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Malone, G. A.

Publications and source records attributed to Malone, G. A..

18 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Improved Electroformed Structural Copper and Copper Alloys

Electroforming offers a superior means for fabricating internally cooled heat exchangers and structures subjected to thermal environments. Copper is deposited from many such applications because of the good thermal conductivity. It suffers from mediocre yield strength as a structural material and loses mechanical strength at intermediate temperatures. Mechanical properties similar to those of electroformed nickel are desired. Phase 1 examined innovative means to improve deposited copper structural performance. Yield strengths as high as 483 MPa (70 ksi) were obtained with useful ductility while retaining a high level of purity essential to good thermal conductivity. Phase 2 represents a program to explore new additive combinations in copper electrolytes to produce a more fine, equiaxed grain which can be thermally stabilized by other techniques such as alloying in modest degrees and dispersion strengthening. Evaluation of new technology - such as the codeposition of fullerness (diamond-like) particles were made to enhance thermal conductivity in low alloys. A test fire quality tube-bundle engine was fabricated using these copper property improvement concepts to show the superiority of the new coppers and fabrications methods over competitive technologies such as brazing and plasma deposition.

Malone, G. A.↗
NASA NTRS1995

High temperature barrier coatings for refractory metals

Improvements in high temperature oxidation resistant metal coating technology will allow NASA and commercial entities to develop competitive civil space transport and communication systems. The success of investigations completed in this program will have a positive impact on broadening the technology base for high temperature materials. The work reported herein describes processes and procedures for successfully depositing coherent oxidation barrier coatings on refractory metals to prevent degradation under very severe operating environments. Application of the new technology developed is now being utilized in numerous Phase 3 applications through several prominent aerospace firms. Major achievements have included: (1) development of means to deposit thick platinum and rhodium coatings with lower stress and fewer microcracks than could be previously achieved; (2) development of processes to deposit thick adherent coatings of platinum group metals on refractory substrates that remain bonded through high temperature excursions and without need for intermediate coatings (bonding processes unique to specific refractory metals and alloys have been defined; (3) demonstration that useful alloys of refractory and platinum coatings can be made through thermal diffusion means; (4) demonstration that selected barrier coatings on refractory substrates can withstand severe oxidizing environments in the range of 1260 deg and 1760 deg C for long time periods essential to the life requirements of the hardware; and (5) successful application of the processes and procedures to prototype hardware. The results of these studies have been instrumental in improved thermal oxidation barrier coatings for the NASP propulsion system. Other Phase 3 applications currently being exploited include small uncooled thrusters for spacecraft and microsatellite maneuvering systems.

Malone, G. A.↗
NASA NTRS1989

High performance alloy electroforming

Electroformed copper and nickel are used in structural applications for advanced propellant combustion chambers. An improved process has been developed by Bell Aerospace Textron, Inc. wherein electroformed nickel-manganese alloy has demonstrated superior mechanical and thermal stability when compared to previously reported deposits from known nickel plating processes. Solution chemistry and parametric operating procedures are now established and material property data is established for deposition of thick, large complex shapes such as the Space Shuttle Main Engine. The critical operating variables are those governing the ratio of codeposited nickel and manganese. The deposition uniformity which in turn affects the manganese concentration distribution is affected by solution resistance and geometric effects as well as solution agitation. The manganese concentration in the deposit must be between 2000 and 3000 ppm for optimum physical properties to be realized. The study also includes data regarding deposition procedures for achieving excellent bond strength at an interface with copper, nickel-manganese or INCONEL 718. Applications for this electroformed material include fabrication of complex or re-entry shapes which would be difficult or impossible to form from high strength alloys such as INCONEL 718.

Malone, G. A.↗
NASA NTRS1985

Study of high performance alloy electroforming

More panels electroformed with intentional variations of pulse plating parameters are being made. Pulse plating frequency was noted to have a significant effect regarding mechanical properties. The use of a high pulse frequency (assuming fixed duty cycles) results in an increase in ductility and a decrease in ultimate and yield strengths. Electroforming to intermediate frequencies is being done to obtain the best possible combination of ductility and strength. Results of some tests from high frequency specimens are tabulated.

