Engineering topics

Rogers, Jan R.

Publications and source records attributed to Rogers, Jan R..

At least 37 records · Page 2

NASA NTRS2012

Laser Remediation of Threats Posed by Small Orbital Debris

The continually increasing amount of orbital debris in near Earth space poses an increasing challenge to space situational awareness. Recent collisions of spacecraft caused abrupt increases in the density of both large and small debris in near Earth space. An especially challenging class of threats is that due to the increasing density of small (1 mm to 10 cm dimension) orbital debris. This small debris poses a serious threat since: (1) The high velocity enables even millimeter dimension debris to cause serious damage to vulnerable areas of space assets, e.g., detector windows; (2) The small size and large number of debris elements prevent adequate detection and cataloguing. We have identified solutions to this threat in the form of novel laser systems and novel ways of using these laser systems. While implementation of the solutions we identify is challenging we find approaches offering threat mitigation within time frames and at costs of practical interest. We base our analysis on the unique combination of coherent light specifically structured in both space and time and applied in novel ways entirely within the vacuum of space to deorbiting small debris. We compare and contrast laser based small debris removal strategies using ground based laser systems with strategies using space based laser systems. We find laser systems located and used entirely within space offer essential and decisive advantages over groundbased laser systems.

Fork, Richard L.↗

NASA NTRS2012

Experimental Studies of Carbon Nanotube Materials for Space Radiators

Game ]changing propulsion systems are often enabled by novel designs using advanced materials. Radiator performance dictates power output for nuclear electric propulsion (NEP) systems. Carbon nanotubes (CNT) and carbon fiber materials have the potential to offer significant improvements in thermal conductivity and mass properties. A test apparatus was developed to test advanced radiator designs. This test apparatus uses a resistance heater inside a graphite tube. Metallic tubes can be slipped over the graphite tube to simulate a heat pipe. Several sub ]scale test articles were fabricated using CNT cloth and pitch ]based carbon fibers, which were bonded to a metallic tube using an active braze material. The test articles were heated up to 600 C and an infrared (IR) camera captured the results. The test apparatus and experimental results are presented here.

SanSoucie, MIchael P.↗

NASA NTRS2010

Low Mass Printable Devices for Energy Capture, Storage, and Use

The energy-efficient, environmentally friendly technology that will be presented is the result of a Space Act Agreement between NthDegree Technologies Worldwide, Inc., and the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center (MSFC). The work combines semiconductor and printing technologies to advance lightweight electronic and photonic devices having excellent potential for commercial and exploration applications. Device development involves three projects that relate to energy generation and consumption: (1) a low-mass efficient (low power, low heat emission) micro light-emitting diode (LED) area lighting device; (2) a low-mass omni-directional efficient photovoltaic (PV) device with significantly improved energy capture; and (3) a new approach to building super-capacitors. These three technologies, energy capture, storage, and usage (e.g., lighting), represent a systematic approach for building efficient local micro-grids that are commercially feasible; furthermore, these same technologies, appropriately replacing lighting with lightweight power generation, will be useful for enabling inner planetary missions using smaller launch vehicles and to facilitate surface operations during lunar and planetary surface missions. The PV device model is a two sphere, light trapped sheet approximately 2-mm thick. The model suggests a significant improvement over current thin film systems. For lighting applications, all three technology components are printable in-line by printing sequential layers on a standard screen or flexographic direct impact press using the three-dimensional printing technique (3DFM) patented by NthDegree. One primary contribution to this work in the near term by the MSFC is to test the robustness of prototype devices in the harsh environments that prevail in space and on the lunar surface. It is anticipated that this composite device, of which the lighting component has passed off-gassing testing, will function appropriately in such environments consistent with NASA s exploration missions. Advanced technologies such as this show promise for both space flight and terrestrial applications.

