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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 145 records · Page 8

Joining of Silicon Carbide: Diffusion Bond Optimization and Characterization

Joining and integration methods are critically needed as enabling technologies for the full utilization of advanced ceramic components in aerospace and aeronautics applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. In the application, several SiC substrates with different hole patterns to form fuel and combustion air channels are bonded to form the injector. Diffusion bonding is a joining approach that offers uniform bonds with high temperature capability, chemical stability, and high strength. Diffusion bonding was investigated with the aid of titanium foils and coatings as the interlayer between SiC substrates to aid bonding. The influence of such variables as interlayer type, interlayer thickness, substrate finish, and processing time were investigated. Optical microscopy, scanning electron microscopy, and electron microprobe analysis were used to characterize the bonds and to identify the reaction formed phases.

Halbig, Michael C.↗

Effect of thermal aging on the tribological properties of polyimide films and polyimide-bonded graphite fluoride films

The effect of thermal aging on the weight loss, adherence, friction and wear of polyimide films and polyimide-bonded graphite fluoride films applied to 440C-HT stainless steel disks and to 304 stainless steel thin foils was studied. The films were exposed at temperatures of 315, 345, 370 or 400 C for 100 hours or more and then evaluated at temperatures of 25, 315 or 345 C in atmospheres of dry or moist air. Polyimide films were found to be brittle after thermal exposure; but polyimide-bonded graphite fluoride films possessed good adherence and gave low friction and wear results. Thus, polyimide-bonded graphite fluoride films appear to be good candidates for solid lubrication applications where long thermal soaks are prevalent.

Fusaro, R. L.↗

Sailboard Fin Design

In high performance boardsailing, demands on the vertical fin or "skeg" often produce "spinout" - when the skeg loses horizontal lift creating a force imbalance and causing the tail of the board to slide sideways. Richard Caldwell, RACE Technology, Inc. used NASA airfoil technology to solve this problem and formed a business based on his solution. After determining that the spinout resulted from air ventilating down the low pressure side of the underwater fin, he adapted the airfoil technology to the design of a short board skeg, which would overcome the problem and lower the drag, resulting in improved performance. He patented his RACE 145 foil section, formed his company and later returned to Langley for additional technical assistance. The company's newest product is a rigid sail that also incorporates NASA technology and has excellent performance. This company no longer exists - product is no longer in production.

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Atomic Layer Thermopiles: Comprehensive static calibration, comparison and application in subsonic and supersonic flows

Here, this paper compares the calibration of different heat flux sensors in radiation- and convection-based sub- and supersonic operation. First, four heat flux sensors based on different principles: ALTP (Transverse Seebeck Effect), HFM-8E (differential-layer device), coaxial Thermocouple and a TG-2000 (circular-foil gage) are calibrated in a laser-based radiation setup. In a second step, all heat flux sensors are compared with a slug-calorimeter within a subsonic convection-dominated facility based on stagnation-point measurements of an impinging hot air jet. The obtained results indicate that a sensitivity transfer between a radiative calibrated sensor used in a mainly convective environment is not always possible and can lead to significant, systematic errors. Calibration in a subsonic shear flow with thermocouple readings demonstrate small divergence from the manufacturer provided sensitivity. Finally, supersonic testing with high frequency shock-boundary layer interactions highlight the need for ALTP rather than the conventional use of thermocouple arrays to resolve the high frequency phenomena associated with shock boundary layer interactions.

42 ENGINEERING↗

Effect of thermal aging on the tribological properties of polyimide films and polyimide-bonded graphite fluoride films

Weight loss, adherence, friction and wear of polyimide films and polyimide-bonded graphite fluoride films applied to stainless steel disks and to 304 stainless steel thin foils were studied. The films were exposed at temperatures of 315 D, 345 D, 370 D, or 400 C for 100 hours or more and then evaluated at temperatures of 25 D, 315 D, or 345 C in atmospheres of dry or moist air. Polyimide films were found to be brittle after thermal exposure; but polyimide-bonded graphite fluoride possessed good adherence and gave low friction and wear results. Polyimide-bonded graphite fluoride films appear to be good candidates for solid lubrication applications where long thermal soaks are prevalent.

