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At least 145 records · Page 8

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NASA NTRS1991

A millimeter wave technique for measuring ice thickness on the Space Shuttle's external tank

A solution is presented for detecting and measuring ice that can form on the spray-on foam insulation protecting Space Shuttle fueltanks. The method involves the measurement of the emission properties of the fueltank with a mm-wave radiometer. Emission from the insulated panel is measured for the case of insulation with the original rough surface and the case of insulation sanded down to have a smooth surface. The radiative transfer calculations are facilitated by using a smooth surface, and experimental evidence demonstrates the effective and accurate prediction of ice thickness on the smooth surface. The panel with a rough surface is measured, and the emmision levels are higher than those predicted by model calculations. Sensitivity to ice thickness is similar in both situations in spite of the bias introduced by the rough surface.

Kendra, John E.↗

NASA NTRS1990

Thermal response of various thermal barrier coatings in a high heat flux rocket engine

Traditional APS ZrO2-Y2O3 thermal barrier coatings (TBCs) formed by air plasma spraying and low pressure and air plasma sprayed ZrO2-Y2O3/NiCrAlY cermet coatings were tested in an H2-O2 rocket engine. The test cycle was approximately 1.2 s at 1400 C in a hydrogen-rich environment. During testing, the maximum metal temperature without a coating was 1310 C. The traditional ZrO2-Y2O3 TBCs with a 100-125 micron thick ceramic layer reduced the maximum metal temperature by approximately 350 C. Increasing the ceramic layer thickness to 200-225 microns resulted in an additional metal temperature reduction of 100 C. However, the cermet coatings, consisting of a ceramic and metal mixture, exhibited a much lower thermal protection capability by reducing the maximum metal temperature by approximately 100 C. It was also found that the surface roughness of the traditional TBCs had little effect on the thermal response.

Nesbitt, J. A.↗

NASA NTRSDate not supplied

Solar White Thermal Coating for Cryogenic Propulsion Systems

NASA is currently conducting research into the potential of storing cryogenic fluid in low Earth orbit (LEO). Having cryogenic propellant readily available for high-performance propulsion systems can be very beneficial for deep space missions in the near future. One of the key challenges to storing cryogenic fluid in LEO is minimizing boil-off. To address the challenge, NASA is evaluating new concepts in thermal insulation. One recent experimental study evaluated the feasibility of using Yttrium Oxide (Y2O3), formed into tiles or spray coating that can potentially be used as a thermal coating for cryogenic propellant storage applications in deep space. Due to its temperature and wavelength dependent optical properties, this “solar white” material can reflect a vast majority of the Sun’s radiative energy while having a very high infrared emissivity for rejecting heat to deep space. As a part of the material development and proof of concept testing, multiple tests have been run at KSC and GRC to demonstrate the performance of the material. At GRC, the tests were run using the Deep Space Solar Simulator (DS3) which contains a thermal vacuum chamber in which the solar white sample was exposed to a deep space environment (< 10 K, optically dense walls) while under full illumination via solar lamp. In order to improve the use of the test results and apply them to spacecraft, there is a need to be able to model the material properties within NASA’s standard thermal modeling tools. As such, it was set out to verify a thermal model of one of the experiments using Thermal Desktop with Sinda. The thermal model of the DS3 test setup includes the solar white sample along with a solar lamp simulator capable of outputting heat at varying wavelengths. The model was developed in order to validate the test results and also to help predict results that will be obtained in future tests. This paper will review the modeling methods and thermal analysis results for various test cases that were run within the DS3 facility.