Frazier, Donald O.↗

NASA NTRS2010

Improved Creep Measurements for Ultra-High Temperature Materials

Our team has developed a novel approach to measuring creep at extremely high temperatures using electrostatic levitation (ESL). This method has been demonstrated on niobium up to 2300 C, while ESL has melted tungsten (3400 C). This method has been extended to lower temperatures and higher stresses and applied to new materials, including a niobium-based superalloy, MASC. High-precision machined spheres of the sample are levitated in the NASA MSFC ESL, a national user facility and heated with a laser. The samples are rotated with an induction motor at up to 30,000 revolutions per second. The rapid rotation loads the sample through centripetal acceleration, producing a shear stress of about 60 MPa at the center, causing the sample to deform. The deformation of the sample is captured on high-speed video, which is analyzed by machine-vision software from the University of Massachusetts. The deformations are compared to finite element models to determine the constitutive constants in the creep relation. Furthermore, the non-contact method exploits stress gradients within the sample to determine the stress exponent in a single test.

Hyers, Robert W.↗

NASA NTRS2008

High-precision Non-Contact Measurement of Creep of Ultra-High Temperature Materials for Aerospace

For high-temperature applications (greater than 2,000 C) such as solid rocket motors, hypersonic aircraft, nuclear electric/thermal propulsion for spacecraft, and more efficient jet engines, creep becomes one of the most important design factors to be considered. Conventional creep-testing methods, where the specimen and test apparatus are in contact with each other, are limited to temperatures approximately 1,700 C. Development of alloys for higher-temperature applications is limited by the availability of testing methods at temperatures above 2000 C. Development of alloys for applications requiring a long service life at temperatures as low as 1500 C, such as the next generation of jet turbine superalloys, is limited by the difficulty of accelerated testing at temperatures above 1700 C. For these reasons, a new, non-contact creep-measurement technique is needed for higher temperature applications. A new non-contact method for creep measurements of ultra-high-temperature metals and ceramics has been developed and validated. Using the electrostatic levitation (ESL) facility at NASA Marshall Space Flight Center, a spherical sample is rotated quickly enough to cause creep deformation due to centrifugal acceleration. Very accurate measurement of the deformed shape through digital image analysis allows the stress exponent n to be determined very precisely from a single test, rather than from numerous conventional tests. Validation tests on single-crystal niobium spheres showed excellent agreement with conventional tests at 1985 C; however the non-contact method provides much greater precision while using only about 40 milligrams of material. This method is being applied to materials including metals and ceramics for non-eroding throats in solid rockets and next-generation superalloys for turbine engines. Recent advances in the method and the current state of these new measurements will be presented.

Rogers, Jan R.↗

NASA NTRS2008

Informatics and High Throughput Screening of Thermophysical Properties

The combination of computer-aided experiments with computational modeling enables a new class of powerful tools for materials research. A non-contact method for measuring density, thermal expansion, and creep of undercooled and high-temperature materials has been developed, using electrostatic levitation and optical diagnostics, including digital video. These experiments were designed to take advantage of the large volume of data (many gigabytes/experiment, terabytes/campaign) to gain additional information about the samples. For example, using sub-pixel interpolation to measure about 1000 vectors per image of the sample's surface allows the density of an axisymmetric sample to be determined to an accuracy of about 200 ppm (0.02%). A similar analysis applied to the surface shape of a rapidly rotating sample is combined with finite element modeling to determine the stress-dependence of creep in the sample in a single test. Details of the methods for both the computer-aided experiments and computational models will be discussed.

Hyers, Robert W.↗

NASA NTRS2008

Anomalies in the Thermophysical Properties of Undercooled Glass-Forming Alloys

The surface tension, viscosity, and density of several bulk metallic glass-forming alloys have been measured using noncontact techniques in the electrostatic levitation facility (ESL) at NASA Marshall Space Flight Center. All three properties show unexpected behavior in the undercooled regime. Similar deviations were previously observed in titanium-based quasicrystal-forming alloys,but the deviations in the properties of the glass-forming alloys are much more pronounced. New results for anomalous thermophysical properties in undercooled glass-forming alloys will be presented and discussed.

