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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS1976

A fractographic study of the edge-sliding mode in fracture toughness testing

A fractographic study of Mode II fracture surfaces has been conducted for the purpose of identifying the microstructural mechanisms responsible for fracture in the edge-sliding mode. A compact shear (CS) specimen was employed to generate the fracture surfaces and also to establish Mode II fracture toughness values for Ti-6Al-4V, A533-B steel, and several aluminum alloys. In all tests, one of the two edge cracks sustained complete Mode II fracture while the other exhibited only a limited amount of subcritical crack growth. Mode II fracture surfaces, which were unique in appearance, have been examined by optical and scanning electron microscopy. It was determined that shear (or parabolic) microvoid coalescence was the dominant mechanism for Mode II fracture. It was also established that most of the surface abrasions were created by the relative sliding of the fracture surfaces during unstable fracture rather than the crack initiation process.

Jones, D. L.↗
NASA NTRS1972

Exploration of alloy surface and slurry modification to improve oxidation life of fused silicide coated niobium alloys

Edge and surface modifications of niobium alloys were investigated prior to coating with Si-20Cr-20Fe and slurry composition modification for performance in a 1370 C ambient pressure slow cycle test. The best coating obtained was Si-20Cr-20Mn with an average life of 63 cycles, compared to 40 for Si-20Cr-20Fe on FS-85 (100 percent improvement in weight parity life). Edge beading extended the lives of Si-20Cr-20Fe-coated Cb-752 and FS-85 to 57 and 41 cycles respectively (50 and 20 percent improvements in weight parity life respectively). W, Al2O3 and ZrO2(CaO) surface modifications altered coating crack frequency and microstructure and increased life somewhat.

Levine, S. R.↗
NASA NTRS1988

Wear of liquid nitrogen-cooled 440C bearing steels in an oxygen environment

This paper presents up-to-date findings of the research being conducted to understand the mechanism of sliding wear in unlubricated 440C bearing steels under oxidative conditions. A sliding wear test rig has been designed and built with a cylinder-on-flat geometry. The equipment is capable of testing specimens under high axial loads and sliding speeds in a simulated LOX environment. Samples of 440C steel, quenched and tempered to a hardness of Rc 56, were tested under a load of 890 N and a sliding speed of 2.05 m/sec for total sliding distances of up to 5.54 km. Flash temperatures during these tests were measured with an IR camera and a fast digital recorder. Microstructural and microanalytical data from the worn surfaces and the debris particles are analyzed extensively, along with wear rates, flash temperatures, surface profiles, hardnesses, and residual stresses, in the context of oxidation and wear theories.

Chaudhuri, Dilip K.↗
NASA NTRS1992

Multispectral variable magnification glancing incidence x ray telescope

A multispectral, variable magnification, glancing incidence, x-ray telescope capable of broadband, high resolution imaging of solar and stellar x-ray and extreme ultraviolet radiation sources is discussed. The telescope includes a primary optical system which focuses the incoming radiation to a primary focus. Two or more rotatable mirror carriers, each providing a different magnification, are positioned behind the primary focus at an inclination to the optical axis. Each carrier has a series of ellipsoidal mirrors, and each mirror has a concave surface covered with a multilayer (layered synthetic microstructure) coating to reflect a different desired wavelength. The mirrors of both carriers are segments of ellipsoids having a common first focus coincident with the primary focus. A detector such as an x-ray sensitive photographic film is positioned at the second respective focus of each mirror so that each mirror may reflect the image at the first focus to the detector at the second focus. The carriers are selectively rotated to position a selected mirror for receiving radiation from the primary optical system, and at least the first carrier may be withdrawn from the path of the radiation to permit a selected mirror on the second carrier to receive the radiation.

Hoover, Richard B.↗
NASA NTRS2002

Experimental Methods in Reduced-gravity Soldering Research

The National Center for Microgravity Research, NASA Glenn Research Center, and NASA Johnson Space Center are conducting an experimental program to explore the influence of reduced gravity environments on the soldering process. An improved understanding of the effects of the acceleration environment is important to application of soldering during current and future human space missions. Solder joint characteristics that are being considered include solder fillet geometry, porosity, and microstructural features. Both through-hole and surface mounted devices are being investigated. This paper focuses on the experimental methodology employed in this project and the results of macroscopic sample examination. The specific soldering process, sample configurations, materials, and equipment were selected to be consistent with those currently on-orbit. Other apparatus was incorporated to meet requirements imposed by operation onboard NASA's KC-135 research aircraft and instrumentation was provided to monitor both the atmospheric and acceleration environments. The contingent of test operators was selected to include both highly skilled technicians and less skilled individuals to provide a population cross-section that would be representative of the skill mix that might be encountered in space mission crews.