Fusaro, R. L.↗

2003 NASA Seal/Secondary Air System Workshop

The following reports were included in the 2003 NASA Seal/Secondary Air System Workshop:Low Emissions Alternative Power (LEAP); Overview of NASA Glenn Seal Developments; NASA Ultra Efficient Engine Technology Project Overview; Development of Higher Temperature Abradable Seals for Industrial Gas Turbines; High Misalignment Carbon Seals for the Fan Drive Gear System Technologies; Compliant Foil Seal Investigations; Test Rig for Evaluating Active Turbine Blade Tip Clearance Control Concepts; Controls Considerations for Turbine Active Clearance Control; Non-Contacting Finger Seal Developments and Design Considerations; Effect of Flow-Induced Radial Load on Brush Seal/Rotor Contact Mechanics; Seal Developments at Flowserve Corporation; Investigations of High Pressure Acoustic Waves in Resonators With Seal-Like Features; Numerical Investigations of High Pressure Acoustic Waves in Resonators; Feltmetal Seal Material Through-Flow; "Bimodal" Nuclear Thermal Rocket (BNTR) Propulsion for Future Human Mars Exploration Missions; High Temperature Propulsion System Structural Seals for Future Space Launch Vehicles; Advanced Control Surface Seal Development for Future Space Vehicles; High Temperature Metallic Seal Development for Aero Propulsion and Gas Turbine Applications; and BrazeFoil Honeycomb.

Steinetz, Bruce M.↗

The effect of a coating on the thermo-oxidative stability of Celion 6000 graphite fiber/PMR 15 polyimide composites

The thermooxidative stability in air at 316 C of unidirectional, uncoated and aluminum-coated Celion 6000 graphite fiber/PMR 15 polyimide composites has been determined for exposure times up to nominally 2000 h. Comparison of the weight loss data and microstructural integrity reveals that a thin aluminum-foil coating can provide significant protection from oxidation. A quantitative description of the average depth of the reaction zone and the maximum length of cracks produced during oxidation as a function of time in uncoated Celion 6000/PMR 15 are given.

Hurwitz, F. I.↗

Quantitative spatiotemporal density evolution of aluminum heated purely by monochromatic electrons

A spatially resolved air-wedge shearing interferometer and shadowgraph diagnostic provides measurements of electron density with a resolution of ∼40 μm. A ∼100-ns-long, monoenergetic electron bunch at 19.8 MeV and a current of 1.4 kA (8.5×1014 e−) heats 100-μm-thick aluminum (Al) foils in a 1-mm-spot to Te∼1 eV. A 5-ns-long, ∼60 mJ, frequency doubled Nd:YAG laser probes the dense Al plasma. Electron densities up to 1020cm−3 are resolved; the maximum resolvable density is limited by opacity, transmission, and spatial fringe density achievable with the detector. This diagnostic provides measurements of the total phase shift, transmission, and electron density. Several measurements at different time slices provide the ability to determine the velocity of the leading edge of the shadowgraph and compare it to the motion of different density shells. These measurements are also compared to radiation hydrodynamics simulations. A rough quantitative agreement is shown between the hydro simulations and the measurements; there are differences in the exact density distributions.

Coleman, J. E. (ORCID:0000000308873757)↗

Friction and wear of some ferrous-base metallic glasses

Sliding friction experiments, X-ray photoelectron spectroscopy (XPS) analysis, and electron microscopy and diffraction studies were conducted with ferrous base metallic glasses (amorphous alloys) in contact with aluminum oxide at temperatures to 750 C in a vacuum. Sliding friction experiments were also conducted in argon and air atmospheres. The results of the investigation indicate that the coefficient of friction increases with increasing temperature to 350 C in vacuum. The increase in friction is due to an increase in adhesion resulting from surface segregation of boric oxide and/or silicon oxide to the surface of the foil. Above 500 C the coefficient of friction decreased rapidly. The decrease correlates with the segregation of boron nitride to the surface. Contaminants can come from the bulk of the material to the surface upon heating and impart boric oxide and/or silicon oxide at 350 C and boron nitride above 500 C. The segregation of contaminants is responsible for the friction behavior. The amorphous alloys have superior wear resistance to crystalline 304 stainless steel. The relative concentrations of the various constituents at the surfaces of the amorphous alloys are very different from the nominal bulk compositions.