Malone, G. A.↗
NASA NTRS1985

Study of high performance alloy electroforming

The nickel-manganese experimental electrolyte was hydrogen peroxide treated and carbon purified for removal of residual sodium saccharin and related organic decomposition products from the plating of previous test panels. The saccharin additive was used to reduce stress where high concentrations of manganese and high pulse peak current densities were used. A large quantity of nickel-manganese alloy plates containing 0.35 to 0.40 percent by weight manganese was electroformed for testing to supply data for a mechanical property data table. The aluminum billet required for the machining of the subscale SSME main combustion chamber was acquired.

Malone, G. A.↗
NASA NTRS1984

Study of high performance alloy electroforming

The first series of heat treated nickel manganese alloys are tested for mechanical properties at temperatures of 148.9 C (300 F) and 260 C (500 F). All material receives the same heat treatment in order to provide a common basis for comparison of results. Mechanical property performance improves with increasing manganese content in the alloy. Although all manganese bearing alloy is significantly superior to conventional electroformed nickel, samples containing over 3000 ppm manganese display outstanding ultimate and yield strengths while maintaining reasonably satisfactory ductility. Alloy containing over 6000 ppm of manganese is very competitive to Inconel 718 (mill annealed and age hardened) at all temperatures of interest, although ductility is not as great in the electrodeposited counterpart.

Malone, G. A.↗
NASA NTRS1984

Study of high performance alloy electroforming

Nickel-manganese alloy electrodeposits from an electrolyte containing more manganese ion than previously used is being evaluated at two bath operating temperatures with a great variety of pulse plating conditions. Saccharine was added as a stress reducing agent for the electroforming of several of the samples with highest manganese content. All specimens for mechanical property testing have been produced but are not through the various heat treatments as yet. One of the heat treatment will be at 343 C (650 F), the temperature at which the MCC outer electroformed nickel shell is stress relieved. A number of retainer specimens from prior work have been tested for hardness before and after heat treatment. There appears to be a fairly good correlation between hardness and mechanical properties. Comparison of representative mechanical properties with hardnesses are made for nickel-manganese electrodeposits and nickel-cobalt-manganese deposits.

Malone, G. A.↗
NASA NTRS1984

Study of high performance alloy electroforming

Using the two nickel-manganese alloy electroforming baths of near identical compositions, panels were electroformed under the same deposition parameters of current density, bath temperature, pH, and pulse plating conditions of duty cycle and frequency. By changing the electrolyte agitation conditions, significant effects on mechanical properties were noted. Since electrolyte agitation conditions on the typical flat panels studied to date will not be identical to those existing on a complex curved shape such as the SSME combustion chamber simulation, it is most important that these effects be evaluated prior to Phase B studies. The subscale chamber has been fabricated and shield support tooling is being made. Electroforming of optimized alloy test bars is being deferred until the electrolyte agitation effects are more fully appraised.

Malone, G. A.↗
NASA NTRS1984

Study of high performance alloy electroforming

Nickel-manganese electroformed specimens and nickel-cobalt-manganese samples were heat treated at 343 C (650 F) for comparison of room temperature ductility with that observed for alloys heat treated at 315.6C (600 F). All heat treatments were for 24 hours. This heat treatment temperature increase generally did not result in significant improvements in ductility. However, increases in yield strength - with slight decreases in tensile strengths - were noted for the nickel-manganese and nickel-cobalt-manganese alloys. For the case of employing fairly high manganese contents in the electrolyte and countering ensuing high tensile stress in the alloy by saccharin additions to the bath, it was noted that nickel-manganese alloys with over 0.4% by weight manganese retained high ultimate and yield strengths after the 343 C (650 F) heat treatment for 24 hours. Elongations were still lower than desired. For alloys with less than 0.4% by weight manganese this heat treatment provided excellent ductility, but very significant reductions in ultimate and yield strengths were noted.

Malone, G. A.↗
NASA NTRS1983

Electroforming for High-Performance Products

Report describes development of processes and procedures for preparation of specifications for electroforming nickel and copper outer shells on cooled rocket thrust-chamber liners. Specifications represent merging of technical contributions from many sources into guide for producers of electroformed, high-performance products. Raw materials, conducting solutions and deposition rates are evaluated.