Pettegrew, Richard D.↗
NASA NTRS2003

Alumina Volatility in Water Vapor at Elevated Temperatures

The volatility of alumina in high temperature water vapor was determined by a weight loss technique. Sapphire coupons were exposed at temperatures between 1250 and 1500 C, water partial pressures between 0.15 and 0.68 atm in oxygen, total pressure of 1 atm, and flowing gas velocities of 4.4 cm/s. The pressure dependence of sapphire volatility was consistent with AI(OH)3(g) formation. The enthalpy of reaction to form Al(OH)3(g) from sapphire and water vapor was determined to be 210 +/- 20 kJ/mol, comparing favorably to other studies. Microstructural examination of tested sapphire coupons revealed surface etching features consistent with a volatilization process.

Opila, Elizabeth J.↗
NASA NTRS2015

Techniques for Achieving Zero Stress in Thin Films of Iridium, Chromium, and Nickel

We examine techniques for achieving zero intrinsic stress in thin films of iridium, chromium, and nickel deposited by magnetron sputter deposition. The intrinsic stress is further correlated to the microstructural features and physical properties such as surface roughness and optical density at a scale appropriate to soft X-ray wavelengths. The examination of the stress in these materials is motivated by efforts to advance the optical performance of light-weight X-ray space telescopes into the regime of sub-arcsecond resolution through various deposition techniques that rely on control of the film stress to values within 10-100 MPa. A characteristic feature of the intrinsic stress behavior in chromium and nickel is their sensitivity to the magnitude and sign of the intrinsic stress with argon gas pressure and deposition rate, including the existence of a critical argon process pressure that results in zero film stress which scales linearly with the atomic mass of the sputtered species. While the effect of stress reversal with argon pressure has been previously reported by Hoffman and others for nickel and chromium, we report this effect for iridium. In addition to stress reversal, we identify zero stress in the optical functioning iridium layer shortly after island coalescence for low process pressures at a film thickness of approximately 35nm. The measurement of the low values of stress during deposition was achieved with the aid of a sensitive in-situ instrument capable of a minimum detectable level of stress, assuming a 35nm thick film, in the range of 0.40-6.0 MPa for <111> oriented crystalline silicon substrate thicknesses of 70-280 microns, respectively.

X-ray optical thin films↗
NASA NTRSDate not supplied

Electrical Discharge Machining of Additively Manufactured Superalloys Containing Oxide Dispersions

Superalloys can be strengthened by oxide dispersions to potentially improve their mechanical properties at high temperatures. Additive manufacturing has opened new paths for introducing oxide particles into superalloys with increased processing flexibility, to potentially provide oxide dispersion strengthening. Numerically controlled electrical discharge machining (EDM) has often been used as a machining process for initial sectioning, detailed roughing, and even finishing operations of conventional superalloys. The objective of this study was to examine how additively manufactured superalloys containing oxide dispersions respond when sectioned using EDM. Consistent sections of several superalloys, two containing an oxide dispersion, were sliced using a typical EDM machine with standard brass wire and a typical roughing condition set. Roughness, microstructure, and residual stress at the EDM surfaces were compared for the varied superalloys.

superalloys↗
NASA NTRS2018

Systems and Methods for Post-Treatment of Dry Adhesive Microstructures

Provided are systems and methods for the post-treatment of dry adhesive microstructures. The microstructures may be post-treated to comprise mushroom-like flaps at their tips to interface with the contact surface. In some aspects, a change in material composition of the microstructures in a dry adhesive may affect mechanical properties to enhance or diminish overall adhesive performance. For example, conductive additives can be added to the material to improve adhesive performance. In other aspects, microstructures comprising conductive material may allow for pre-load engagement sensing systems to be integrated into the microstructures.

