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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

A highly durable injector faceplate design concept for O2/H2 propellants

Two different O2/H2 injector faceplate designs were used in a test bed rocket engine at the NASA Lewis Research Center facility. This test bed was operated in a pulsing mode to evaluate thrust chamber wall materials and coatings. Degradation of the sintered mesh injector face plates resulted in the substitution of a photoetched diffusion-bonded platelet faceplate. This faceplate accumulated over 4200 thermal cycles without damage or degradation. Prior testing for a total of 17,446 cycles required 19 sintered mesh faceplates. This average of 918 cycles per unit showed the diffusion bonded faceplate to have a thermal cycle capability ranging from 150 to 500 percent of that of the sintered wire unit. The test data also showed that the diffusion-bonded faceplate provided a more uniform flow of gaseous H2 through its discrete and uniformly spaced propellant orifices resulting in enhanced face cooling (no local hot spots) and increased performance. The injector faceplate designs are described and the results of the injector comparison test data are presented.

Mueggenburg, H. H.↗
NASA NTRS2003

Effect of Sizings on the Durability of High Temperature Polymer Composites

To increase performance and durability of high-temperature composite for potential rocket engine components, it is necessary to optimize wetting and interfacial bonding between high modulus carbon fibers and high-temperature polyimide resins. Sizing commercially supplied on most carbon fiber are not compatible with polyimides. In this study, the chemistry of sizing on two high modulus carbon fiber (M40J and M60J, Tiray) was characterized. A continuous desizling system that uses an environmentally friendly chemical-mechanical process was developed for tow level fiber. Composites were fabricated with fibers containing the manufacturer's sizing, desized, and further treated with a reactive finish. Results of room-temperature tests after thermal aging show that the reactive finish produces a higher strength and more durable interface compared to the manufacturer's sizing. When exposed to moisture blistering tests, however, the butter bonded composite displayed a tendency to delaminate, presumably due to trapping of volatiles.

Allred, Ronald E.↗
NASA NTRS1994

Performance and durability of high emittance heat receiver surfaces for solar dynamic power systems

Haynes 188, a cobalt-based superalloy, will be used to make thermal energy storage (TES) containment canisters for a 2 kW solar dynamic ground test demonstrator (SD GTD). Haynes 188 containment canisters with a high thermal emittance (epsilon) are desired for radiating heat away from local hot spots, improving the heating distribution, which will in turn improve canister service life. In addition to needing a high emittance, the surface needs to be durable in an elevated temperature, high vacuum environment for an extended time period. Thirty-five Haynes 188 samples were exposed to 14 different types of surface modification techniques for emittance and vacuum heat treatment (VHT) durability enhancement evaluation. Optical properties were obtained for the modified surfaces. Emittance enhanced samples were exposed to VHT for up to 2692 hours at 827 C and less than or equal to 10(exp -6) torr with integral thermal cycling. Optical properties were taken intermittently during exposure, and after final VHT exposure. The various surface modification treatments increased the emittance of pristine Haynes 188 from 0.11 up to 0.86. Seven different surface modification techniques were found to provide surfaces which met the SD GTD receiver VHT durability requirement. Of the 7 surface treatments, 2 were found to display excellent VHT durability: an alumina based (AB) coating and a zirconia based coating. The alumina based coating was chosen for the epsilon enhancement surface modification technique for the SD GTD receiver. Details of the performance and vacuum heat treatment durability of this coating and other Haynes 188 emittance surface modification techniques are discussed. Technology from this program will lead to successful demonstration of solar dynamic power for space applications, and has potential for application in other systems requiring high emittance surfaces.

Degroh, Kim K.↗
NASA NTRS1999

Performance and Durability of High Temperature Foil Air Bearing for Oil-Free Turbomachinery

The performance and durability of advanced, high temperature foil air bearings are evaluated under a wide range (10-50 kPa) of loads at temperatures from 25 to 650 C. The bearings are made from uncoated nickel based superalloy foils. The foil surface experiences sliding contact with the shaft during initial start/stop operation. To reduce friction and wear, the solid lubricant coating, PS304, is applied to the shaft by plasma spraying. PS304, is a NiCr based Cr2O3 coating with silver and barium fluoride/calcium fluoride solid lubricant additions. The results show that the bearings provide lives well in excess of 30,000 cycles under all of the conditions tested. Several bearings exhibited lives in excess of 100,000 cycles. Wear is a linear function of the bearing load. The excellent performance measured in this study suggests that these bearings and the PS304 coating are well suited for advanced high temperature, oil-free turbomachinery applications.

