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At least 19 records

Task 4 supporting technology. Densification requirements definition and test objectives. Propellant densification requirements definition

The primary challenge of the X-33 CAN is to build and test a prototype LO2 and LH2 densification ground support equipment (GSE) unit, and perform tank thermodynamic testing within the 15 month phase 1 period. The LO2 and LH2 propellant densification system will be scaled for the IPTD LO2 and LH2 tank configurations. The IPTD tanks were selected for the propellant technology demonstration because of the potential benefits to the phase 1 plan: tanks will be built in time to support thermodynamic testing; minimum cost; minimum schedule risk; future testing at MSFC will build on phase 1 data base; and densification system will be available to support X-33 and RLV engine test at IPTD. The objective of the task 1 effort is to define the preliminary requirements of the propellant densification GSE and tank recirculation system. The key densification system design parameters to be established in Task 1 are: recirculation flow rate; heat exchanger inlet temperature; heat exchanger outlet temperature; maximum heat rejection rate; vent flow rate (GN2 and GH2); densification time; and tank pressure level.

Lak, Tibor↗

Sol-gel synthesis and densification of aluminoborosilicate powders. Part 2: Densification

Aluminoborosilicate (ABS) powders, high in alumina content, were synthesized by the sol-gel process utilizing four different methods of synthesis. The effect of these methods on the densification behavior of ABS powder compacts was studied. Five regions of shrinkage in the temperature range 25-1184 C were identified. In these regions, the greatest shrinkage occurred between the gel-to-glass transition temperature (T sub g approximately equal to 835 C) and the crystallization transformation temperature (T sub t approximately equal 900 C). The dominant mechanism of densification in this range was found to be viscous sintering. ABS powders were amorphous to x-rays up to T sub t at which a multiphasic structure crystallized. No 2Al2O3.B2O3 was found in these powders as predicted in the phase diagram. Above T sub t, densification was the result of competing mechanisms including grain growth and boria fluxed viscous sintering. Apparent activation energies for densification in each region varied according to the method of synthesis.

Bull, Jeffrey↗

The significance of biomass densification in biological-based biorefineries: A critical review

Replacing fossil fuels with renewable biofuels derived from lignocellulosic biomass is an important aspect of addressing environmental challenges and developing a sustainable industrial society. Densification overcomes the problems of low bulk density and poor flowability of biomass and has been commercialized for producing solid biofuels, but the overall impact of densification on biological-based biorefineries that primarily target liquid fuels (e.g., ethanol) is still under investigation. Herein, this review provides a thorough summary of the application of densified biomass in biological-based biorefineries. First, the effects of densification parameters as well as variables of biomass materials on the densified products’ quality are reviewed, and different commonly used densification technologies are also discussed and compared. Then, the discussion focuses on the physiochemical modifications of biomass caused by densification that may influence further pretreatment and/or enzymatic hydrolysis in biorefineries. Industrial pelleting has been generally shown to exhibit positive/neutral effects on the enzymatic hydrolysis of multiple biomass feedstocks after pretreatments, indicating the viability of using pellets as starting feedstocks in biorefineries. Densification causes structural disruption of biomass, which may facilitate further biochemical conversions. Integrating biomass densification in the feedstock supply chain is feasible for large-scale biorefineries to overcome the techno-economic barriers and become profitable. Suggestions are presented for the efficiency enhancement and cost reduction in densification-based biorefineries. To enable wider applications, it is now the time to employ more demo and full-scale activities in different regions of the world pushing the research and innovation of densification integrated within biorefining.

09 BIOMASS FUELS↗

Modeling the Effects of Microwave Heating on Densification in Chemical Vapor Infiltration