Miyoshi, K.↗

Friction and wear of some ferrous-base metallic glasses

Sliding friction experiments, X-ray photoelectron spectroscopy (XPS) analysis, and electron microscopy and diffraction studies were conducted with ferrous base metallic glasses (amorphous alloys) in contact with aluminium oxide at temperatures to 750 C in a vacuum. Sliding friction experiments were also conducted in argon and air atmospheres. The results of the investigation indicate that the coefficient of friction increases with increasing temperature to 350 C in vacuum. The increase in friction is due to an increase in adhesion resulting from surface segregation of boric oxide and/or silicon oxide to the surface of the foil. Above 500 C the coefficient of friction decreased rapidly. The decrease correlates with the segregation of boron nitride to the surface. Contaminants can come from the bulk of the material to the surface upon heating and impart boric oxide and/or silicon oxide at 350 C and boron nitride above 500 C. The segregation of contaminants is responsible for the friction behavior. The amorphous alloys have superior wear resistance to crystalline 304 stainless steel. The relative concentrations of the various constituents at the surfaces of the amorphous alloys are very different from the nominal bulk compositions.

Miyoshi, K.↗

Hydrodynamic air lubricated compliant surface bearing for an automotive gas turbine engine. 2: Materials and coatings

Material coatings for an air-lubricated, compliant journal bearing for an automotive gas turbine engine were exposed to service test temperatures of 540 C or 650 C for 300 hours, and to 10 temperature cycles from room temperatures to the service test temperatures. Selected coatings were then put on journal and partial-arc foils and tested in start-stop cycle tests at 14 kPa (2 psi) loading for 2000 cycles. Half of the test cycles were performed at a test chamber service temperature of 540 C (1000 F) or 650 C (1200 F); the other half were performed at room temperature. Based on test results, the following combinations and their service temperature limitations are recommended: HL-800 TM (CdO and graphite) on foil versus chrome carbide on journal up to 370 C (700 F); NASA PS 120 (Tribaloy 400, silver and CaF2 on journal versus uncoated foil up to 540 C (1000 F); and Kaman DES on journal and foil up to 640 C (1200 F). Kaman DES coating system was further tested successfully at 35 kPa (5 psi) loading for 2000 start-stop cycles.

Bhushan, B.↗

Deicing System Protects General Aviation Aircraft

Kelly Aerospace Thermal Systems LLC worked with researchers at Glenn Research Center on deicing technology with assistance from the Small Business Innovation Research (SBIR) program. Kelly Aerospace acquired Northcoast Technologies Ltd., a firm that had conducted work on a graphite foil heating element under a NASA SBIR contract and developed a lightweight, easy-to-install, reliable wing and tail deicing system. Kelly Aerospace engineers combined their experiences with those of the Northcoast engineers, leading to the certification and integration of a thermoelectric deicing system called Thermawing, a DC-powered air conditioner for single-engine aircraft called Thermacool, and high-output alternators to run them both. Thermawing, a reliable anti-icing and deicing system, allows pilots to safely fly through ice encounters and provides pilots of single-engine aircraft the heated wing technology usually reserved for larger, jet-powered craft. Thermacool, an innovative electric air conditioning system, uses a new compressor whose rotary pump design runs off an energy-efficient, brushless DC motor and allows pilots to use the air conditioner before the engine even starts

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Microbial Monitoring of New Cleanrooms Used to Curate Astrobiologically Relevant Asteroid Samples from Bennu and Ryugu