DellaCorte, C.↗
NASA NTRS2000

Performance and Durability of High Temperature Foil Air Bearings for Oil-Free Turbomachinery

The performance and durability of advanced, high temperature foil air bearings are evaluated under a wide range (10-50 kPa) of loads at temperatures from 25 to 650 C. The bearings are made from uncoated nickel based superalloy foils. The foil surface experiences sliding contact with the shaft during initial start/stop operation. To reduce friction and wear, the solid lubricant coating, PS304, is applied to the shaft by plasma spraying. PS304 is a NiCr based Cr2O3 coating with silver and barium fluoride/calcium fluoride solid lubricant additions. The results show that the bearings provide lives well in excess of 30,000 cycles under all of the conditions tested. Several bearings exhibited lives in excess of 100,000 cycles. Wear is a linear function of the bearing load. The excellent performance measured in this study suggests that these bearings and the PS304 coating are well suited for advanced high temperature, oil-free turbomachinery applications.

DellaCorte, C.↗
NASA NTRS2001

Slightly Conductive Transparent Films for Space Applications: Manufacturability and Durability

Highly transparent, slightly conductive films of co-deposited indium tin oxide (ITO) and MgF, have possible applications for environmental protection of exterior surfaces of spacecraft. Reliable preparation of films with the desired sheet resistivity (approximately 10(exp 8) ohms/square) is difficult because the electrical properties of ITO-Mg F, are highly dependent on film composition. We have investigated the use of plasma emission monitoring to improve the reproducibility of films prepared by RF magnetron sputtering. While considerable improve ment was observed, it appears that some in-situ electrical or optica l characterization will be needed for reliable production coating wit h ITO-MgF,. We have also done further evaluation of a possibly undesi rable photoconductive effect previously observed in these films.

Uppala, N.↗
NASA NTRS1992

High-temperature durability considerations for HSCT combustor

The novel combustor designs for the High Speed Civil Transport will require high temperature materials with long term environmental stability. Higher liner temperatures than in conventional combustors and the need for reduced weight necessitates the use of advanced ceramic matrix composites. The combustor environment is defined at the current state of design, the major degradation routes are discussed for each candidate ceramic material, and where possible, the maximum use temperatures are defined for these candidate ceramics.

Jacobson, Nathan S.↗
NASA NTRS1981

Development of a high-temperature durable catalyst for use in catalytic combustors for advanced automotive gas turbine engines

Durable catalytic reactors for advanced gas turbine engines were developed. Objectives were: to evaluate furnace aging as a cost effective catalytic reactor screening test, measure reactor degradation as a function of furnace aging, demonstrate 1,000 hours of combustion durability, and define a catalytic reactor system with a high probability of successful integration into an automotive gas turbine engine. Fourteen different catalytic reactor concepts were evaluated, leading to the selection of one for a durability combustion test with diesel fuel for combustion conditions. Eight additional catalytic reactors were evaluated and one of these was successfully combustion tested on propane fuel. This durability reactor used graded cell honeycombs and a combination of noble metal and metal oxide catalysts. The reactor was catalytically active and structurally sound at the end of the durability test.

Tong, H.↗
NASA NTRS1999

Advances in Thin Film Thermocouple Durability Under High Temperature and Pressure Testing Conditions

Thin film thermocouples for measuring material surface temperature have been previously demonstrated on several material systems and in various hostile test environments. A well-developed thin film fabrication procedure utilizing shadow masking for patterning the sensors elements had produced thin films with sufficient durability for applications in high temperature and pressure environments that exist in air-breathing and hydrogen-fueled burner rig and engine test facilities. However, while shadow masking had been a reliable method for specimens with flat and gently curved surfaces, it had not been consistently reliable for use on test components with sharp contours. This work reports on the feasibility of utilizing photolithography processing for patterning thin film thermocouples. Because this patterning process required changes in the thin film deposition process from that developed for shadow masking, the effect of these changes on thin film adherence during burner rig testing was evaluated. In addition to the results of changing the patterning method, the effects on thin film adherence of other processes used in the thin film fabrication procedure is also presented.

Martin, Lisa C.↗
NASA NTRS2012

Leveraging Cloud Computing to Improve Storage Durability, Availability, and Cost for MER Maestro

The Maestro for MER (Mars Exploration Rover) software is the premiere operation and activity planning software for the Mars rovers, and it is required to deliver all of the processed image products to scientists on demand. These data span multiple storage arrays sized at 2 TB, and a backup scheme ensures data is not lost. In a catastrophe, these data would currently recover at 20 GB/hour, taking several days for a restoration. A seamless solution provides access to highly durable, highly available, scalable, and cost-effective storage capabilities. This approach also employs a novel technique that enables storage of the majority of data on the cloud and some data locally. This feature is used to store the most recent data locally in order to guarantee utmost reliability in case of an outage or disconnect from the Internet. This also obviates any changes to the software that generates the most recent data set as it still has the same interface to the file system as it did before updates