Hyers, Robert W.↗

NASA NTRS2007

Measurement of Creep Properties of Ultra-High-Temperature Materials by a Novel Non-Contact Technique

A non-contact technique for measuring the creep properties of materials has been developed and validated as part of a collaboration among the University of Massachusetts, NASA Marshall Space Flight Center Electrostatic Levitation Facility (ESL), and the University of Tennessee. This novel method has several advantages over conventional creep testing. The sample is deformed by the centripetal acceleration from the rapid rotation, and the deformed shapes are analyzed to determine the strain. Since there is no contact with grips, there is no theoretical maximum temperature and no concern about chemical compatibility. Materials may be tested at the service temperature even for extreme environments such as rocket nozzles, or above the service temperature for accelerated testing of materials for applications such as jet engines or turbopumps for liquid-fueled engines. The creep measurements have been demonstrated to 2400 C with niobium, while the test facility, the NASA MSFC ESL, has processed materials up to 3400 C. Furthermore, the ESL creep method employs a distribution of stress to determine the stress exponent from a single test, versus the many tests required by conventional methods. Determination of the stress exponent from the ESL creep tests requires very precise measurement of the surface shape of the deformed sample for comparison to deformations predicted by finite element models for different stress exponents. An error analysis shows that the stress exponent can be determined to about 1% accuracy with the current methods and apparatus. The creep properties of single-crystal niobium at 1985 C showed excellent agreement with conventional tests performed according to ASTM Standard E-139. Tests on other metals, ceramics, and composites relevant to rocket propulsion and turbine engines are underway.

Hyers, Robert W.↗

NASA NTRS2006

Measuring the Thermophysical and Structural Properties of Glass-Forming and Quasicrystal-Forming Liquids

The thermophysical properties of glass-forming and quasicrystal-forming alloys show many interesting features in the undercooled liquid range. Some of the features in the thermophysical property curves are expected to reflect changes in the structure and coordination of the liquid. These measurements require containerless processing such as electrostatic levitation to access the undercooled liquid regime. An overview of the state of the art in measuring the thermophysical properties and structure of undercooled liquid glass-forming and quasicrystal-forming alloys will be presented, along with the status of current measurements.

Hyers, Robert W.↗

NASA NTRS2006

Thermophysical Properties Measurements of Zr62Cu20Al10Ni8

Thermophysical property studies performed at high temperature can prove challenging because of reactivity problems brought on by the elevated temperatures. Contaminants from measuring devices and container walls can cause changes in properties. To prevent this, containerless processing techniques can be employed to isolate a sample during study. A common method used for this is levitation. Typical levitation methods used for containerless processing are, aerodynamically, electromagnetically and electrostatically based. All levitation methods reduce heterogeneous nucleation sites, 'which in turn provide access to metastable undercooled phases. In particular, electrostatic levitation is appealing because sample motion and stirring are minimized; and by combining it with optically based non-contact measuring techniques, many thermophysical properties can be measured. Applying some of these techniques, surface tension, viscosity and density have been measured for the glass forming alloy Zr62Cu20Al10Ni8 and will be presented with a brief overview of the non-contact measuring method used.

Bradshaw, Richard C.↗

NASA NTRS2006

Floating the Ball: Advances in the Technology of Electrostatic Levitation

Electrostatic Levitation (ESL) is an emerging technology. The MSFC ESL is a NASA facility that supports investigations of refractory solids and melts. The facility can be used to process a wide variety of materials including metals, alloys, ceramics, glasses and semiconductors. Containerless processing via ESL provides a high-purity environment for the study of high temperature materials and access to metastable states. Scientific topics investigated in the facility include nucleation, undercooling, metastable state formation and metallic glass formation. Additionally, the MSFC ESL provides data for the determination of phase diagrams, time-temperature-transition diagrams, viscosity, surface tension, density, heat capacity and creep resistance. In order to support a diverse research community, the MSFC ESL facility has developed a number of technical capabilities, including a portable system for in situ studies of structural tran$hrmations during processing at the high-energy X-ray beamline at the Advanced Photon Source of Argonne National Laboratory. The capabilities of the MSFC ESL facilities will be discussed and selected results of materials processing and characterization studies will be presented.

