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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
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

The p-version of the finite element method in incremental elasto-plastic analysis

Whereas the higher-order versions of the finite elements method (the p- and hp-version) are fairly well established as highly efficient methods for monitoring and controlling the discretization error in linear problems, little has been done to exploit their benefits in elasto-plastic structural analysis. Aspects of incremental elasto-plastic finite element analysis which are particularly amenable to improvements by the p-version is discussed. These theoretical considerations are supported by several numerical experiments. First, an example for which an analytical solution is available is studied. It is demonstrated that the p-version performs very well even in cycles of elasto-plastic loading and unloading, not only as compared to the traditional h-version but also in respect to the exact solution. Finally, an example of considerable practical importance - the analysis of a cold-worked lug - is presented which demonstrates how the modeling tools offered by higher-order finite element techniques can contribute to an improved approximation of practical problems.

Holzer, Stefan M.↗
NASA NTRS1995

Direct-Circulation Stirling-Cycle Refrigerator

In proposed cryogenic system, cold working fluid (helium) circulated directly from Stirling-cycle refrigerator machinery through loop of tubing to provide 15 W of cooling power at temperature of 80 K to scientific instruments or other devices located at some distance from machinery. (Separation of cooled devices from machinery may be dictated by engineering requirements including, need to isolate cooled devices from vibrations of machinery.) Advantages include less complexity, smaller size, lighter weight, and lower power consumption.

Ellison, Woody↗
NASA NTRS1995

Production of aluminum-lithium near net shape extruded cylinders

In the late 1980's, under funding from the Advanced Launch System Program, numerous near net shape technologies were investigated as a means for producing high quality, low cost Aluminum-Lithium (Al-Li) hardware. Once such option was to extrude near net shape barrel panels instead of producing panels by machining thick plate into a final tee-stiffened configuration (which produced up to 90% scrap). This method offers a reduction in the volume of scrap and consequently reduces the buy-to-fly cost. Investigation into this technology continued under Shuttle-C funding where four Al alloys 2219, 2195, 2096, and RX 818 were extruded. Presented herein are the results of that program. Each alloy was successfully extruded at Wyman Gordon, opened and flattened at Ticorm, and solution heat treated and stretched at Reynolds Metals Company. The first two processes were quite successful while the stretching process did offer some challenges. Due to the configuration of the panels and the stretch press set-up, it was difficult to induce a consistent percentage of cold work throughout the length and width of each panel. The effects of this variation will be assessed in the test program to be conducted at a future date.

Hartley, Paula J.↗
NASA NTRS2003

Case Studies of Fatigue Life Improvement Using Low Plasticity Burnishing in Gas Turbine Engine Applications

Surface enhancement technologies such as shot peening, laser shock peening (LSP), and low plasticity burnishing (LPB) can provide substantial fatigue life improvement. However, to be effective, the compressive residual stresses that increase fatigue strength must be retained in service. For successful integration into turbine design, the process must be affordable and compatible with the manufacturing environment. LPB provides thermally stable compression of comparable magnitude and even greater depth than other methods, and can be performed in conventional machine shop environments on CNC machine tools. LPB provides a means to extend the fatigue lives of both new and legacy aircraft engines and ground-based turbines. Improving fatigue performance by introducing deep stable layers of compressive residual stress avoids the generally cost prohibitive alternative of modifying either material or design. The X-ray diffraction based background studies of thermal and mechanical stability of surface enhancement techniques are briefly reviewed, demonstrating the importance of minimizing cold work. The LPB process, tooling, and control systems are described. An overview of current research programs conducted for engine OEMs and the military to apply LPB to a variety of engine and aging aircraft components are presented. Fatigue performance and residual stress data developed to date for several case studies are presented including: * The effect of LPB on the fatigue performance of the nickel based super alloy IN718, showing fatigue benefit of thermal stability at engine temperatures. * An order of magnitude improvement in damage tolerance of LPB processed Ti-6-4 fan blade leading edges. * Elimination of the fretting fatigue debit for Ti-6-4 with prior LPB. * Corrosion fatigue mitigation with LPB in Carpenter 450 steel. *Damage tolerance improvement in 17-4PH steel. Where appropriate, the performance of LPB is compared to conventional shot peening after exposure to engine operating temperatures.