Cryogenic↗

DOE OSTI2015

Further work on credible levels of water moderation - 14267

The Research and Test Reactor (RTR) manufacturing operation produces aluminum clad fuel plates that are assembled into 'box type' elements that are used in reactors like the Advanced Test Reactor, University of Missouri, and Massachusetts Institute of Technology. These fuel plates and elements are stored in both horizontal and vertical arrangements during the manufacturing process. Since the presence of water is so important to criticality safety of the operations, a study was undertaken to establish credible levels of water moderation. At the NCSD 2013 Topical meeting, credible levels of interspersed water moderation from multiple sources including firefighting, steam and rain were presented. This covered the initial portions of the research. Subsequent research was conducted on water films resulting from these water sources. This phase of the research involved the formation of water films. These can form from condensation, water sprays or immersion. The thickness of the water films from these sources ranged from 0.04 cm to 0.30 cm for vertical fuel plates. Studies were also conducted on horizontal plates, stacks of plates and assembled elements. For fuel plates, the films ranged from essentially zero for stacked plates to 0.25 cm. For an element, there was sufficient adhesion that all of the channels were filled. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2019

The Tribological Behavior of Hybrid Graphene/Tungsten Disulfide Nanoparticle Coatings

Environmental concerns regarding the disposal of fluid lubricants have led to the application of green technologies to metalworking processes in the form of dry lubricants. These dry lubricants are typically applied as spray coatings that employ the use of nanoparticles. The possible use of graphene in the form of graphene/tungsten disulfide (G/WS{sub 2}) nanoparticle spray coatings has been examined in this research. The investigation was performed through the use of ball-on-disk tests at ambient temperatures to ascertain the possible application of the aerosol spray coatings to the aluminum forming processes. The coatings proved to possess good adhesion to the Al-Mg alloy substrate. The nanoparticle spray coatings were tested at various graphene to WS{sub 2} concentrations and under varying loads. A low steady-state COF was noted for all graphene concentrations during sliding contact under all the loads examined. The durability of the coatings was observed to improve with increasing loads. The low COF was attributed to the formation of wear-induced transfer layers on the steel balls and tribolayers on the coated Al-Mg surfaces. The coating durability was related to the concentration of graphene within the nanoparticle spray coatings and the stability of the tribolayers during sliding contact. The results highlight that the G/WS{sub 2} nanoparticle spray coatings could be considered for aluminum metalworking processes.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Factors controlling marine aerosol size distributions and their climate effects over the northwest Atlantic Ocean region

Abstract. Aerosols over Earth's remote and spatially extensive ocean surfaces have important influences on planetary climate. However, these aerosols and their effects remain poorly understood, in part due to the remoteness and limited observations over these regions. In this study, we seek to understand factors that shape marine aerosol size distributions and composition in the northwest Atlantic Ocean region. We use the GEOS-Chem model with the TwO-Moment Aerosol Sectional (TOMAS) microphysics algorithm model to interpret measurements collected from ship and aircraft during the four seasonal campaigns of the North Atlantic Aerosols and Marine Ecosystems Study (NAAMES) conducted between 2015 and 2018. Observations from the NAAMES campaigns show enhancements in the campaign-median number of aerosols with diameters larger than 3 nm in the lower troposphere (below 6 km), most pronounced during the phytoplankton bloom maxima (May/June) below 2 km in the free troposphere. Our simulations, combined with NAAMES ship and aircraft measurements, suggest several key factors that contribute to aerosol number and size in the northwest Atlantic lower troposphere, with significant regional-mean (40–60∘ N and 20–50∘ W) cloud-albedo aerosol indirect effect (AIE) and direct radiative effect (DRE) processes during the phytoplankton bloom. These key factors and their associated simulated radiative effects in the region include the following: (1) particle formation near and above the marine boundary layer (MBL) top (AIE: −3.37 W m−2, DRE: −0.62 W m−2); (2) particle growth due to marine secondary organic aerosol (MSOA) as the nascent particles subside into the MBL, enabling them to become cloud-condensation-nuclei-sized particles (AIE: −2.27 W m−2, DRE: −0.10 W m−2); (3) particle formation and growth due to the products of dimethyl sulfide, above and within the MBL (−1.29 W m−2, DRE: −0.06 W m−2); (4) ship emissions (AIE: −0.62 W m−2, DRE: −0.05 W m−2); and (5) primary sea spray emissions (AIE: +0.04 W m−2, DRE: −0.79 W m−2). Our results suggest that a synergy of particle formation in the lower troposphere (particularly near and above the MBL top) and growth by MSOA contributes strongly to cloud-condensation-nuclei-sized particles with significant regional radiative effects in the northwest Atlantic. To gain confidence in radiative effect magnitudes, future work is needed to understand (1) the sources and temperature dependence of condensable marine vapors forming MSOA, (2) primary sea spray emissions, and (3) the species that can form new particles in the lower troposphere and grow these particles as they descend into the marine boundary layer.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2012