Microwave heating has great potential to accelerate the synthesis of ceramic matrix composites (CMCs) by a process called Chemical Vapor Infiltration (CVI). In CVI, reactive gases ingress a porous preform and undergo chemical transformation to deposit solid ceramic phase within the pores at high temperature thus, densifying the preform. However, the competing effects of chemical kinetics and gas transport are known to result in non-uniform densification as the outer surfaces of the preform experience faster depositions compared to the core. Achieving spatial temperature control plays a key role improving the densification quality. Microwave heating can potentially create temperature inversion such that the core of the preform is hotter than the outer surface and subsequently, lead to improved densification while keeping the manufacturing times and costs low. In the present work, a computational modeling strategy has been developed that accounts for the key physical phenomena responsible for densification of porous preforms using microwave heating. Specifically, a chemical kinetics model has been formulated for Silicon Carbide (SiC) deposition from MTS/H2 precursor. The model is implemented in a pore-resolved reactive transport solver, Quilt. The CVI simulations are performed for several conditions. Initially, parameterized temperature control is imposed to identify optimum conditions for good densification quality at a fraction of processing time. Further, simulations of microwave heating of porous SiC preforms are performed using OpenFOAM. A strategy to achieve and enhance temperature inversion is identified. The resulting temperature profiles are used in the pore-resolved densification simulations to analyze the densification behavior. It is observed that the temperature inversion achieved by microwave heating leads to significant improvements in densification quality and at the same time, keeps the manufacturing time low.

36 MATERIALS SCIENCE↗

Effects of temperature inversion on densification in chemical vapor infiltration

In a classical chemical vapor infiltration (CVI) process, the competing effects of chemical kinetics and reagent gas transport lead to non–uniform depositions such that outer layers of a preform densify faster leaving the core highly porous. Currently, CVI must be performed at a sufficiently low temperature to achieve good densification quality which leads to high processing time and cost. Volumetric heating of the preform, especially through microwaves, can create temperature inversion such that the core is hotter than the outer surface and potentially, overcome the challenges associated with isothermal CVI. Direct numerical simulations (DNS) of densification under various such temperature distributions indicate that microwave heating in CVI processing can lead to better (uniform) densification of porous preforms. Here the role of key parameters describing the temperature distributions on the densification behavior is investigated. Strategic temporal control of the temperature distribution shows that processing times can be reduced by almost half while maintaining a good densification quality similar to that of low–temperature isothermal processing. Inside–out densification due to the inverted temperature profile is a key distinguishing characteristic of microwave assisted CVI.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Propellant Densification Ground Testing Conducted for Launch Vehicles

The NASA Glenn Research Center at Lewis Field has taken the lead in the development of practical densified cryogenic propellants for launch vehicle applications. The technology of subcooling cryogenic propellants below their normal boiling point to produce a denser fluid is one of the key process technologies necessary to meet the challenge of single-stage-to-orbit and reusable launch vehicles. Densified propellants are critical to lowering launch costs because they enable more propellant to be packed into a given unit volume, thus improving the performance by reducing the overall size and weight of the launch vehicle. This two-pronged research and test program has evolved into (1) conducting tank loading tests using densified liquid hydrogen and (2) developing two large-scale propellant densification systems that will be performance tested next year at Glenn. The propellant-loading test program was undertaken at Glenn in coordination with Lockheed Martin Michoud Space Systems. In this testing, the liquid hydrogen recirculation and densification process was simulated, and the thermal stratification of the densified propellant was recorded throughout the tank. The test article was a flight-weight tank constructed from composite materials similar to those to be used on the X-33 launch vehicle. The tank geometry as designed by Lockheed Martin had two cylindrical lobes with a center septum. Liquid hydrogen flow rate, pressure data, and temperature data plotted over time were collected while the subscale tank was filled with 27 R (15 K) densified liquid hydrogen propellant. This testing has validated mathematical models and demonstrated the readiness of densified propellant technology for near-term use. It marks the first time that such a process has been carried out with a multiple-lobe, flight-similar tank. Glenn researchers have also been working on providing a process and critical test data for the continuous production of densified liquid hydrogen (LH2) and densified liquid oxygen (LO2). Each densification production process uses a high-efficiency, subatmospheric boiling bath heat exchanger to cool the working fluid. A near triple-point hydrogen boiling bath is used to condition and subcool hydrogen to 27 R (15 K), and a nitrogen boiling bath is used to cool the liquid oxygen to 120 R (66.7 K). Multistage centrifugal compressors operating at cryogenic inlet conditions maintain the heat exchanger bath vapor pressure below 1 atm. The LO2 propellant densification unit shown in the photograph has a 30 lb/sec capacity, whereas the LH2 unit was designed to process 8 lb/sec of propellant. Each densification unit will be transported to Glenn's South Forty area after all fabrication work is completed sometime late next year. There the LO2 and LH2 densifier performance tests will be conducted with another larger Lockheed Martin tank designated the Structural Test Article (STA). This liquid oxygen tank is a full-scale, flight-weight, prototype aluminum tank designed for the X-33. It has a capacity of 20,000 gallons of LO2. The tank loading and recirculation testing planned for next year with STA will provide the data necessary for full-scale development of propellant densification technology.