Prevey, Paul S.↗
NASA NTRS2012

Tensile Properties of GRCop-84

This is a chapter in the final report on GRCop-84 for the Reusable Launch Vehicle (RLV) Second Generation/Project Constellation Program. It contains information on the tensile properties of GRCop-84. GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) was produced by extrusion and Hot Isostatic Pressing (HIPing). Some of the extrusions were rolled to plate and sheet while other extrusions were drawn into tubing. The material was further subjected to various heat treatments corresponding to annealing, anticipated typical brazing conditions, an end-of-life condition and various elevated temperature exposures to attempt to improve creep resistance. As anticipated, cold work increased strength while decreasing ductility. Annealing at 600 C (1112 F) and higher temperatures was effective. An exposure for 100 h at 500 C (932 F) resulted in an increase in strength rather than the anticipated decrease. High temperature simulated-braze cycles and thermal exposures lowered the strength of GRCop-84, but the deceases were small compared to precipitation strengthened copper alloys. It was observed that the excess Cr could form large precipitates that lower the reduction in area though it appears a minimum amount is required. Overall, GRCop-84 exhibits good stability of its tensile properties, which makes it an excellent candidate for rocket engine liners and many other high temperature applications.

Ellis, David L.↗
NASA NTRS2012

Improvement of GRCop-84 Through the Addition of Zirconium

GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) has excellent strength, creep resistance, low cycle fatigue (LCF) life and stability at elevated temperatures. It suffers in comparison to many commercially available precipitation-strengthened alloys below 500 C (932 F). It was observed that the addition of Zr consistently improved the mechanical properties of Cu-based alloys especially below 500 C. In an effort to improve the low temperature properties of GRCop-84, 0.35 wt.% Zr was added to the alloy. Limited tensile, creep, and LCF testing was conducted to determine if improvements occur. The results showed some dramatic increases in the tensile and creep properties at the conditions tested with the probability of additional improvements being possible through cold working. LCF testing at room temperature did not show an improvement, but improvements might occur at elevated temperatures.

Ellis, David L.↗
DOE OSTI2020

Role of Material Condition in Precursor Corrosion Damage and Stress Corrosion Crack Initiation Behavior of Alloy 600 in PWR Primary Water

Stress corrosion crack (SCC) initiation testing has been performed on a 15% cold-worked UNS N06600 (Alloy 600) heat in the mill-annealed (MA), solution annealed (SA), and thermally treated (TT) conditions to assess the role of grain boundary (GB) carbides on stress-assisted intergranular attack (IGA) and short crack nucleation and growth. The SCC initiation tests were conducted at constant load equivalent to materials yield stress in 360oC simulated PWR primary water with dissolved hydrogen at the Ni/NiO stability line. Results revealed the highest SCC initiation susceptibility in the Alloy 600 MA material followed by the TT and SA materials, suggesting the GB carbide distribution did not have a controlling effect on SCC initiation resistance. Quantitative assessments were conducted on IGA and short cracks to help understand this phenomenon and the role of GB carbides on precursor damage development that lead to differences in macroscopic SCC initiation behavior are discussed.

Zhai, Ziqing↗
DOE OSTI2022

Effect of Water Chemistry on Crack Growth Rate in Neutron Irradiated X-750 and XM-19

The Advanced Test Reactor (ATR) National Science User Facility (NSUF) was used to study the effect of neutron damage on crack growth rates (CGR) under simulated boiling water reactor (BWR) water chemistry conditions using a fast neutron spectrum to accelerate the damage process. Nickel based Alloy X-750 and XM-19 were irradiated in the ATR center flux trap (CFT), with this experiment marking the first civilian project to utilize this position within the reactor. 0.4T-CT specimens were used to study crack growth rates for two sample fluences (~1.9 x 1020 n/cm2 and ~9.5 x 1020 n/cm2, E > 1MeV)) in both normal water chemistry (NWC) at 2.5 ppm O2 and hydrogen water chemistry (HWC) at ~80 ppb H2. CGR testing was conducted at a temperature of 288 °C. A decrease in CGR was observed for both alloys with the average ratio (CGR in NWC/CGR in HWC) being a factor of 281 for the XM-19 samples and a factor of 27.8 for the X-750 samples. Observed CGRs in this study showed little difference compared to non-irradiated samples (the non-irradiated XM-19 was 20% cold worked), suggesting limited sensitivity of these susceptible alloys to irradiation effects. Detailed results of CGR response to varying environmental electrochemical potential (ECP) and water purity will be presented in the context of crack growth mitigation in different water chemistries and the change in material behavior relative to non-irradiated samples of the material.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of Water Chemistry on Crack Growth Rates in Neutron Irradiated X-750 and XM-19