Corrosion resistant neutron absorbing coatings

A method of forming a corrosion resistant neutron absorbing coating comprising the steps of spray or deposition or sputtering or welding processing to form a composite material made of a spray or deposition or sputtering or welding material, and a neutron absorbing material. Also a corrosion resistant neutron absorbing coating comprising a composite material made of a spray or deposition or sputtering or welding material, and a neutron absorbing material.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Corrosion resistant neutron absorbing coatings

36 MATERIALS SCIENCE↗

DOE OSTI2020

Combined Experimental/Numerical Study of the Soot Formation Process in a Gasoline Direct-Injection Spray in the Presence of Laser-Induced Plasma Ignition

Here, combustion issued from an eight-hole, direct-injection spray was experimentally studied in a constant-volume pre-burn combustion vessel using simultaneous high-speed diffused back-illumination extinction imaging (DBIEI) and OH* chemiluminescence. DBIEI has been employed to observe the liquid-phase of the spray and to quantitatively investigate the soot formation and oxidation taking place during combustion. The fuel-air mixture was ignited with a plasma induced by a single-shot Nd:YAG laser, permitting precise control of the ignition location in space and time. OH* chemiluminescence was used to track the high-temperature ignition and flame. The study showed that increasing the delay between the end of injection and ignition drastically reduces soot formation without necessarily compromising combustion efficiency. For long delays between the end of injection and ignition (1.9 ms) soot formation was eliminated in the main downstream charge of the fuel spray. However, poorly atomized and large droplets formed at the end of injection (dribble) eventually do form soot near the injector even when none is formed in the main charge. The quantitative soot measurements for these spray and ignition scenarios, resolved in time and space, represents a significant new achievement. Reynolds-averaged Navier-Stokes (RANS) simulations were performed to assess spray mixing and combustion. An analysis of the predicted fuel-air mixture in key regions, defined based upon experimental observations, was used to explain different flame propagation speeds and soot production tendencies when varying ignition timing. The mixture analysis indicates that soot production can be avoided if the flame propagates into regions where the equivalence ratio (Φ) is already below 2. Reactive RANS simulations have also been performed, but with a poor match against the experiment, as the flame speed and heat-release rate are largely over estimated. This modeling weakness appears related to a very high level of turbulent viscosity predicted for the high-momentum spray in the RANS simulations, which is an important consideration for modeling ignition and flame propagation in mixtures immediately created by the spray.

42 ENGINEERING↗

DOE OSTI2016

Thickness and microstructure characterization of TGO in thermal barrier coatings by 3D reconstruction

Yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBCs) are prepared by plasma spraying. Thermally grown oxide (TGO) would be formed between YSZ topcoat and bond coat after 50 h thermal service for YSZ TBCs. The electron back scattered diffraction (EBSD) results reveal that the TGO layer is composed of α-Al{sub 2}O{sub 3} and cubic Al{sub 2}NiO{sub 4} layers. Measured values of TGO thickness from the 2D-SEM image are greater than or equal to its real thickness due to the fact that the TGO layer is much rolling so that up and down surfaces of the TGO can't be completely perpendicular to the cross-section direction confirmed by 3D-SEM. Furthermore, 3D-SEM results reveal that the real thickness of TGO layer is 3.10 μm instead of 7.1 μm. In addition, 3D-EBSD confirmed that α-Al{sub 2}O{sub 3} layer in TGO is composed of single layer of grains and Al{sub 2}NiO{sub 4} layer consist of multilayer of grains while α-Al{sub 2}O{sub 3} layer is mixed with single layer and multilayer of α-Al{sub 2}O{sub 3} grains from observation of the 2D-EBSD image. It provides a new method to characterize real thickness and microstructure of TGO, which is also applied to other film materials. - Highlights: •This work provides a new method to measure the real thickness of TGO. •YSZ TBCs were prepared by plasma spraying. •TGO is formed in TBCs by simulating thermal service at 1100 °C for 50 h. •Real thickness and microstructure of TGO were investigated by 3D reconstruction.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Methods and systems for 3D printing with powders