Tomsik, Thomas M.↗

Propellant Densification for Shuttle: The SSME Perspective

The subject of cryogenic propellant densification as a potential upgrade to the Space Shuttle is a subject that has been raised on several occasions over the last decade. Due to advancements in densification technology made as a part of and in parallel to the X-33 project, the subject was raised and studied once again in May 2001. Across the Space Shuttle program people from many disciplines converged to discuss issues and perform trade studies to determine whether densified propellants was worth pursuing. This paper discusses one of these areas, specifically the Space Shuttle Main Engine (SSME). The effects of propellant densification on steady state performance are presented along with discussions of potential transient performance issues. Engine component redesign and retrofit issues are discussed as well the high level requirements to modify the ground test stands to accommodate propellant densification hardware and tanks. And finally, the matter of programmatic concerns enters the subject at hand as part of a discussion of SSME recertification requirements. In the end, potential benefits to SSME performance can be demonstrated and, subject to the densification scheme chosen, there does not appear to insurmountable technical obstacles.

Greene, William D.↗

Sub-melt nanosecond pulsed-laser induced densification and strain-field relaxation in single-crystal diamond

Dislocations and polishing-induced defect networks in synthetic diamond introduce local strain fields and broaden Raman features, limiting performance in optical, thermal, and electronic applications. Laser annealing is emerging as a promising approach to repair surface and near-surface defects in diamond without entering the melt regime, yet surface densification, defect-state modification, and associated structural changes have not been well quantified. In this work, we show that sub-melt nanosecond pulsed-laser annealing (PLA) induces near-surface densification and defect-mediated strain relaxation in single-crystal Chemical Vapor Deposition (CVD) diamond. Single- and two-pulse PLA were applied, and structural evolution was quantified using co-registered ISO 25,178 white-light interferometry, depth-resolved Raman spectroscopy, and cross-sectional STEM with geometric phase analysis (GPA). Across a 5 × 6 grid (n = 30), responsive regions exhibit large reductions in local slope (Sdq 45–65%), developed area (Sdr 60–90%), height spread (Sp, Sz 30–65%), void volume (Vv 57–60%), and roughness amplitude (Sa, Sq 48–57%), consistent with densification of ∼4–6.5 nm. Raman profiling shows narrowing of the diamond line and improved spectral uniformity to depths of ∼2–3 μm. Given that the Raman probing depth significantly exceeds the densified layer thickness, this response is interpreted as consistent with long-range strain-field redistribution originating from the near-surface region. STEM-GPA strain maps further support this interpretation, showing smoother strain fields, suppressed hotspots, and redistribution of localized strain concentrations following PLA. These results are consistent with defect-mediated strain relaxation and densification-driven modification of the near-surface energy state. The approach provides a scalable pathway for improving near-surface structural quality in diamond relevant to electronic, photonic, and quantum applications.

Areal surface metrology (ISO 25,178)↗

Binder-jetted AISI M2 tool steel during hot isostatic pressing: Densification and carbide transformation

Binder jetting (BJ) enables fabrication of complex components from high-alloy steels such as AISI M2; however, residual porosity after sintering limits mechanical performance. This study investigates the coupled effects of binder chemistry, sintering conditions, cooling rate, and subsequent hot isostatic pressing (HIP) on densification, microstructure, and mechanical response in binder-jetted M2 tool steel. HIP increased relative density from ∼93 to 95% to >99% and improved compressive strength by ∼40-70%. Densification was governed by initial pore morphology, where closed porosity was effectively eliminated, while interconnected porosity limited full consolidation. Microstructural analysis (XRD, EBSD, SEM) shows that HIP promotes dissolution of metastable carbides and redistribution of alloying elements (W, Mo, V), transforming heterogeneous carbide networks into finer and more uniformly distributed M 2 C, MC, and M 6 C phases through diffusion-assisted homogenization. Among the investigated conditions, the FluidFuse binder combined with sintering at 1270 °C for 60 min and furnace cooling produced the most balanced response, achieving ∼99.7% density, ∼855 HV hardness, ∼4130 MPa compressive strength, and ∼24% strain. In contrast, higher sintering temperatures promoted carbide coarsening, reducing ductility despite high density. HIP reduces microstructural heterogeneity and drives the system toward a near-equilibrium state with reduced sensitivity to prior processing history. A comparative assessment with conventional and additive manufacturing routes (LPBF, DED, EBM, FFF) shows that the BJ-HIP approach achieves competitive densification and mechanical performance. These findings provide a mechanistic basis for controlling densification and microstructure in high-alloy steels processed via BJAM.

