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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

Fabrication and development of several heat pipe honeycomb sandwich panel concepts

The feasibility of fabricating and processing liquid metal heat pipes in a low mass honeycomb sandwich panel configuration for application on the NASA Langley airframe-integrated Scramjet engine was investigated. A variety of honeycomb panel facesheet and core-ribbon wick concepts was evaluated within constraints dictated by existing manufacturing technology and equipment. The chosen design consists of an all-stainless steel structure, sintered screen facesheets, and two types of core-ribbon; a diffusion bonded wire mesh and a foil-screen composite. Cleaning, fluid charging, processing, and process port sealing techniques were established. The liquid metals potassium, sodium and cesium were used as working fluids. Eleven honeycomb panels 15.24 cm X 15.24 cm X 2.94 cm were delivered to NASA Langley for extensive performance testing and evaluation; nine panels were processed as heat pipes, and two panels were left unprocessed.

Tanzer, H. J.↗
NASA NTRS1982

Turbulent boundary layer over solid and porous surfaces with small roughness

The wind tunnel models and instrumentation used as well as data reduction and error analysis techniques employed are described for an experimental study conducted to measure directly skin friction and obtain profiles of mean velocity, axial and normal turbulence intensity, and Reynolds stress in the untripped boundary on a large diameter axisymmetric body. Results are given for such a body with a (1) smooth, solid surface; (2) a sandpaper roughened, solid surface; (3) a sintered metal, porous surface; (4) a ""smooth'' performated titanium surface; (5) a rough, solid surface made of fine diffusion bonded screening; and (6) a rough, porous surface made of the same screening. The roughness values were in low range (k+ 5 to 7) just above what is normally considered ""hydraulically smooth''. Measurements were taken at several axial locations and tow or normal stream freestream velocities, 45.1 m/sec and 53.5 m/sec.

Kong, F. Y.↗
NASA NTRS1983

An analytical comparison of two wing structures for Mach 5 cruise airplanes

Mach 5 cruise research conducted by NASA is related to aerodynamics, propulsion, and structures. The study of structures includes the propulsion system, fuselage, and wings. Various studies have shown that the achievement of adequate range is largely dependent on a low structural mass fraction. The present investigation is concerned with a study of two wing structure configurations for Mach 5 aircraft. An uprated version (Ti-6242 replacing B-120 titanium) of the YF-12/SR-71 wing structure is considered. The B-120 titanium structure represents the current art of high speed aircraft wing structures. The YF-12 wing structure was designed about 20 years ago when the analytical methods for calculating thermal stresses were limited. The second wing structural configuration studied in the present investigation also used Ti-6242 materials but replaced the corrugated-beaded panels with diffusion bonded honeycomb-core sandwich panels, and replaced the z-stiffened shear webs with sine-wave stiffened shear webs.

Taylor, A. H.↗
NASA NTRS1984

Application of near-term technology to a Mach 2.0 variable-sweep-wing, supersonic-cruise executive jet

The impact of variable sweep wing technology with relaxed static stability requirements on a supersonic-cruise executive jet with transatlantic range was assessed. The baseline vehicle utilized modified, current-technology engines and titanium structures produced with superplastic forming and diffusion bonding; this vehicle meets study requirements for both supersonic-cruise and low-speed characteristics. The baseline concept has a ramp weight of 64,500 pounds with a crew of two and eight passengers. Its Mach 2.0 cruise range is nearly 3,500 nautical miles; its Mach 0.9 cruise range is over 5,000 nautical miles. Takeoff, landing, and balanced field length requirements were calculated for a composite variant and are all less than 5,000 feet.

Beissner, F. L., Jr.↗
NASA NTRS1983

Metallurgical and tensile property analysis of several silicon carbide/titanium composite systems

Several silicon-carbide fiber reinforced titanium matrix composite systems were investigated to determine composite degradation mechanisms and to develop techniques to minimize loss of mechanical properties during fabrication and in service. Emphasis was on interface control by fiber or matrix coatings. Fibers and matrix materials were sputter coated with various metals to determine the effects of the coatings on basic fiber properties, fiber-matrix interactions, and on composite properties. The effects of limited variations in fabrication temperature on composite properties were determined for composites consolidated by standard press-diffusion-bonding techniques.

