the interior of the component during manufacturing. This unique capability promises significant possibilities for creating a new paradigm for nuclear component qualification by leveraging in-situ process data. This report describes FY21 efforts to predict material tensile properties based on data collected during the laser powder bed fusion printing process. The primary focus of this report is the test campaign designed to generate the large quantities of training data required to implement artificial intelligence algorithms that can predict these material properties. Preliminary prediction results and a demonstration of the overall data collection, analysis, and visualization pipeline are also provided.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1989

Gallium arsenide processing for gate array logic

The development of a reliable and reproducible GaAs process was initiated for applications in gate array logic. Gallium Arsenide is an extremely important material for high speed electronic applications in both digital and analog circuits since its electron mobility is 3 to 5 times that of silicon, this allows for faster switching times for devices fabricated with it. Unfortunately GaAs is an extremely difficult material to process with respect to silicon and since it includes the arsenic component GaAs can be quite dangerous (toxic) especially during some heating steps. The first stage of the research was directed at developing a simple process to produce GaAs MESFETs. The MESFET (MEtal Semiconductor Field Effect Transistor) is the most useful, practical and simple active device which can be fabricated in GaAs. It utilizes an ohmic source and drain contact separated by a Schottky gate. The gate width is typically a few microns. Several process steps were required to produce a good working device including ion implantation, photolithography, thermal annealing, and metal deposition. A process was designed to reduce the total number of steps to a minimum so as to reduce possible errors. The first run produced no good devices. The problem occurred during an aluminum etch step while defining the gate contacts. It was found that the chemical etchant attacked the GaAs causing trenching and subsequent severing of the active gate region from the rest of the device. Thus all devices appeared as open circuits. This problem is being corrected and since it was the last step in the process correction should be successful. The second planned stage involves the circuit assembly of the discrete MESFETs into logic gates for test and analysis. Finally the third stage is to incorporate the designed process with the tested circuit in a layout that would produce the gate array as a GaAs integrated circuit.

Cole, Eric D.↗