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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

Thermal Performance of Composite Flexible Blanket Insulations for Hypersonic Aerospace Vehicles

This paper describes the thermal performance of a Composite Flexible Blanket Insulation (C.F.B.I.) considered for potential use as a thermal protection system or thermal insulation for future hypersonic vehicles such as the National Aerospace Plane (N.A.S.P.). Thermophysical properties for these insulations were also measured including the thermal conductivity at various temperatures and pressures and the emissivity of the fabrics used in the flexible insulations. The thermal response of these materials subjected to aeroconvective heating from a plasma arc is also described. Materials tested included two surface variations of the insulations, and similar insulations coated with a Protective Ceramic Coating (P.C.C.). Surface and backface temperatures were measured in the flexible insulations and on Fibrous Refractory Composite Insulation (F.R.C.I.) used as a calibration model. The uncoated flexible insulations exhibited good thermal performance up to 35 W/sq cm. The use of a P.C.C. to protect these insulations at higher heating rates is described. The results from a computerized thermal analysis model describing thermal response of those materials subjected to the plasma arc conditions are included. Thermal and optical properties were determined including thermal conductivity for the rigid and flexible insulations and emissivity for the insulation fabrics. These properties were utilized to calculate the thermal performance of the rigid and flexible insulations at the maximum heating rate.

Kourtides, Demetrius A.↗
NASA NTRS1977

Effect of simulated Earth reentry exposure on mechanical properties of several oxide dispersion strengthened and superalloy sheet materials

The effects of simulated multiple reentry into the earth's atmosphere on the mechanical properties of several high temperature metallic sheet materials were evaluated. The materials included five tin-gage (nominally 0.025- or 0.037-cm) oxide dispersion strengthened (ODS) alloys and two thin-gage (nominally 0.037-cm) superalloys. Multiple reentry conditions were simulated through cyclic Plasma Arc Tunnel (PAT) exposure. PAT exposure generally consisted of 100 cycles of 600 second duration at 1255, 1366, or 1477 K in a Mach 4.6 airstream with an impact pressure of nominally 800 N/m2. PAT exposure generally produced a uniform oxide scale, oxide pits or intergranular oxidation, Kirkendall porosity, and alloy depletion zones except for the aluminum-containing ODS alloys. Only a uniform oxide scale was formed on the aluminum-containing ODS alloys. PAT exposure did not significantly affect the mechanical properties of the thin-gage (nominally 0.025- or 0.037-cm) alloys evaluated. Thus it appears that the microstructural changes produced by Plasma Arc Tunnel exposure has little influence on mechanical properties.

Whittenberger, J. D.↗
DOE OSTI2026

Boride-based Ceramic Super-high Temperature Thermocouples in Harsh Environments (Final Scientific/Technical Report)

An electromotive force (emf) can be generated along a temperature gradient between the cold end and hot end of a thermoelectric material, termed the Seebeck effect. Based on the Seebeck effect, metallic alloys have been extensively employed to detect temperatures for centuries, named thermocouples. However, commercially available thermocouple alloys suffer from limitations, such as oxidation, chemical degradation, and poor long-term stability under high-temperature harsh environments. This DOE-funded project aimed to develop high-temperature, chemically tolerant thermocouples suitable for operation in extreme environments relevant to semiconducting thermoelectric materials. The research focused on boride-based semiconducting thermoelectric compounds as candidates for next-generation thermocouples with enhanced oxidation resistance, chemical stability, and thermal robustness under conditions representative of charcoal-fired electricity facilities. During the funded years, boride materials were synthesized using an arc-plasma technique under ambient air and argon atmospheres, enabling scalable and cost-effective production compared with conventional boride fabrication methods. The synthesized borides were processed into nanostructured powders, followed by consolidation into dense bulk materials using a spark plasma sintering (SPS) bottom-up approach. Comprehensive characterization was performed, including microstructural analysis, electrical transport measurements, and optical and thermal property evaluation. Both p-type and n-type boride electric legs were fabricated and integrated into boride-based thermocouples. The thermal and irradiation stabilities of the boride nanomaterials and bulk thermoelectric materials were systematically evaluated to assess suitability for long-term operation in harsh environments. Additionally, 12 students were broadly hands-on trained spanning the full research workflow, including word processing and technical editing (e.g., LATEX for manuscript and poster preparation), data collection and analysis (using Python and related libraries and hardware interfaces), sample preparation (including arc-plasma synthesis and spark plasma sintering), and advanced characterization techniques (such as X-ray diffraction, UV–vis spectroscopy, electron microscopy, differential thermal analysis (DTA), and Seebeck coefficient measurements, etc). Overall, this project demonstrated the feasibility of boride-based thermoelectric materials as durable high-temperature thermocouples, providing a promising pathway toward robust temperature sensing technologies aligned with DOE energy infrastructure and extreme-environment monitoring needs.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1973

Magneto-plasma-dynamic arc thruster

The performance of a magnetoplasmadynamic arc thruster, in the 600 to 2,100 seconds specific impulse range, was improved by locating its cathode in the exhaust beam downstream of the anode and main propellant injection point.

Burkhart, J. A.↗
NASA NTRS1991

Considerations of metal joining processes for space fabrication, construction and repair

A comprehensive evaluation is conducted of candidate processes for metalworking in orbital (vacuum-microgravity) conditions. Attention is given to electron-beam welding, brazing, gas-tungsten arc welding, laser welding, plasma arc welding, and gas-metal arc welding. It is established that several of these processes will be required to cover all foreseeable requirements. Microgravity effects are considered minor, and efforts are being concentrated on problems associated with vacuum conditions and with process-operator safety.