Rogers, Jan R.↗

NASA NTRS2006

Non-Contact Measurements of Creep Properties of Refractory Materials

State-of-the-art technologies for hypersonic aircraft, nuclear electric/thermal propulsion for spacecraft, and more efficient jet engines are driving ever more demanding needs for high-temperature (>2000 C) materials. At such high temperatures, creep rises as one of the most important design factors to be considered. Since conventional measurement techniques for creep resistance are limited to about 17OO0C, a new technique is in demand for higher temperatures. This paper presents a non-contact method using electrostatic levitation (ESL) which is applicable to both metallic and non-metallic materials. The samples were rotated quickly enough to cause creep deformation by centrifugal acceleration. The deformation of the samples was captured with a high speed camera and then the images were analyzed to estimate creep resistance. Finite element analyses were performed and compared to the experiments to verify the new method. Results are presented for niobium and tungsten, representative refractory materials at 2300 C and 2700 C respectively.

Lee, Jonghyun↗

NASA NTRS2006

Analytical, Numerical, and Experimental Investigation on a Non-Contact Method for the Measurements of Creep Properties of Ultra-High-Temperature Materials

Responsive access to space requires re-use of components such as rocket nozzles that operate at extremely high temperatures. For such applications, new ultra-hightemperature materials that can operate over 2,000 C are required. At the temperatures higher than the fifty percent of the melting temperature, the characterization of creep properties is indispensable. Since conventional methods for the measurement of creep is limited below 1,700 C, a new technique that can be applied at higher temperatures is strongly demanded. This research develops a non-contact method for the measurement of creep at the temperatures over 2,300 C. Using the electrostatic levitator in NASA MSFC, a spherical sample was rotated to cause creep deformation by centrifugal acceleration. The deforming sample was captured with a digital camera and analyzed to measure creep deformation. Numerical and analytical analyses have also been conducted to compare the experimental results. Analytical, numerical, and experimental results showed a good agreement with one another.

Lee, Jonghyun↗

NASA NTRS2004

Containerless Processing of a Lithium Disilicate Glass

Glasses of Li2O.2SiO2 (LS2), and LS2 doped with 0.001wt% platinum (LS2 + 0.001 wt% Pt) compositions were melted, cooled and reheated at controlled rates while levitated (containerless) inside an Electrostatic Levitator (ESL) furnace at the NASA Marshall Space Flight Center, Huntsville, AL. The experiments were conducted in vacuum (approximately 10(exp -5) Pa) using spherical, 2.5 to 3 millimeter diameter, glass samples. The measured critical cooling rate for glass formation, R(sub c), for the LS2 and LS2+0.001 wt% Pt glasses processed at ESL were 14 plus or minus 2 Celsius per minute and 130 plus or minus 5 Celsius per minute, respectively. The values of R(sub c), for the same LS2 and LS2 + 0.001 wt% Pt glasses processed in a container were 62 plus or minus 3 Celsius per minute and 162 plus or minus 5 Celsius per minute, respectively. The effective activation energy for crystallization, E, for this LS2 glass processed without a container at ESL, 392 plus or minus 15 kiloJoules per mole, was higher than that, 270 plus or minus 15 kiloJoules per mole, for an identical glass processed in a container. These results suggest that the glass formation tendency for a containerless LS2 melt is significantly increased compared to an identical melt in contact with a container. The absence of heterogeneous nucleation sites that are inherently present in all melts held in containers, and or a change in the surface composition due to evaporation of Li2O during processing at ESL are likely reasons for the increased glass forming tendency of this containerless LS2 melt.

Ranasinghe, Kisa↗

NASA NTRS2003

Flight Planning for the International Space Station - Levitation Observation of Dendrite Evolution in Steel Ternary Alloy Rapid Solidification (LODESTARS)

During rapid solidification, a molten sample is cooled below its equilibrium solidification temperature to form a metastable liquid. Once nucleation is initiated, growth of the solid phase proceeds and can be seen as a sudden rise in temperature. The heat of fusion is rejected ahead of the growing dendrites into the undercooled liquid in a process known as recalescence. Fe-Cr-Ni alloys may form several equilibrium phases and the hypoeutectic alloys, with compositions near the commercially important 316 stainless steel alloy, are observed to solidify by way of a two-step process known as double recalescence. During double recalescence, the first temperature rise is associated with formation of the metastable ferritic solid phase with subsequent conversion to the stable austenitic phase during the second temperature rise. Selection of which phase grows into the undercooled melt during primary solidification may be accomplished by choice of the appropriate nucleation trigger material or by control of the processing parameters during rapid solidification. Due to the highly reactive nature of the molten sample material and in order to avoid contamination of the undercooled melt, a containerless electromagnetic levitation (EML) processing technique is used. In ground-based EML, the same forces that support the weight of the sample against gravity also drive convection in the liquid sample. However, in microgravity, the force required to position the sample is greatly reduced, so convection may be controlled over a wide range of internal flows. Space Shuttle experiments have shown that the double recalescence behavior of Fe-Cr-Ni alloys changes between ground and space EML experiments. This program is aimed at understanding how melt convection influences phase selection and the evolution of rapid solidification microstructures.