Dadkhah Tehrani, Mohammad↗
NASA NTRS2000

Mechanical, Chemical and Microstructural Characterization of Monazite-Coated Silicon Carbide Fibers

Tensile strengths of as-received Hi-Nicalon and Sylramic fibers and those having monazite surface coatings, deposited by atmospheric pressure chemical vapor deposition, were measured at room temperature and the Weibull statistical parameters determined. The average tensile strengths of uncoated Hi-Nicalon and Sylramic fibers were 3.19 +/- 0.73 and 2.78 +/- 0.53 GPa with a Weibull modulus of 5.41 and 5.52, respectively. The monazite-coated Hi-Nicalon and Sylramic fibers showed strength loss of approx. 10 and 15 percent, respectively, compared with the as-received fibers. The elemental compositions of the fibers and the coatings were analyzed using scanning Auger microprobe and energy dispersive X-ray spectroscopy. The LaPO4 coating on Hi-Nicalon fibers was approximately stoichiometric and about 50 nm thick. The coating on the Sylramic fibers extended to a depth of about 100 to 150 nm. The coating may have been stoichiometric LaPO4 in the first 30 to 40 nm of the layer. However, the surface roughness of Sylramic fiber made this profile somewhat difficult to interpret. Microstructural analyses of the fibers and the coatings were done by scanning electron microscopy, transmission electron microscopy, and selected area electron diffraction. Hi-Nicalon fiber consists of fine beta-SiC nanocrystals ranging in size from 1 to 30 mn embedded in an amorphous matrix. Sylramic is a polycrystalline stoichiometric silicon carbide fiber consisting of submicron beta-SiC crystallites ranging from 100 to 300 nm. Small amount of TiB2 nanocrystallites (approx. 50 nm) are also present. The LaPO4 coating on Hi-Nicalon fibers consisted of a chain of peanut shape particles having monazite-(La) structure. The coating on Sylramic fibers consisted of two layers. The inner layer was a chain of peanut shape particles having monazite-(La) structure. The outer layer was comprised of much smaller particles with a microcrystalline structure.

Bansal, N. P.↗
NASA NTRS2017

GEER Status Update

History: The Glenn Extreme Environments Rig (GEER) first became operational in the early part of 2015. Since that time GEER has completed a number of scientific tests and has undergone improvements in the chemical delivery system and analytics following a year of operations experience. Recent Updates: In June 2016, the GEER process system was rebuilt to provide a more robust system, higher accuracy and new capabilities. New insulation was installed on the exterior of the pressure vessel and gas lines. The newly revamped GEER plumbing system can provide extremely precise custom gas mixtures using any gas desired by the investigator in any combination. GEER can heat the resulting mixture up to 500 deg C and 1500 psia. The 304 stainless steel vessel walls were polished to reduce corrosion rate and reduce unwanted chemical reactions. The process lines were replaced with high purity Sulfinert coated tubing. The GEER team added the ability to individually boost specialty gases to GEER thus allowing operators to make very precise changes to the gas chemistry inside of GEER during a test while at high temperature and pressure. High accuracy mass flow meters were added to further improve gas mixing accuracy and precision. An in-line, integrated Inficon MicroGC Fusion was added for real time gas analysis along with a high purity gas sampling system, providing fully automated, real time analysis of the gas chemistry inside of GEER in minutes. This complements a co-located mass spectrometer and both are used for regular monitoring of the vessel chemistry. All internal vessel components were replaced with polished 304SS equivalents. Hot vent down capability was increased. Finally, an automated liquid injection system was added and is rated for max vessel operating conditions of (1500 psia, 500 C). Recent Results and Publications: In May 2016, GEER completed a test that exposed high temperature electronics to Venus surface conditions for 21.5 days. This demonstrated the potential for operating robotic spacecraft in the Venus environment without the need for thermal or environmental protection. Results from this test were published in December 2016 and received national media attention. In April 2017 GEER implemented an 80 day test at Venus surface conditions to simulate chemical weathering of expected Venus minerals. This test supported a ROSES award to a team led by Prof. Ralph Harvey of Case Western Reserve University. The test concluded in July 2017 and nearly doubled previous operation record of 42 days at Venus surface conditions. Preliminary results of these and previous experiments were presented at the recent Venus Modeling Workshop. In June 2017, NASA TM2017-219437 "Chemical and Microstructural Changes in Metallic and Ceramic Materials Exposed to Venusian Surface Conditions" was published. This report provides an extensive and valuable resource detailing the behavior of a variety of engineering materials at Venus surface conditions. Community Involvement: An external science advisory panel has been formed.