A method of printing a three dimensional article (201) can include forming a bottom layer of the three dimensional article (201) by spraying a dry build material powder (210) onto a build platform (230) while heating the dry build material powder (210). The dry build material powder (210) can include metal or ceramic particles mixed with a polymeric binder having a softening point temperature. The dry build material powder (210) can be heated to a temperature above the softening point temperature such that the dry build material powder (210) adheres to the build platform (230). Subsequent layers can be formed by spraying dry build material powder (210) onto a lower layer while heating the dry build material powder (210) such that the dry build material powder (210) adheres to the lower layer.

Fang, Zhigang Zak↗

NASA NTRS1984

Properties of simulated comet mantle

The properties of freeze-dried dilute dispersions of dust in water ice are of considerable interest in studies of comet nucleus mantles. The formation of a rind residue produced by the sublimation of water ice containing various amounts of fine clay particles may be an important process. A simulation of the development of the dry dust rind on the surface of comets is presented. This rind is the result of preferential ice sublimation. The development and disruption of this rind and its subsequent levitation by water vapor flow is studied. The most interesting rind simulant is produced by dispersing 0.1 micron particles of montmorillonite in water in concentrations of 10%, 1%, and 0.1%. These dispersions are then sprayed into liquid nitrogen in the form of 100 micron droplets. The frozen droplets are then freeze-dried in a vacuum which prevents the ice temperature from rising above -30 C. Sublimation of the nitrogen and the water produced dry rinds. The most striking result was the development of large cohesive matrices of individual clay particles, and in some cases a continuous cohesive crust. Scanning electron microscope (SEM) observations reveal that the material formed by freeze-drying the 0.1% dispersion does not retain the original spherical shape of the sprayed 100 micron droplets; instead it consists of a continuous filamentary network, as shown in the SEM stereo micrographs.

Fanale, F. P.↗

NASA NTRSDate not supplied

X-Ray Diffraction Measurements of Residual Stress in a Cold Sprayed Ni Coating

X-ray diffraction (XRD) was used to investigate the residual stress in a cold sprayed Ni coating which failed to form a bimetallic joint with NASA HR-1. The objective was to apply pure Ni by cold spray as a diffusion barrier between the Ni-based alloy NASA HR-1 and the Cu-based GRCop-42 for a thrust cell assembly. After additive manufacturing of the GRCop-42 cylinder, the commercially pure Ni coating was cold sprayed onto the cylinder. It was intended to have NASA HR-1 applied directly onto the Ni coating by Directed Energy Deposition (DED), however the bond failed during the first layer of DED. Residual stress measurements were collected via the Sin²ψ method in three equally spaced locations on the top surface of the Ni coating in both as-cold sprayed and heat-treated conditions. The results revealed both compressive and tension stresses on the as-cold sprayed sample and compressive stresses in the heat-treated sample. The results were illuminated when plotted at their respective positions and with their respective orientation angles around a circle. This showed rotational symmetry in the residual stress measurements, which correlated to the processing method used during application of the Ni coating.

Laura Wilson↗

NASA NTRS2008

Thermal Spray Formation of Polymer Coatings

This innovation forms a sprayable polymer film using powdered precursor materials and an in-process heating method. This device directly applies a powdered polymer onto a substrate to form an adherent, mechanically-sound, and thickness-regulated film. The process can be used to lay down both fully dense and porous, e.g., foam, coatings. This system is field-deployable and includes power distribution, heater controls, polymer constituent material bins, flow controls, material transportation functions, and a thermal spray apparatus. The only thing required for operation in the field is a power source. Because this method does not require solvents, it does not release the toxic, volatile organic compounds of previous methods. Also, the sprayed polymer material is not degraded because this method does not use hot combustion gas or hot plasma gas. This keeps the polymer from becoming rough, porous, or poorly bonded.