Introduction: NASA has constructed two new cleanrooms to house materials from the OSRIS-REx and Hayabusa2 missions to the asteroids Ryugu (162173) and Bennu (101955), respectively. In accordance with standard astromaterials curation practices, these cleanrooms will be monitored for particulate contamination and maintained to ISO 5 equivalent standards1. Since the samples in these collections are expected to contain prebiotic organic compounds that may help explain the origin of life on Earth, these labs will also be monitored for organic and biological contamination2. Samples from Ryugu arrived on Earth in December, 2020. After basic characterization in Japan, NASA received a subset of these samples at the astromaterials curation facility in Houston in December of 2021. OSIRIS-REx is expected to return samples in September, 2023. Here we present preliminary microbial monitoring results from monthly monitoring of these new labs and the connected microtomy and staging areas that support them, as they are being commissioned. We also compare these results to baseline values for other astromaterials curation labs. We will also briefly describe additional cleaning efforts employed to reduce the bioburden in these new cleanrooms. Methods: Microbial samples were collected from surfaces using a dry macrofoam swab (Puritan Brand 2518051PFRNDFD). Swabs were also opened in the lab but not touched to any surfaces to function as negative controls. Samples and controls were processed inside a class II biosafety cabinet to avoid inadvertent cross contamination. The swabs were suspended in 15 ml of PBS (Phosphate Buffered Saline) and vortexed for 20 seconds to remove cells from the swab surface. The PBS was used to inoculate Petri dishes filled with TSA (Tryptic Soy Agar), Blood Agar, or Reasoners 2 agar to check for microbial growth. Each plate was inoculated with 0.1 ml of PBS. The TSA and blood agar plates were incubated at 35˚C and the Reasoners 2 agar plates were incubated at 25˚C for seven days. Petri dishes filled with Potato dextrose agar, Saboraud dextrose agar, or Saboraud dextrose agar with 0.1 mg/ml of chloramphenicol, an antibiotic, were used to check for fungal growth. These plates were inoculated with 0.3 ml of PBS and incubated at 30˚C. The remaining PBS was frozen at -80 ˚C for DNA sequencing. After incubation, isolates were counted and reisolated for identification. Isolates were identified using the VITEK23 system or by sequencing a portion of the 16S rRNA gene for bacteria or the ribosomal internal transcribed spacer (ITS) for fungi. Sequencing was performed with an ABI 3500 Sanger sequencer. Results: During our initial sampling, six of the seven sites sampled (86%) displayed bacterial or fungal growth. Samples collected from the staging areas and microtomy labs are not included in this calculation since those areas are maintained at a lower ISO 7 equivalent cleanliness standard. A month later, only three of the seven sites (43%) displayed bacterial growth. No fungal growth was detected in the second sampling. Since new equipment had been introduced to the Hayabusa2 lab since the first round of sampling, an additional three sampling sites were included in the second round of sampling. None of these sites displayed microbial growth. These sites will be included in all future sampling efforts. Bacterial isolates have been identified from the following genera at multiple time points: Micrococcus, Staphylococcus, and Bacillus. Isolates from the genera: Microbacterium, Nocardioides, Methylocystis, and Microvirga were identified in the initial sampling, but were not present at later time points. Identification of fungal isolates is in progress. Results are summarized in Table 1. Discussion: The recovery rate or percentage of positive samples4 was initially 86%, which is higher than the median recovery rate for comparable ISO 5 equivalent curation labs like Stardust (33%), Hayabusa (33%), and Cosmic Dust (50%). However, after a month of operation, the recovery rate for these same sites decreased to 43%, which is similar to what we observe in comparable curation cleanrooms with no microbial control requirements. Adding in the new sampling sites further decreases the recovery rate to 30%. With the reduction in recovery rate, we also observed a decrease in microbial diversity. At the first time point, we observed at least 10 different bacterial species and at least two different fungi. This is a higher diversity than the median values for comparable ISO 5 equivalent labs (2-4 isolates per sampling event). After the second sampling, we observed at least 4 bacterial species and no fungi, which is more consistent with comparable labs. We expect the recovery rate and diversity in both labs to continue to decrease as routine operation continues. We will use ultrapure hydrogen peroxide to disinfect equipment and work areas prior to opening any sample containers. Most of the bacterial and fungal isolates were detected on samples from the cleanroom floors. This is consistent with baseline results from other curation labs. Organisms from the genera Bacillus, Staphylococcus, and Micrococcus that were repeatedly detected are common in cleanrooms and on human skin5,6. These organisms are generally thought to be introduced when people enter the cleanroom. Microbacterium, Nocardioides, and Microvirga have also previously been identified in astromaterials cleanrooms, but not as frequently as Bacillus, Staphylococcus, and Micrococcus. Methylocystis is a novel genus in the astromaterials cleanrooms, but it was identified with low accuracy (93% match in the sequenced region of the 16S rRNA gene) and further work is needed to confirm this identification. Microbacterium is a diverse genus with isolates identified from terrestrial and aquatic sediments. Some species of Microbacterium are capable of degrading complex organic compounds found in crude oil. The presence of these bacteria in the OSIRIS REx and Hayabusa2 cleanrooms should be closely monitored. Methylocystis is a genus of methanotrophic bacteria capable of oxidizing methane. If this identification proves to be correct and it is detected again, it should be closely monitored as well. Under nominal operating conditions, samples should not ever encounter the cleanroom floor or other high traffic areas. If we observe an increase in the bioburden in sensitive work areas that appears to be influenced by organism transfer from high traffic areas like the floors, we can employ additional hydrogen peroxide treatments to disinfect high traffic areas. Routine microbial monitoring of these labs will ensure that NASA’s astromaterials collections remain pristine and useful for scientific study. Table 1. Sampling Locations and Colony Counts Bacterial CFUa Fungal CFU Bacterial CFU Fungal CFU Lab - Location 11/2/2021 11/2/2021 12/13/2021 12/13/2021 H2b-Floor 4 8 1 0 H2-staging pass through 3 0 0 0 H2-microtomy pass through TNTCc 0 0 0 H2 Microscope 1 NA NA 0 0 H2 Microscope 2 NA NA 0 0 H2-Table NA NA 0 0 OREXd- microtomy pass through 0 0 6 0 OREX – Anteroom pass through 0 0 0 0 OREX – Floor 1 2 0 0 OREX Witness Foil Table 3 0 1 0 Staging-Floor 16 0 15 0 Microtomy-Floor 3 0 2 0 a: CFU = Colony Forming Unit b: H2 = Hayabusa2 Lab c: TNTC = too numerous to count d: OREX = OSIRIS-REx Lab References: 1. ISO 14644-1:2015 - Cleanrooms and associated controlled environments -- Part 1: Classification of air cleanliness by particle concentration. 37 (2015). 2. McCubbin, F. M. et al. Space Sci Rev 215, (2019). 3. Pincus, D. H. Encyclopedia of Rapid Microbiological Methods (2005). 4. The United States Pharmacopeial Convention. USP General Chapter <1116> 17, 784–794 (2013). 5. Sheraba, N. S., Yassin, A. S. & Amin, M. BMC Research Notes 3, 278 (2010). 6. Utescher, C. L. de A., Franzolin, M. R., Trabulsi, L. R. & Gambale, V. Brazilian Journal of Microbiology 38, 710–716 (2007).