Kremic, Tibor↗
NASA NTRS2024

Finite Element Simulation of the Direct Energy Deposition using Comsol Multiphysics

Direct Energy Deposition (DED) is an emerging technology extensively employed in metal Additive Manufacturing (AM). Despite its widespread industrial application, mathematical modeling in this domain remains challenging. This complexity arises from the intricate nature of the modeling approach and the nonlinear behavior of material parameters across a broad temperature range. Consequently, experimentalists often resort to a trial-and-error method to achieve structures with desired properties. However, this approach can be time-consuming and may not always yield parts with the requisite characteristics, highlighting the necessity for mathematical modeling to enhance manufacturing success. This study focuses on thin-walled manufacturing with a single bead thickness, adjusting laser parameters to produce such structures. The laser cladding speed, typical for DED manufacturing, is considered to be on the order of centimeters per second. The various wall thicknesses and heights are explored to discern the general characteristics of walls manufactured via this DED approach. Our modeling approach diverges from the conventional DED modeling based on activation-deactivation of predefined mesh domains, commonly implemented in many finite element codes. Instead, a method is proposed that effectively models layer cladding and melt pool dynamics, enabling predictions of the microstructure in the resulting structures. The formation mechanisms of cellular, dendritic columnar, and stray (equiaxed) grains, which arise from the interplay between nucleation and growth from the surface is analyzed. The study also examines the feasibility of microstructure formation to demonstrate the various thermal characteristics inherent in wall manufacturing. Our results illustrate how different process parameters influence the temperature gradient and cooling rate of the molten pool, subsequently affecting the primary dendrite arm spacing (PDAS). This modeling technique allows for the investigation of diverse thermal conditions, facilitating the prediction of microstructure and residual stresses in the manufactured parts.

modeling↗
NASA NTRS2020

Microscale Characterization of Damage Accumulation in CMCs

The developing roles of damage mechanisms in the failure response of SiC/SiC minicomposites was investigated by the characterization of microscale damage accumulation with respect to microstructure. A multi-modal approach combining spatially resolved acoustic emission (AE) with tensile testing in-SEM (scanning electron microscope) was used to simultaneously examine surface (observed in-SEM) and bulk damage (monitored via AE). Strong agreement was shown between the evolving crack density estimated by AE and in-SEM measurements. The following were observed: (i) in-plane matrix content and distribution impacted crack growth; (ii) spatially-distributed matrix cracks generated varying stress-dependent AE; and (iii) certain individual cracks became more probable failure locations due to unique combinations of damage mechanisms that drove their growth. This approach enabled characterizing potential failure determinants and suggests that early damage behavior is related to certain microstructural features (e.g. surface flaws), while subsequent damage behavior is coupled to interactions of local mechanisms evolving with stress.

ceramic matrix composites↗
NASA NTRS2017

Analyzing the Chemical and Spectral Effects of Pulsed Laser Irradiation to Simulate Space Weathering of a Carbonaceous Chondrite

Space weathering processes alter the chemical composition, microstructure, and spectral characteristics of material on the surfaces of airless bodies. The mechanisms driving space weathering include solar wind irradiation and the melting, vaporization and recondensation effects associated with micrometeorite impacts e.g., [1]. While much work has been done to understand space weathering of lunar and ordinary chondritic materials, the effects of these processes on hydrated carbonaceous chondrites is poorly understood. Analysis of space weathering of carbonaceous materials will be critical for understanding the nature of samples returned by upcoming missions targeting primitive, organic-rich bodies (e.g., OSIRIS-REx and Hayabusa 2). Recent experiments have shown the spectral properties of carbonaceous materials and associated minerals are altered by simulated weathering events e.g., [2-5]. However, the resulting type of alteration i.e., reddening vs. bluing of the reflectance spectrum, is not consistent across all experiments [2-5]. In addition, the microstructural and crystal chemical effects of many of these experiments have not been well characterized, making it difficult to attribute spectral changes to specific mineralogical or chemical changes in the samples. Here we report results of a pulsed laser irradiation experiment on a chip of the Murchison CM2 carbonaceous chondrite to simulate micrometeorite impact processing.