Flemings, Merton C.↗

NASA NTRS2003

Studies of Nucleation and Growth, Specific Heat and Viscosity of Undercooled Melts of Quasicrystal and Polytetrahedral-Phase Forming Alloys

From extensive ground based work on the phase diagram and undercooling studies of Ti-Zr-Ni alloys, have clearly identified the composition of three different phases with progressively increasing polytetrahedral order such as, (Ti/Zr), the C14 Laves phase, and the i-phase, that nucleate directly from the undercooled liquid. The reduced undercooling decreases progressively with increasing polytetrahedral order in the solid, supporting Frank s hypothesis. A new facility for direct measurements of the structures and phase transitions in undercooled liquids (BESL) was developed and has provided direct proof of the primary nucleation of a metastable icosahedral phase in some Ti-Zr-Ni alloys. The first measurements of specific heat and viscosity in the undercooled liquid of this alloy system have been completed. Other than the importance of thermo-physical properties for modeling nucleation and growth processes in these materials, these studies have also revealed some interesting new results (such as a maximum of C(sup q, sub p) in the undercooled state). These ground-based results have clearly established the necessary background and the need for conducting benchmark nucleation experiments at the ISS on this alloy system.

Kelton, K. F.↗

NASA NTRS2001

Evolution of Local Microstructures: Spatial Instabilities of Coarsening Clusters

This work examines the diffusional growth of discrete phase particles dispersed within a matrix. Engineering materials are often microstructurally heterogeneous, and the details of the microstructure determine how well that material performs in a given application. Critical to the development of designing multiphase microstructures with long-term stability is the process of Ostwald ripening. Ripening, or phase coarsening, is diffusion-limited and arises in polydisperse multiphase materials. Growth and dissolution occur because fluxes of solute, driven by chemical potential gradients at the interfaces of the dispersed phase material, depend on particle size. Competitive kinetics of these processes dictates that larger particles grow at the expense of smaller ones, overall leading to an increase of the average particle size. The classical treatment of phase coarsening was done by Todes, Lifshitz, and Slyozov, (TLS) in the limit of zero volume fraction, V(sub V)=0 of the dispersed phase. Since the publication of TLS theory, there have been numerous investigations, many of which sought to describe the kinetic scaling behavior over a range of volume fractions. Some studies in the literature report that the relative increase in coarsening rate at low (but not zero) volume fractions compared to that predicted by TLS is proportional to V(exp 1/2)(sub v) whereas others suggest V(exp 1/3)(sub v).This issue has been addressed recently by simulation studies at low volume fractions in three dimensions by members of the Rensselaer/MSFC team.

Glicksman, Martin E.↗

NASA NTRS2001

Studies of Nucleation, Growth, Specific Heat, and Viscosity of Undercooled Melts of Quasicrystals and Polytetrahedral-Phase-Forming Alloys

Undercooling experiments and thermal physical property measurements of metallic alloys on the International Space Station (ISS) are planned. This recently-funded research focuses on fundamental issues of the formation and structure of highly-ordered non-crystallographic phases (quasicrystals) and related crystal phases (crystal approximants), and the connections between the atomic structures of these phases and those of liquids and glasses. It extends studies made previously by us of the composition dependence of crystal nucleation processes in silicate and metallic glasses, to the case of nucleation from the liquid phase. Motivating results from rf-levitation and drop-tube measurements of the undercooling of Ti/Zr-based liquids that form quasicrystals and crystal approximants are discussed. Preliminary measurements by electrostatic levitation (ESL) are presented.

Kelton, K. F.↗