AISI M2 tool steel↗

Phase Field Modeling of Pressure Induced Densification in Solid Electrolytes

Adoption of dense and homogeneous solid electrolytes can possibly mitigate the propagation of lithium dendrites and enable lithium metal anodes. Application of external pressure helps to minimize the sintering temperature in oxide ceramics and can potentially densify softer sulfide electrolytes even under room temperature conditions. Here, a previously developed phase field-based computational scheme for predicting the high-temperature sintering-induced densification of oxide ceramic solid electrolytes is extended in the present context to capture the influence of external pressure for densifying solid electrolytes. Two different bulk deformation mechanisms, namely, "reorganization" and "creep deformation," are dominant under external pressure, which is different from the surface and grain-boundary diffusion-induced densification of solid electrolytes that occurs during high temperature sintering. External pressure also increases the points of contact between the particles, which further enhances the propensity of diffusion-induced sintering process. Results obtained from simulations indicate that densification under external pressure is independent of the solid electrolyte particle morphology. Finally, a phase map is generated between applied pressure and temperature for achieving complete densification of oxide ceramics, which can possibly guide the synthesis of thin and dense solid electrolyte separators.

25 ENERGY STORAGE↗

Smaller feature size impairs densification in digital light processing 3D printed ceramic samples

In this study, we investigate how geometric miniaturization affects the sintering densification behavior of alumina cylinders with various wall thicknesses (down to ∼500 µm in green body) fabricated via digital light processing (DLP). As the wall thickness decreased, the density of the sintered samples consistently declined. Microstructural characterization revealed the presence of a crack-rich surface skin that is ∼500 µm thick. As the wall thickness decreases, the skin's volume fraction rises, and its poor local densification increasingly dominates the part average, leading to an overall decrease in the density of the sintered samples. For the thinnest wall (500 µm) cylinder, macroscopic warping occurred during sintering. We suggest that warping further disrupts particle packing and induces through-thickness nonuniformity, further impairing densification in addition to the skin-fraction effect. These results highlight how geometric miniaturization may adversely influence the sintering behavior and final density of DLP-printed ceramics through distinct densification-limiting mechanisms.

Materials science↗

Temperature-induced densification in compressed basaltic glass revealed by in-situ ultrasonic measurements

Abstract Acoustic velocities of a model basalt glass (64 mol% CaMgSi2O6 + 36 mol% CaAl2Si2O8) were measured along different pressure-temperature (P-T) paths. One set of experiments involved isothermal compression-decompression cycles, performed at temperatures of 300, 641, 823, and 1006 K and pressures up to 12.2 GPa. The other set of experiments involved constant-load heating-cooling cycles at temperatures up to 823 K and pressures up to 7.5 GPa. Both sets of experiments were performed in a multi-anvil apparatus using a synchrotron-based ultrasonic technique. Our results show that the glass compressed isothermally at 300 K (cold-compression) displays anomalously decreasing compressional (VP) and shear (VS) wave velocities with increasing pressure until ~8 GPa. Beyond 8 GPa, both VP and VS start to increase sharply with pressure and irreversible densification of the glass occurred, producing large hysteresis loops of velocities upon decompression. However, for the glass compressed isothermally at increasingly higher temperatures (hot-compression), the velocity minima gradually shift to lower pressures. At temperature close to the glass transition temperature Tg, the velocity minima disappear completely, displaying a monotonic increase of velocities during compression and higher VP and VS during decompression. In addition, constant-load heating-cooling experiments show that velocities generally decrease slightly with increasing temperature, but start to increase once heated above a threshold temperature (~650 K). During cooling the velocities increase almost linearly with decreasing temperature, resulting in higher velocities (~1.5–2.5% higher) when returned to 300 K. This implies that a temperature-induced densification may have occurred in the glass at high pressures. Raman spectra on recovered samples show that the hot-compressed and high-P heated glasses contain distinctly densified and depolymerized structural signatures compared to the initial glass and the cold-compressed glass below the velocity transition pressure PT (~8 GPa). Such densification may be attributed to the breaking of bridging oxygen bonds and compaction in the intermediate-range structure. Our results demonstrate that temperature can facilitate glass densification at high pressures and point out the importance of P-T history in understanding the elastic properties of silicate glasses. Comparison with melt velocity suggests that hot-compressed glasses may better resemble the pressure dependence of velocity of silicate melts than cold-compressed glasses, but still show significantly higher velocities than melts. If the abnormal acoustic behaviors of cold-compressed glasses were used to constrain melt fractions in the mantle low-velocity regions, the melt fractions needed to explain a given velocity reduction would be significantly underestimated at high pressures.