A B Regberg↗

Foil bearings for axial and radial support of high speed rotors: Design, development, and determination of operating characteristics

Flexible surface thrust and journal foil bearings were fabricated, and their performance was demonstrated, both individually and jointly as a unified rotor support system. Experimental results are documented with graphs and oscilloscopic data of trajectories, waveforms, and scans of amplitude response. At speeds of 40,000 to 45,000 rpm and a mean clearance of the order of 15 to 20 micrometers (600 to 800 micrometers, the resilient, air lubricated, spiral groove thrust bearings support a load of 127 N (29 lb; 13 kgf), equivalent to 3.0 N/sq cm (4.5 lb/sq in 0.31 kgf sq cm). Journal bearings with polygonal sections provided stable and highly damped supports at speeds up to 50,000 rpm.

Licht, L.↗

Experimental determination of stator endwall heat transfer

Local Stanton numbers were experimentally determined for the endwall surface of a turbine vane passage. A six vane linear cascade having vanes with an axial chord of 13.81 cm was used. Results were obtained for Reynolds numbers based on inlet velocity and axial chord between 73,000 and 495,000. The test section was connected to a low pressure exhaust system. Ambient air was drawn into the test section, inlet velocity was controlled up to a maximum of 59.4 m/sec. The effect of the inlet boundary layer thickness on the endwall heat transfer was determined for a range of test section flow rates. The liquid crystal measurement technique was used to measure heat transfer. Endwall heat transfer was determined by applying electrical power to a foil heater attached to the cascade endwall. The temperature at which the liquid crystal exhibited a specific color was known from a calibration test. Lines showing this specific color were isotherms, and because of uniform heat generation they were also lines of nearly constant heat transfer. Endwall static pressures were measured, along with surveys of total pressure and flow angles at the inlet and exit of the cascade.