Malone, G. A.↗
NASA NTRS1975

Investigation of electroforming techniques

Copper and nickel electroforming was examined for the purpose of establishing the necessary processes and procedures for repeatable, successful fabrication of the outer structures of regeneratively cooled thrust chambers. The selection of electrolytes for copper and nickel deposition is described. The development studies performed to refine and complete the processes necessary for successful chamber shell fabrication and the testing employed to verify the applicability of the processes and procedures to small scale hardware are described. Specifications were developed to afford a guideline for the electroforming of high quality outer shells on regeneratively cooled thrust chamber liners. Test results indicated repeatable mechanical properties could be produced in copper deposits from the copper sulfate electrolyte with periodic current reversal and in nickel deposits from the sulfamate solution. Use of inert, removable channel fillers and the conductivizing of such is described. Techniques (verified by test) which produce high integrity bonds to copper and copper alloy liners are discussed.

Malone, G. A.↗
NASA NTRS1975

Investigation of electroforming techniques, literature analysis report

A literature analysis is presented of reports, specifications, and documented experiences with the use of electroforming to produce copper and nickel structures for aerospace and other engineering applications. The literature period covered is from 1948 to 1974. Specific effort was made to correlate mechanical property data for the electrodeposited material with known electroforming solution compositions and operating conditions. From this survey, electrolytes are suggested for selection to electroform copper and nickel outer shells on regeneratively cooled thrust chamber liners, and other devices subject to thermal and pressure exposure, based on mechanical properties obtainable, performance under various thermal environments, and ease of process control for product reproducibility. Processes of potential value in obtaining sound bonds between electrodeposited copper and nickel and copper alloy substrates are also discussed.

Malone, G. A.↗
NASA NTRS1974

Nondestructive evaluation of electroformed outer shells for regeneratively cooled thrust chambers

Electroforming is presently a prime technique for producing the outer jackets of regeneratively cooled thrust chambers for rocket engines. Good bond integrity of the electroformed joints adjacent to the coolant passages is important to the useful service life of these aerospace systems. This investigation demonstrated that nondestructive evaluation techniques such as ultrasonic 'C' scan, holography, and acoustic emission are capable of detecting low integrity bonds which could lead to premature failures in the subject hardware.

Malone, G. A.↗
NASA NTRS1974

Nondestructive tests of regenerative chambers

The capabilities and limitations of nondestructive evaluation methods were studied to detect and locate bond deficiencies in regeneratively cooled thrust chambers for rocket engines. Flat test panels and a cylinder were produced to simulate regeneratively cooled thrust chamber walls. Planned defects with various bond integrities were produced in the panels to evaluate the sensitivity, accuracy, and limitations of nondestructive methods to define and locate bond anomalies. Holography, acoustic emission, and ultrasonic scan were found to yield sufficient data to discern bond quality when used in combination and in selected sequences. Bonding techniques included electroforming and brazing. Materials of construction included electroformed nickel bonded to Nickel 200 and OFHC copper, electroformed copper bonded to OFHC copper, and 300 series stainless steel brazed to OFHC copper. Variations in outer wall strength, wall thickness, and defect size were evaluated for nondestructive test response.

Malone, G. A.↗
NASA NTRS1973

Nondestructive evaluation of regeneratively cooled thrust chambers for rocket engines

Review of a development program for nondestructive tests applicable to hardware with electroformed nickel bonds. The four steps of the program include the selection of some most promising nondestructive evaluation methods out of existing methods, the fabrication of test panels for simulation of cooled thrust chamber walls with bonds of various integrities, the evaluation of the test panels by personnel without previous knowledge of the planned bond integrity, and the verification of actual bond strength in the test panels by destructive tests. Ultrasonics, acoustic emission and holography are evaluated in nondestructive testing applications.

Stauffis, C. R.↗
NASA NTRS1972

Nondestructive test of regenerative chambers

Flat panels simulating internally cooled regenerative thrust chamber walls were fabricated by electroforming, brazing and diffusion bonding to evaluate the feasibility of nondestructive evaluation techniques to detect bonds of various strength integrities. Ultrasonics, holography, and acoustic emission were investigated and found to yield useful and informative data regarding the presence of bond defects in these structures.

Malone, G. A.↗