The Advanced Test Reactor (ATR) National Science User Facility (NSUF) was used to study the effect of neutron damage on crack growth rates (CGR) under simulated boiling water reactor (BWR) water chemistry conditions using a fast neutron spectrum to accelerate the damage process. Nickel based Alloy X-750 and XM-19 were irradiated in the ATR center flux trap (CFT), with this experiment marking the first civilian project to utilize this position within the reactor. 0.4T-CT specimens were used to study crack growth rates for two sample fluences (~1.9 x 1020 n/cm2 and ~9.5 x 1020 n/cm2, E > 1MeV) in both normal water chemistry (NWC) at 2.5 ppm O2 and hydrogen water chemistry (HWC) at ~80 ppb H2. A decrease in CGR was observed with HWC for both alloys with the average ratio (CGR in NWC/CGR in HWC) being a factor of 281 for the XM-19 samples and a factor of 27.8 for the X-750 samples. Observed CGRs in this study showed little difference compared to non-irradiated samples (the non-irradiated XM-19 was 20% cold worked), suggesting limited sensitivity of these susceptible alloys to irradiation effects. The CGR response to varying environmental electrochemical potential (ECP) and water purity will be presented.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Applying NIR and MIR spectroscopy for C and soil property prediction in northern cold-region ecosystems. Which approach works better?

Here, developing reliable predictions of soil attributes is necessary to understand northern cold-region climate-soil feedback. Calibration models using near-infrared (NIR) and mid-infrared (MIR) spectroscopy were developed to predict eight commonly measured soil properties for 119 soil samples representing a range of vegetation types, parent materials, and soil types spanning >23° of latitude from southeast Alaska to the Canadian high Arctic. In order to obtain a more accurate prediction, this study compared the performance of linear and non-linear calibration techniques, including lasso regression (Lasso), support vector machine (SVM), random forest (RF) and classic partial least squares (PLS) to predict different soil properties of these soils. Comparing the four models, we noticed that their performance was quite similar for MIR overall, while NIR achieved better results with a PLS model for our dataset. PLS coupled with MIR showed a better performance for soil parameters, such as total organic carbon (TOC), total nitrogen (TN), cation exchange capacity (CEC) and clay (R-squared of 0.9, 0.81, 0.80, and 0.84) when compared with NIR (R-squared of 0.85, 0.72, 0.81 and 0.68). However, using either MIR or NIR spectroscopy, PLS predictions for bulk density (BD) and sand content were not accurate. The variable importance analysis based on the PLS model successfully estimated the relative contribution of wavelengths influencing soil property predictions most. Overall, TOC, TN, CEC and clay mineral predictions are closely related to the occurrence of specific spectral bands in the MIR region. For example, wavelengths at 2978 and 1761 cm -1 for TOC and TN, as well as at 3064 cm -1 for CEC, were selected as the most influential predictor variables. We demonstrated that MIR spectroscopy is a powerful tool for more extensive monitoring in soils of the northern cold climate region; however, NIR could be utilized for rapid estimates when the highest accuracy is not essential.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1991

Transient response of a high-capacity heat pipe for Space Station Freedom

High-capacity heat pipe radiator panels have been proposed as the primary means of heat rejection for Space Station Freedom. In this system, the heat pipe would interface with the thermal bus condensers. Changes in system heat load can produce large temperature and heat load variations in individual heat pipes. Heat pipes could be required to start from an initially cold state, with heat loads temporarily exceeding their low-temperature transport capacity. The present research was motivated by the need for accurate prediction of such transient operating conditions. In this work, the cold startup of a 6.7-meter long high-capacity heat pipe is investigated experimentally and analytically. A transient thermohydraulic model of the heat pipe was developed which allows simulation of partially-primed operation. The results of cold startup tests using both constant temperature and constant heat flux evaporator boundary conditions are shown to be in good agreement with predicted transient response.

Ambrose, J. H.↗
DOE OSTI2022

Hygrothermal simulation of exterior retrofits in a cold climate

This work presents results from moisture modeling as part of a project undertaken by Pacific Northwest National Laboratory and its research partners, the University of Minnesota, and the Oak Ridge National Laboratory. The research goal is to identify exterior wall retrofit systems for cold climates that are low cost, energy efficient, and do not result in moisture durability problems. A base case wall was identified representing a typical wood frame construction, circa 1950. Retrofit options were selected based on input from industry, academia, and published work and seven options were constructed and installed at the University of Minnesota’s cold weather exposure facility in Cloquet, MN. Measurements were carried out during winter months and the data was used for model validation. Hygrothermal simulations were then carried out using WUFI (Version 6.4) in accordance with standard ANSI/ASRHAE 160-2016, Criteria for Moisture-Control Design Analysis in Buildings. Simulations were run out to three years and results show that the exterior retrofits improve thermal performance and do not negatively impact moisture durability of the existing wall.