Chang, George W.↗
NASA NTRS1981

High temperature durable catalyst development

A program has been carried out to develop a catalytic reactor capable of operation in environments representative of those anticipated for advanced automotive gas turbine engines. A reactor consisting of a graded cell honeycomb support with a combination of noble metal and metal oxide catalyst coatings was built and successfully operated for 1000 hr. At an air preheat temperature of 740 K and a propane/air ratio of 0.028 by mass, the adiabatic flame temperature was held at about 1700 K. The graded cell monolithic reaction measured 5 cm in diameter by 10.2 cm in length and was operated at a reference velocity of 14.0 m/s at 1 atm. Measured NOx levels remained below 5 ppm, while unburned hydrocarbon concentrations registered near zero and carbon monoxide levels were nominally below 20 ppm.

Snow, G. C.↗
NASA NTRS1996

Durable High-Density Data Storage

The focus ion beam (FIB) micromilling process for data storage provides a new non-magnetic storage method for archiving large amounts of data. The process stores data on robust materials such as steel, silicon, and gold coated silicon. The storage process was developed to provide a method to insure the long term storage life of data. We estimate that the useful life of data written on silicon or gold-coated silicon to be on the order of a few thousand years without the need to rewrite the data every few years. The process uses an ion beam to carve material from the surface, much like stone cutters in ancient civilizations removed material from stone. The deeper the information is carved into the media, the longer the expected life of the information. The process can record information in three formats: (1) binary at densities of 23 Gbits/square inch, (2) alphanumeric at optical or non-optical density, and (3) graphical at optical and non-optical density. The formats can be mixed on the same media; and thus, it is possible to record, in a human-viewable format, instructions that can be read using an optical microscope. These instructions provide guidance on reading the remaining higher density information.

Lamartine, Bruce C.↗
NASA NTRS1998

Effects of Ambient High Temperature Exposure on Alumina-Titania High Emittance Surfaces for Solar Dynamic Systems

Solar dynamic (SD) space power systems require durable, high emittance surfaces on a number of critical components, such as heat receiver interior surfaces and parasitic load radiator (PLR) elements. To enhance surface characteristics, an alumina-titania coating has been applied to 500 heat receiver thermal energy containment canisters and the PLR of NASA Lewis Research Center's (LeRC) 2 kW SD ground test demonstrator (GTD). The alumina-titania coating was chosen because it had been found to maintain its high emittance under vacuum (less than or equal to 10(exp -6) torr) at high temperatures (1457 F (827 C)) for an extended period (approximately 2,700 hours). However, preflight verification of SD systems components, such as the PLR require operation at ambient pressure and high temperatures. Therefore, the purpose of this research was to evaluate the durability of the alumina-titania coating at high temperature in air. Fifteen of sixteen alumina-titania coated Incoloy samples were exposed to high temperatures (600 F (316 C) to l500 F (816 C)) for various durations (2 to 32 hours). Samples, were characterized prior to and after heat treatment for reflectance, solar absorptance, room temperature emittance and emittance at 1,200 F (649 C). Samples were also examined to detect physical defects and to determine surface chemistry using optical microscopy, scanning electron microscopy operated with an energy dispersive spectroscopy (EDS) system, and x ray photoelectron spectroscopy (XPS). Visual examination of the heat-treated samples showed a whitening of samples exposed to temperatures of 1,000 F (538 C) and above. Correspondingly, the optical properties of these samples had degraded. A sample exposed to 1,500 F (816 C) for 24 hours had whitened and the thermal emittance at 1,200 F (649 C) had decreased from the non-heat treated value of 0.94 to 0.62. The coating on this sample had become embrittled with spalling off the substrate noticeable at several locations. Based on this research it is recommended that preflight testing of SD components with alumina-titania coatings be restricted to temperatures no greater than 600 F (316 C) in air to avoid optical degradation. Moreover, components with the alumina-titania coating are likely to experience optical property degradation with direct atomic oxygen exposure in space.

deGroh, Kim K.↗
NASA NTRS2018

Polymer-Filled Metal Foams for Contamination Resistant Aircraft Leading Edges

Adhesion of contaminants has been identified as a ubiquitous issue for aeronautic exterior surfaces. Organic coatings have been demonstrated to enable reduction in insect residue adhesion as well as a reduction in ice adhesion strength. These approaches however, have yet to demonstrate sufficient durability to enable application to commercial aircraft wing leading edges. High durability materials have been developed in parallel to these efforts; contaminant adhesion issues are not addressed. This work describes a first attempt to identify a solution to the seemingly competing issues of contaminant adhesion and durability. A co-continuous network of organic and metallic domains may provide greater durability, while still enabling the changes in surface-contaminant interactions that have been realized. To that end, unique properties have been achieved through fabrication of composite metal foam materials. Likewise, extensive research has been dedicated toward development of polymeric coatings for mitigation of insect residue adhesion.This work describes initial results from infusion of a low surface free energy epoxy resin into a composite metal foam substrate for the purpose of generating a durable contaminant adhesion-resistant material.