Thompson, M. S.↗
NASA NTRSDate not supplied

How strong is ocean mixing in the Pacific Ocean cold tongue, and does it matter?

Microstructure observations within the Pacific Ocean cold tongue reveal that strong surface boundary layer turbulence often penetrates into the thermocline producing hundreds of W/m^2 of downward heat transport during nighttime and early morning. Hence, it has been suggested that ocean turbulent mixing contributes significantly to the sea-surface temperature budget and modulates air-sea interaction on a wide range of timescales with consequences for global climate and weather. However, most observations of ocean microstructure in the cold tongue are from 0 N,140 W. In this presentation, I will attempt to characterize ocean mixing at and beyond 0 N,140 W using models. Questions to be addressed include: 1) can we model ocean mixing at 0 N,140 W? And 2) how does ocean mixing vary in space and time beyond 0 N,140 W? Finally, 3) how does ocean mixing compare to the air-sea heat flux in the sea-surface temperature budget? Results will be derived from existing observations at 0 N, 140 W and a new hierarchy of regional ocean process simulations including a 20-year-long submesoscale-permitting regional model and month-long turbulence-permitting large eddy simulations embedded in a regional model.

Strong↗
NASA NTRS1986

Dislocation mechanism based model for stage II fatigue crack propagation rate

Repeated plastic deformation, which of course depends on dislocation mechanism, at or near the crack tip leads to the fatigue crack propagation. By involving the theory of thermally activated flow and the cumulative plastic strain criterion, an effort is made here to model the stage II fatigue crack propagation rate in terms of the dislocation mechanism. The model, therefore, provides capability to ascertain: (1) the dislocation mechanism (and hence the near crack tip microstructures) assisting the crack growth, (2) the relative resistance of dislocation mechanisms to the crack growth, and (3) the fracture surface characteristics and its interpretation in terms of the dislocation mechanism. The local microstructure predicted for the room temperature crack growth in copper by this model is in good agreement with the experimental results taken from the literature. With regard to the relative stability of such dislocation mechanisms as the cross-slip and the dislocation intersection, the model suggests an enhancement of crack growth rate with an ease of cross-slip which in general promotes dislocation cell formation and is common in material which has high stacking fault energy (produces wavy slips). Cross-slip apparently enhances crack growth rate by promoting slip irreversibility and fracture surface brittleness to a greater degree.

Mazumdar, P. K.↗
NASA NTRS1993

A study of subsurface crack initiation produced by rolling contact fatigue

Results of subsurface crack initiation studies produced by pure rolling contact fatigue in 7075-T6 aluminum alloy are presented in this article. Microstructural changes and subsequent crack initiation below the contacting surface in cylindrical test specimens subjected to repeated rolling contact are illustrated. The rolling conditions are simulated in a three-dimensional elastic-plastic finite element model in order to estimate the plastic strains and residual stresses in the test material. The numerically estimated distribution of plastic strains in the model correlate well with the extent of microstructural changes observed in the test specimen. Results also indicate that a combination of plastic strains and low values of residual stresses is conducive to subsurface crack initiation and growth.

Kumar, Arun M.↗
NASA NTRS1975

Processing eutectics in space

The investigations of directional solidification have indicated the necessity of establishing a secure foundation in earth-based laboratory processing in order to properly assess low-gravity processing. Emphasis was placed on evaluating the regularity of microstructure of the rod-like eutectic Al-Al3Ni obtained under different conditions of growth involving the parameters of thermal gradient, solidification rate, and interfacial curvature. In the case of Al-Al3Ni, where the Al3Ni phase appears as facets rods, solidification rate was determined to be a controlling parameter. Zone melting of thin eutectic films showed that for films of the order of 10 to 20 micrometers thick, the extra surface energy appears to act to stabilize a regular microstructure. The results suggest that the role of low-gravity as provided in space-laboratory processing of materials is to be sought in the possibility of generating a higher thermal gradient in the solidifying ingot for a given power input-output arrangement than can be obtained under normal one-g processes.

Douglas, F. C.↗