Brewer, W. D.↗
NASA NTRS1985

Vacuum plasma coatings for turbine blades

Turbine blades, vacuum plasma spray coated with NiCrAlY, CoCrAlY or NiCrAlY/Cr2O3, were evaluated and rated superior to standard space shuttle main engine (SSME) coated blades. Ratings were based primarily on 25 thermal cycles in the MSFC Burner Rig Tester, cycling between 1700 F (gaseous H2) and -423 F (liquid H2). These tests showed no spalling on blades with improved vacuum plasma coatings, while standard blades spalled. Thermal barrier coatings of ZrO2, while superior to standard coatings, lacked the overall performance desired. Fatigue and tensile specimens, machined from MAR-M-246(Hf) test bars identical to the blades were vacuum plasma spray coated, diffusion bond treated, and tested to qualify the vacuum plasma spray process for flight hardware testing and application. While NiCrAlY/Cr2O3 offers significant improvement over standard coatings in durability and thermal protection, studies continue with an objective to develop coatings offering even greater improvements.

Holmes, R. R.↗
NASA NTRS1986

Improved Joint Design for Box-Stiffened Panels

Mass and strength analyses and system requirements identified titanium-box-stiffened-skin wall candidate for lightweight fuselage of pressurized vehicle. Photoelastic models of stiffener-to-skin joint used to identify quickly modifications to joint that lowers severity of stress concentration. Results with various photoelastic models cut from polyurethane sheet led to novel diffusion-bond joint with reduced stress concentration.

Davis, R. C.↗
NASA NTRS1985

Advances in Joining Techniques Used in Development of SPF/DB Titanium Sandwich Reinforced with Metal Matrices

Three and four-sheet expanded titanium sandwich sheets have been developed at Douglas Aircraft Company, a division of McDonnell Douglas Corporation, under contract to NASA Langley Research Center. In these contracts, spot welding and roll seam welding are used to join the core sheets. These core sheets are expanded to the face sheets and diffusion bonded to form various type cells. The advantages of various cell shapes and the design parameters for optimizing the wing and fuselage concepts are discussed versus the complexity of the spot weld pattern. In addition, metal matrix composites of fibers in an aluminum matrix encapsulated in a titanium sheath are aluminum brazed successfully to the titanium sandwich face sheets. The strength and crack growth rate of the superplastic-formed/diffusion bonded (SPF/DB) titanium sandwich with and without the metal matrix composites are described.

Fischler, J. E.↗
NASA NTRS1987

Joining of ceramics for high temperature applications

Summarized is a literature survey of the methods for joining ceramics to ceramics or ceramics to metals for high temperature applications. Also mechanical properties and potential applications of the joints are considered. The joining of ceramics is usually carried out by brazing or diffusion bonding. Especially the latter has been found useful, increasing the application of bonded ceramics. The possibility of using electron beam and laser beam welding for joining ceramics has also recently been investigated. The bonding of ceramics has found numerous applications typical for high operating temperatures, i.e., sensors and thermocouples.

Vilpas, Martti↗
NASA NTRS1987

Advanced radiator concepts utilizing honeycomb panel heat pipes

The feasibility of fabricating and processing moderate temperature range vapor chamber type heat pipes in a low mass honeycomb panel configuration for highly efficient radiator fins for potential use on the space station was investigated. A variety of honeycomb panel facesheet and core-ribbon wick concepts were evaluated within constraints dictated by existing manufacturing technology and equipment. Concepts evaluated include type of material, material and panel thickness, wick type and manufacturability, liquid and vapor communication among honeycomb cells, and liquid flow return from condenser to evaporator facesheet areas. A thin-wall all-welded stainless steel design with methanol as the working fluid was the initial prototype unit. It was found that an aluminum panel could not be fabricated in the same manner as a stainless steel panel due to diffusion bonding and resistance welding considerations. Therefore, a formed and welded design was developed. The prototype consists of ten panels welded together into a large panel 122 by 24 by 0.15 in., with a heat rejection capability of 1000 watts and a fin efficiency of essentially 1.0.