Robbins, Samuel J.↗
NASA NTRS2003

Fabrication And Evaluation Of Sic/Sic Tubes With Various Fiber Architectures

SiC/SiC composites are excellent material candidates for high temperature applications where the performance requirements are high strength, high creep-rupture resistance, high environmental durability, and high thermal conductivity. In the past, the NASA UEET program has demonstrated fabrication of high-performance SiC/SiC flat panels reinforced by Sylramic-iBN SiC fibers. Currently NASA UEET is scaling up this SiC/SiC system by fabrication of more complex shaped components using the same fiber type. This paper reports the effects of various fiber architectures on the processing, mechanical, and durability behavior of small-diameter 0.5" ID SiC/SiC tubes, which are potential sub-elements for leading edges and cooling channels in turbine vanes and blades. Nine different fiber architectures were utilized for construction of seamless tube preforms, from simple 2D jelly-rolling to complex braiding, pin-weaving, filament-winding and 3D orthogonal weaving with approximately 5% fibers in the thru-thickness direction. Using the BN interphase and Sic matrix processing steps established for the flat panels, SiC/SiC tubes were fabricated with wall thicknesses of approximately 60 mils and total fiber fractions of approximately 35%. The "D" split ring tests for hoop tensile properties, micro-structural examinations for relationship between fiber architecture formation and matrix infiltration, and the low-pressure burner rig tests for the high temperature durability under thru-thickness thermal gradient were conducted. The better matrix infiltration and higher hoop strength were achieved using the tri-axial braided and the three-float pin woven SiC/SiC tubes. In general, it needs not only higher hoop direction fibers but also axial direction fibers for the higher hoop strength and the better infiltration, respectively. These results are analyzed to offer general guidelines for selecting fiber pre-form architectures and SiC/SiC processes that maximize tube hoop strength, thru-thickness thermal conductivity, and burner-rig durability under a high thermal gradient.

Yun, H. M.↗
NASA NTRS2004

The Influence of Sizings on the Durability of High-Temperature Polymer Composites

To increase performance and durability of high-temperature composites for potential rocket engine components, it is necessary to optimize wetting and interfacial bonding between high modulus carbon fibers and high-temperature polyimide resins. Sizings commercially supplied on most carbon fibers are not compatible with polyimides. In this study, the chemistry of sizings on two high-modulus carbon fibers (M40J and M60J, Toray) was characterized as was the chemistry of PMR-II-50 fluorinated polyimide resin. The carbon fibers were characterized using single filament wetting, scanning electron microscopy, fourier transform infrared spectroscopy, and x-ray photoelectron spectroscopic measurements. The polyimide matrix resins were coated onto glass filaments for characterization by wetting measurements. Surface energy components were obtained by wetting with nondispersive (methylene iodide), acidic (ethylene glycol), and basic (formamide) probes. A continuous desizing system that uses an environmentally friendly chemical-mechanical process was developed for tow level fiber. Composites were fabricated with fibers containing the manufacturer's sizing, desized, and further treated with a reactive finish. Results of room-temperature tests after thermal aging show that the reactive finish produces a higher strength and more durable interface compared to the manufacturer's sizing. When exposed to moisture blistering tests, however, the better bonded composite displayed a tendency to delaminate, presumably due to trapping of volatiles.

Allred, Ronald E.↗
NASA NTRS1984

Status of high efficiency module design and fabrication

The status of an ongoing DOE program to develop an AM1 photoelectric module with 15 percent conversion efficiency at normal heating temperatures, is reviewed. Emphasis is given to the efforts of a private company to develop a high efficiency module which also has high durability in normal operating conditions. The main design options considered are: high efficiency modules; large area modules; and optimized module fabrication techniques. The design of an automatic system for encapsulating module stacks is described.

Nowlan, M. J.↗
NASA NTRS1983

Thermoelectric energy conversion with solid electrolytes

The alkali metal thermoelectric converter (AMTEC) is a device for the direct conversion of heat to electrical energy. The sodium ion conductor beta-double prime-alumina is used to form a high-temperature regenerative concentration cell for elemental sodium. An AMTEC of mature design should have an efficiency of 20 to 40 percent, a power density of 0.5 kilowatt per kilogram or more, no moving parts, low maintenance requirements, high durability, and efficiency independent of size. It should be usable with high-temperature combustion, nuclear, or solar heat sources. Experiments have demonstrated the feasibility of the AMTEC and confirmed the theoretical analysis of the device. A wide range of applications from aerospace power to utility power plants appears possible.

Cole, T.↗