Boyle, Robert J.↗

Experimental determination of stator endwall heat transfer

Local Stanton numbers were experimentally determined for the endwall surface of a turbine vane possage. A six vane linear cascade having vanes with an axial chord of 13.81 cm was used. Resutls were obtained for Reynolds numbers based on inlet velocity and axial chord between 75,000 and 495,000. The test section was connected to a low pressure exhaust system. Ambient air was drawn into the test section, inlet velocity was controlled up to a maximum of 59.4 m/sec. The effect of the inlet boundary layer thickness on the endwall heat transfer was determined for a range of test section flow rates. The liquid crystal measurement technique was used to measure heat transfer. Endwall heat transfer was determined by applying electrical power to a foil heater attached to the cascade endwall. The temperature at which the liquid crystal exhibited a specific color was known from a calibration test. Lines showing this specific color were isotherms, and because of uniform heat generation they were also lines of nearly constant heat transfer. Endwall static pressures were measured, along with surveys of total pressure and flow angles at the inlet and exit of the cascade.

Boyle, Robert J.↗

An Application of the Direct Coulomb Electron Pair Production Process to the Energy Measurement of the "VH-Group" in the "Knee" Region of the "All-Particle" Energy Spectrum

The "all-particle" cosmic ray energy spectrum appears to be exhibiting a significant change in the spectral index just above approximately 3000 TeV. This could indicate (1) a change in the propagation of the cosmic rays in the galactic medium, and/or (2) the upper limit of the supernova shock wave acceleration mechanism, and/or (3) a new source of high-energy cosmic rays. Air shower and JACEE data indicate the spectral change is associated with a composition change to a heavier element mixture whereas DICE does not indicate this. A detector concept will be presented that utilizes the energy dependence of the production of direct Coulomb electron-positron pairs by energetic heavy ions. Monte Carlo simulations of a direct electron pair detector consisting of Pb target foils interleaved with planes of 1-mm square scintillating optical fibers will be discussed. The goal is to design a large area, non-saturating instrument to measure the energy spectrum of the individual cosmic ray elements in the "VH-group" for energies greater than 10 TeV/nucleon.

Derrickson, J. H.↗

NASA Tech Briefs, May 2006

T-Shaped Emitter Metal Structures for HBTs Rigorous Estimation of SNR of a PSK Communication Link Advanced Ka-Band Transceiver With Monopulse Tracking EMI Filters for Low-Temperature Applications Lightweight Electronic Camera for Research on Clouds Pilot Weather Advisor System Waveguide Power-Amplifier Module for 80 to 150 GHz Better Back Contacts for Solar Cells on Flexible Substrates Topics covered include:Tunable, Highly Stable Lasers for Coherent Lidar; Improved Photon-Emission-Microscope System; Program Synthesizes UML Sequence Diagrams; Aspect-Oriented Subprogram Synthesizes UML Sequence Diagrams; Updated Computational Model of Cosmic Rays Near Earth; Software for Alignment of Segments of a Telescope Mirror; Simulation of Dropping of Cargo With Parachutes; DAVE-ML Utility Program; Robust Control for the Mercury Laser Altimeter; Thermally Stable Piezoelectric and Pyroelectric Polymers; Combustion Synthesis of Ca3(PO4)2 Net-Shape Surgical Implants; Stochastic Representation of Chaos Using Terminal Attractors; Two High-Temperature Foil Journal Bearings; Using Plates To Represent Fillets in Finite-Element Modeling; Repairing Chipped Silicide Coatings on Refractory Metal Substrates; Simplified Fabrication of Helical Copper Antennas; Graded-Index "Whispering-Gallery" Optical Microresonators; Optical Profilometers Using Adaptive Signal Processing; Manufacture of Sparse-Spectrum Optical Microresonators; Exact Tuning of High-Q Optical Microresonators by Use of UV; Automation for "Direct-to" Clearances in Air-Traffic Control; Improved Traps for Removing Gases From Coolant Liquids; and Lunar Constellation of Frozen Elliptical Inclined Orbits.

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