Aldykiewicz Jr, Antonio↗
DOE OSTI2021

Semi-integral LOCA test of cold-spray chromium coated zircaloy-4 accident tolerant fuel cladding

Enhancing the accident tolerance of PWRs came under serious consideration following the 2011 Fukushima Daiichi nuclear power plant events. While the current nuclear fuels are based on mature technology and have an excellent operational record, further enhancing their strength through accident tolerant fuel (ATF) research and development continues to be of interest. Particularly, the chromium coated clad ATF technology represents an evolutionary change to improve the high temperature performance of existing Zircaloy claddings. Additionally, despite several years of investigation of coated cladding, the integral loss of coolant accident (LOCA) performance of chromium coated cladding has had little attention. In this work, cold-spray chromium coated zircaloy-4 claddings are evaluated using EDF's semi-integral LOCA test facility. Results show that the chromium coating induces a reduced ballooning and burst and an increased burst temperature in the investigated conditions. However, these tests exhibit limited benefits concerning the post-quench behavior of the coated specimens which occurs in the last stage of a prototypical LOCA scenario.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Cold air quench control of local crystallization environment in fully air-processed carbon-based perovskite solar cells

Carbon-based perovskite solar cells (C-PSCs) present a low-cost route to efficient photovoltaic technology. Gas quenching is an essential process commonly used for solvent extraction in scalable module fabrication using solution processes, but film quality remains highly sensitive to the localized environmental processing temperature, especially during intermediate phase transitions before perovskite film high temperature annealing. In this study, we introduce a cold air quench strategy to precisely control the local crystallization temperature that simultaneously promotes uniform crystallization and facilitates strain relaxation in fully air-processed C-PSCs. It is found that implementing dry air at 10 °C as the quenching gas yields a champion power conversion efficiency (PCE) of 20.52 %, with preferential (110) orientation and reduced, homogenized in-plane strain. This newly developed technique of a cost-effective low temperature air quenching process also enhances carrier lifetime, reduces interface recombination, and improves charge extraction. Furthermore, this work presents cold air quenching as a scalable, economic method to control perovskite crystallization and strain in C-PSC fabrication, advancing the industrial viability of high-performance perovskite modules.

14 SOLAR ENERGY↗
DOE OSTI2026

Cold Trap Replacement Project Report

This report documents the replacement of the Mechanisms Engineering Test Loop (METL) cold trap. The work involved preparation of the facility to replace the cold trap, removal of the existing welded cold trap from the sodium purification circuit, installation of a new replacement cold trap, completion of associated welds and examinations, restoration of instrumentation and heaters, and controlled return of the cold trap circuit to service. The replacement represented a significant maintenance evolution because the cold trap is an integral welded component of the sodium system. As a result, the work required coordinated control of sodium chemistry, deliberate formation of freeze plugs, inert gas management, precision cutting and welding, and a staged reheating and refill sequence. The activity was executed using procedural controls intended to protect personnel, preserve system cleanliness, and maintain the integrity of the sodium boundary throughout the work. This report provides a narrative summary of the milestone, including the purpose of the work, the pre-job system condition, the major field activities performed, observations made during execution, and the resulting post-work condition of the METL cold trap circuit.

42 ENGINEERING↗
DOE OSTI2021

A Sodium–Antimony–Telluride Intermetallic Allows Sodium-Metal Cycling at 100% Depth of Discharge and as an Anode-Free Metal Battery

In this work, repeated cold rolling and folding is employed to fabricate a metallurgical composite of sodium–antimony–telluride Na 2 (Sb 2/6 Te 3/6 Vac 1/6 ) dispersed in electrochemically active sodium metal, termed “NST-Na.” This new intermetallic has a vacancy-rich thermodynamically stable face-centered-cubic structure and enables state-of-the-art electrochemical performance in widely employed carbonate and ether electrolytes. NST-Na achieves 100% depth-of-discharge (DOD) in 1 m NaPF 6 in G2, with 15 mAh cm –2 at 1 mA cm –2 and Coulombic efficiency (CE) of 99.4%, for 1000 h of plating/stripping. Sodium-metal batteries (SMBs) with NST-Na and Na 3 V 2 (PO 4 ) 3 (NVP) or sulfur cathodes give significantly improved energy, cycling, and CE (>99%). An anode-free battery with NST collector and NVP obtains 0.23% capacity decay per cycle. Imaging and tomography using conventional and cryogenic microscopy (Cryo-EM) indicate that the sodium metal fills the open space inside the self-supporting sodiophilic NST skeleton, resulting in dense (pore-free and solid electrolyte interphase (SEI)-free) metal deposits with flat surfaces. The baseline Na deposit consists of filament-like dendrites and “dead metal”, intermixed with pores and SEI. Density functional theory calculations show that the uniqueness of NST lies in the thermodynamic stability of the Na atoms (rather than clusters) on its surface that leads to planar wetting, and in its own stability that prevents decomposition during cycling.

36 MATERIALS SCIENCE↗