Russell, C.↗
NASA NTRSDate not supplied

Indirect Magnetic Measurements on the Aerodynamic Heating Facility (AHF)

The arc jet complex at NASA Ames Research Center (ARC) investigates various thermal protection systems (TPS) and their performance in high enthalpy flow environments to improve heat shields used in atmospheric entry. The arc jet operates by inducing an arc between two electrodes and passing the heated gas through a supersonic nozzle. The arc plasma is typically a partially ionized air mixture at low temperature (< 2 eV) but operates for long periods of time (up to 30 min) at high power (< 60 MW). However, simulations using the in-house ARC Heater Simulator (ARCHeS) code predict that the arc is still unstable to MHD instabilities, primarily the kink instability, which limit the operational envelope of the facility [1]. Consequently, it is important to better characterize these instabilities to improve facility stability and extend operational ranges. Due to the high enthalpy and long timescales (i.e., minutes) arc diagnostics must be non-invasive (i.e., optical or magnetic). This work will cover the development of tri-axial magnetic hall sensors for arc jet instabilities and subsequent 3D characterization of arc motion. The latest results describing the kink instability amplitude, frequency and wavelength will be presented and represent the first measurements of this instability in a NASA arc jet facility. References: [1] Meurisse, J. (2018). 3D Unsteady Model of Arc Heater Plasma Flow Using the ARC Heater Simulator (ARCHeS), APS Gaseous Electronics Conference, 2018: APS.

Sebastian Vicente Colom↗
NASA NTRS1995

Swirl Ring Improves Performance Of Welding Torch

Plasma-arc welding torch modified to create vortex in plasma gas to focus arc into narrower and denser column. Swirl ring contains four channels with angled exit holes to force gas to swirl as it flows out of torch past tip of electrode. Degradation of electrode and orifice more uniform and need to rotate torch during operation to compensate for asymmetry in arc reduced or eliminated. Used in both keyhole and nonkeyhole welding modes.

Mcgee, William F.↗
NASA NTRS1993

Vision-aided Monitoring and Control of Thermal Spray, Spray Forming, and Welding Processes

Vision is one of the most powerful forms of non-contact sensing for monitoring and control of manufacturing processes. However, processes involving an arc plasma or flame such as welding or thermal spraying pose particularly challenging problems to conventional vision sensing and processing techniques. The arc or plasma is not typically limited to a single spectral region and thus cannot be easily filtered out optically. This paper presents an innovative vision sensing system that uses intense stroboscopic illumination to overpower the arc light and produce a video image that is free of arc light or glare and dedicated image processing and analysis schemes that can enhance the video images or extract features of interest and produce quantitative process measures which can be used for process monitoring and control. Results of two SBIR programs sponsored by NASA and DOE and focusing on the application of this innovative vision sensing and processing technology to thermal spraying and welding process monitoring and control are discussed.

Agapakis, John E.↗
NASA NTRS1993

Interactions between spacecraft and their environments

Interactions between spacecraft and their environments are discussed using the SSF and the SP-100 power system. It is recommended that discontinuous structure potentials of more than 100 V on a spacecraft must be connected with an insulating material of sufficient thickness to stand off the potential difference. Particular attention must be paid to conductors with a plasma arcing threshold higher than the conductor potential relative to the surrounding plasma. To avoid arcing, spacecraft surfaces should avoid exposed conductors, or at least exposed conductor-insulator junctions for LEO missions. To avoid differential charging, fully conductive surfaces should be used every where for GEO missions.

Ferguson, Dale C.↗
DOE OSTI2026

AMVOS: Additive Manufacturing Video Object Segmentation Dataset

This dataset provides labeled video frames from four additive manufacturing (AM) processes for video object segmentation (VOS) tasks. It contains 90 video segments comprising 900 individually annotated frames across five AM datasets: laser hot-wire directed energy deposition (LHW-DED), tungsten inert gas wire arc additive manufacturing (TIG-WAAM), plasma arc welding (PAW), visible-light polymer extrusion (visPolymer), and near-infrared polymer extrusion (irPolymer). Each video segment consists of 10 contiguous frames with corresponding pixel-level object instance annotations. Depending on the process, two of four object classes are labeled per frame: Melt Pool, Feed Wire, Nozzle, or Material. Raw frames are provided as .jpg files and annotations as palettized .png files. The dataset follows the directory structure of established VOS benchmarks (DAVIS, YouTube-VOS, MOSE), enabling direct integration into VOS model training and evaluation pipelines for foundation model fine-tuning, domain adaptation, or zero-shot performance benchmarking. Data was collected at Oak Ridge National Laboratory's Manufacturing Demonstration Facility.

Wetzel, Jon [ORNL]↗
NASA NTRS1995

Ternary gas plasma welding torch

A plasma arc welding torch is discussed. A first plasma gas is directed through the body of the welding torch and out of the body across the tip of a welding electrode disposed at the forward end of the body. A second plasma gas is disposed for flow through a longitudinal bore in the electrode. The second plasma gas enters one end of the electrode and exits the electrode at the tip thereof for co-acting with the electric welding arc to produce the desired weld. A shield gas is directed through the torch body and circulates around the head of the torch adjacent to the electrode tip.

Rybicki, Daniel J.↗
NASA NTRS1989

Multihole Arc-Welding Orifice

Modified orifice for variable-polarity plasma-arc welding directs welding plume so it creates clean, even welds on both Inconel(R) and aluminum alloys. Includes eight holes to relieve back pressure in plasma. Quality of welds on ferrous and nonferrous alloys improved as result.

Swaim, Benji D.↗