Geochemistry & Geophysics↗

Performance Tests of a Liquid Hydrogen Propellant Densification Ground System for the X33/RLV

A concept for improving the performance of propulsion systems in expendable and single-stage-to-orbit (SSTO) launch vehicles much like the X33/RLV has been identified. The approach is to utilize densified cryogenic liquid hydrogen (LH2) and liquid oxygen (LOX) propellants to fuel the propulsion stage. The primary benefit for using this relatively high specific impulse densified propellant mixture is the subsequent reduction of the launch vehicle gross lift-off weight. Production of densified propellants however requires specialized equipment to actively subcool both the liquid oxygen and liquid hydrogen to temperatures below their normal boiling point. A propellant densification unit based on an external thermodynamic vent principle which operates at subatmospheric pressure and supercold temperatures provides a means for the LH2 and LOX densification process to occur. To demonstrate the production concept for the densification of the liquid hydrogen propellant, a system comprised of a multistage gaseous hydrogen compressor, LH2 recirculation pumps and a cryogenic LH2 heat exchanger was designed, built and tested at the NASA Lewis Research Center (LeRC). This paper presents the design configuration of the LH2 propellant densification production hardware, analytical details and results of performance testing conducted with the hydrogen densifier Ground Support Equipment (GSE).

Tomsik, Thomas M.↗

Evaluating Greenland Surface-Mass-Balance and Firn-Densification Data Using ICESat-2 Altimetry

Surface-mass-balance (SMB) and firn-densification (FD) models are widely used in altimetry studies as a tool to separate atmospheric-driven from ice-dynamics-driven ice-sheet mass changes and to partition observed volume changes into ice-mass changes and firn-air-content changes. Until now, SMB models have been principally validated based on comparison with ice core and weather station data or comparison with widely separated flight radar-survey flight lines. Firn-densification models have been primarily validated based on their ability to match net densification over decades, as recorded in firn cores, and the short-term time-dependent component of densification has rarely been evaluated at all. The advent of systematic ice-sheet-wide repeated ice-surface-height measurements from ICESat-2 (the Ice Cloud, and land Elevation Satellite, 2) allows us to measure the net surface-height change of the Greenland ice sheet at quarterly resolution and compare the measured surface-height differences directly with those predicted by three FD–SMB models: MARv3.5.11 (Modèle Atmosphérique Régional version 3.5.11) and GSFCv1.1 and GSFCv1.2 (the Goddard Space Flight Center FD–SMB models version 1.1 and 1.2). By segregating the data by season and elevation, and based on the timing and magnitude of modelled processes in areas where we expect minimal ice-dynamics-driven height changes, we investigate the models' accuracy in predicting atmospherically driven height changes. We find that while all three models do well in predicting the large seasonal changes in the low-elevation parts of the ice sheet where melt rates are highest, two of the models (MARv3.5.11 and GSFCv1.1) systematically overpredict, by around a factor of 2, the magnitude of height changes in the high-elevation parts of the ice sheet, particularly those associated with melt events. This overprediction seems to be associated with the melt sensitivity of the models in the high-elevation part of the ice sheet. The third model, GSFCv1.2, which has an updated high-elevation melt parameterization, avoids this overprediction.