Coquill, Scott↗

NASA NTRS1958

Effects of Nose Shape and Spray Control Strips on Emergence and Planing Spray of Hydro-ski Models

The emergence and planing-spray characteristics of flat-bottom surfaces representative of hydro-skis with various bow shapes and deflectors were investigated for trims of 12° and 20° and a speed of 30 feet per second. The emergence-spray characteristics of the models with various bow shapes were investigated for depths of submersion of the bow from 0.50 inch to -0.50 inch. The planing-spray characteristics of the models with the various deflectors were determined for a draft corresponding to a length-beam ratio of 4 . The emergence- and planing-spray patterns are shown in the photographs taken from forward of and above the models and from the side of the models. The most favorable emergence spray was obtained with a bow of triangular plan form and sharp profile. The greatest improvement in planing spray was obtained with vertical chine strips and a transverse barrier strip located forward of the wetted planing area.

John R McGehee↗

NASA NTRS1981

Ice/frost detection using millimeter wave radiometry

A series of ice detection tests was performed on the shuttle external tank (ET) and on ET target samples using a 35/95 GHz instrumentation radiometer. Ice was formed using liquid nitrogen and water spray inside a test enclosure containing ET spray on foam insulation samples. During cryogenic fueling operations prior to the shuttle orbiter engine firing tests, ice was formed with freon and water over a one meter square section of the ET LOX tank. Data analysis was performed on the ice signatures, collected by the radiometer, using Georgia Tech computing facilities. Data analysis technique developed include: ice signature images of scanned ET target; pixel temperature contour plots; time correlation of target data with ice present versus no ice formation; and ice signature radiometric temperature statistical data, i.e., mean, variance, and standard deviation.

Gagliano, J. A.↗

NASA NTRS1986

Development testing of large volume water sprays for warm fog dispersal

A new brute-force method of warm fog dispersal is described. The method uses large volume recycled water sprays to create curtains of falling drops through which the fog is processed by the ambient wind and spray induced air flow. Fog droplets are removed by coalescence/rainout. The efficiency of the technique depends upon the drop size spectra in the spray, the height to which the spray can be projected, the efficiency with which fog laden air is processed through the curtain of spray, and the rate at which new fog may be formed due to temperature differences between the air and spray water. Results of a field test program, implemented to develop the data base necessary to assess the proposed method, are presented. Analytical calculations based upon the field test results indicate that this proposed method of warm fog dispersal is feasible. Even more convincingly, the technique was successfully demonstrated in the one natural fog event which occurred during the test program. Energy requirements for this technique are an order of magnitude less than those to operate a thermokinetic system. An important side benefit is the considerable emergency fire extinguishing capability it provides along the runway.

Keller, V. W.↗

DOE OSTI2012

Large-Scale Spray Releases: Initial Aerosol Test Results

One of the events postulated in the hazard analysis at the Waste Treatment and Immobilization Plant (WTP) and other U.S. Department of Energy (DOE) nuclear facilities is a breach in process piping that produces aerosols with droplet sizes in the respirable range. The current approach for predicting the size and concentration of aerosols produced in a spray leak involves extrapolating from correlations reported in the literature. These correlations are based on results obtained from small engineered spray nozzles using pure liquids with Newtonian fluid behavior. The narrow ranges of physical properties on which the correlations are based do not cover the wide range of slurries and viscous materials that will be processed in the WTP and across processing facilities in the DOE complex. Two key technical areas were identified where testing results were needed to improve the technical basis by reducing the uncertainty due to extrapolating existing literature results. The first technical need was to quantify the role of slurry particles in small breaches where the slurry particles may plug and result in substantially reduced, or even negligible, respirable fraction formed by high-pressure sprays. The second technical need was to determine the aerosol droplet size distribution and volume from prototypic breaches and fluids, specifically including sprays from larger breaches with slurries where data from the literature are scarce.

Schonewill, Philip P.↗