Benjamin E. Smith↗

Probing the high-pressure densification of amorphous silica nanomaterials using SBA-15: An investigation into the paradoxical nature of the first sharp diffraction peak

The densification and X-ray scattering of mesoporous silica (SBA-15) were measured simultaneously under gigapascal (GPa) pressures. The results are compared to previous work on amorphous silica (aSiO 2 ) and demonstrate the feasibility of measuring the densification of aSiO 2 nanomaterials with small angle X-ray scattering (SAXS) in-situ in a diamond anvil cell. Compared to fused silica, the position of the SBA-15 first sharp diffraction peak (FSDP) is 7 times more sensitive to pressure and has a transition in its pressure dependance at a lower pressure (~2 GPa vs.~13 GPa). SBA-15 has two densification regimes, low-density amorphous and highdensity amorphous, which have equations of state comparable to low-density amorphous and high-density amorphous fused silica. Further, the transition between these two regimes occurs at a lower pressure than for fused silica (~1.5 GPa vs.~13 GPa). The results suggest that there is no direct relationship between the FSDP position and the aSiO 2 density during compression.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Densification and coarsening during solid state sintering of ceramics: A review of the models. II - Grain growth

Two processes occur simultaneously during the sintering of a ceramic powder compact: densification and coarsening (or grain growth). Both processes have as their driving force the reduction of the excess free surface energy of the powder particles. Several different mechanisms of atom transport, operating concurrently or consecutively, may be responsible for the two processes. Algebraic, geometric and topological models have been proposed and refined in attempts to determine the mechanism, or mechanisms, responsible for densification under defined processing conditions. These efforts have met with varying degrees of success. Recently, it has become apparent that more attention must be paid to the coarsening processes during sintering. The models for both densification and coarsening during solid state sintering are reviewed with particular emphasis on their applicability to engineering ceramics.

Shaw, Nancy J.↗

Application of powder densification models to the consolidation processing of composites

Unidirectional fiber reinforced metal matrix composite tapes (containing a single layer of parallel fibers) can now be produced by plasma deposition. These tapes can be stacked and subjected to a thermomechanical treatment that results in a fully dense near net shape component. The mechanisms by which this consolidation step occurs are explored, and models to predict the effect of different thermomechanical conditions (during consolidation) upon the kinetics of densification are developed. The approach is based upon a methodology developed by Ashby and others for the simpler problem of HIP of spherical powders. The complex problem is devided into six, much simpler, subproblems, and then their predicted contributions are added to densification. The initial problem decomposition is to treat the two extreme geometries encountered (contact deformation occurring between foils and shrinkage of isolated, internal pores). Deformation of these two geometries is modelled for plastic, power law creep and diffusional flow. The results are reported in the form of a densification map.

Wadley, H. N. G.↗

Propellant Densification for Launch Vehicles: Simulation and Testing 1999

One of the many key technologies required to make single-stage to orbit an actuality, the technology of sub-cooling cryogenic propellants below their normal saturation temperatures and thereby making them more dense, is unquestionably on its way towards full and practical realization. The technology of Propellant Densification has been the subject of an extensive research and development program overseen by Lockheed Martin Michoud Space Systems and NASA Glenn Research Center over the past several years. This paper presents a status report of this research and development. Specifically examined within this paper is the status of the current and continuing efforts on the mathematical simulation of the in-tank propellant densification process currently baselined for the Lockheed Martin VentureStar Reusable Launch Vehicle (RLV). Keys to this modeling effort are an understanding and quantification of the effects of thermal stratification and the ability to capture the complex and unique multiple section tank geometries being proposed for future launch vehicles. A simulation that properly captures these phenomena has been developed by Lockheed Martin. Also discussed is the significant test program that has been undertaken in coordination with NASA Glenn Research Center. In this testing, the liquid hydrogen recirculation and densification process was simulated and the thermal stratification of the densified propellant was recorded throughout the tank. This testing marks the first time that such a process has been carried out within a multiple-lobe, flight-similar tank. The results from this testing have gone a long way towards grounding the mathematical models and towards demonstrating the readiness of the technology for near-term use. A further and even more ambitious test program examining the production and utilization of densified propellants is being planned for late-autumn 1999. An overview of these plans is presented.

Knowles, Timothy E.↗