Fleischman, G. L.↗
NASA NTRS1989

The influence of advanced processing on PWA 1480

High thermal gradient casting of PWA 1480 was evaluated as an avenue for reducing the size of casting porosity. Hot isostatic pressing (HIP) was also employed for the elimination of casting pores. An alternate to the standard PWA 1480 coating plus diffusion bonding aging heat treatment cycle was also evaluated for potential improvements in the properties of interest to the Space Shuttle Main Engine (SSME) application. Microstructural changes associated with the high thermal gradient casting process were quantified by measurement of the size and density of the casting porosity, the amount of retained casting eutectic, and dendrite arm spacings. The results of the advanced processing have shown an improvement in material microstructure due to high thermal gradient casting. Improved homogeneity of PWA 1480 is advantageous in providing an improved solution heat treatment window and, potentially, easier HIP. High thermal gradient casting improves fatigue life by reducing casting pore size. The alternate heat treatment improves the balance of strength and ductility which appears to improve low cycle fatigue life, but with a reduction in short time stress rupture life. Based upon these tests, hot isostatic pressing appears to afford further improvements in cyclic life, though additional evaluation is suggested. Development of the alternate heat treatment is not recommended due to the reduced stress rupture capability and the need to develop a new properties data base. High thermal gradient casting and HIP are recommended for application to single crystal castings.

Fritzemeier, L. G.↗
NASA NTRS1990

Advanced fabrication technology for high speed aircraft structures

An overview of the development of the weld-brazing process for fabricating Ti-6Al-4V skin-stiffened panels, a brazing process for fabricating Bsc/Al titanium honeycomb core panels, and the enhanced diffusion bonding (EDB) process for fabricating Ti-14Al-21Nb titanium aluminide structural elements are presented. Data presented include the shear strengths of full-scale weldbrazed Ti-6Al-4V skin stiffened and Bsc/Al titanium honeycomb core sandwich panels designed to meet the requirements of an upper wing panel on the NASA YF-12. These results verified that the materials, fabrication processes, and structural concepts were qualified for Mach 3 flight. Shear strengths of each of the panel concepts following flight service evaluation are also reported. Comparisons made with the cost and weight of the original wing panel indicated that the weldbrazed titanium panels resulted in a 15-20 percent cost savings and the brazed Bsc/Al panel showed a 30 percent weight savings. It was also shown that the strengths of the EDB joints were sufficient to develop stresses in the Ti-14Al-21Nb face sheets of the sandwich structure which were above the yield strength of the material.

Bales, T. T.↗
NASA NTRS1991

Preliminary studies on NiAl/Nb2Be17 reaction and effectiveness of BeO as an interfacial reaction barrier

The interfacial reaction between NiAl and Nb2Be17 (used as a reinforcement for the alloy) was studied by measuring diffusion bonding of NiAl and Nb2Be17 plates in a hot press under a vacuum of 10 exp -5 atm. It was found that, after 2 hrs of hot pressing at 1373 K, the reaction between NiAl and Nb2Be17 was extensive. A 40 to 50-micron-thick reaction zone consisted of three distinct layers at the NiAl/Nb2Be17 interface: layer A next to Nb2Be17, layer B in the middle, and layer C next to NiAl. Results of analysis of the reaction layers using energy dispersive spectroscopy (EDS) were inconclusive because of the inabiliaty of EDS to detect Be.

Misra, Ajay K.↗
NASA NTRS1992

NLS propulsion - Government view

The paper discusses the technology development for the Space Transportation Main Engine (STME). The STME is a liquid oxygen/liquid hydrogen engine with 650,000 pounds of thrust, which may be flown in single-engine or multiple-engine configurations, depending upon the payload and mission requirements. The technological developments completed so far include a vacuum plasma spray process, the liquid interface diffusion bonding, and a thin membrane platelet technology for the combustion chamber fabrication; baseline designs for the hydrogen turbopump and the oxygen pump; and the engine control system. The family of spacecraft for which this engine is being developed includes a 20,000 pound payload to LEO and a 150,000 pound to LEO vehicle.

Smelser, Jerry W.↗
NASA NTRS1993

Manufacturing Complicated Shells And Liners

Explosive forming, wax filling, and any one of welding, diffusion bonding, or brazing used in method of manufacturing large, complicated shell-and-liner vessels or structures. Method conceived for manufacture of film-cooled rocket nozzles but applicable to joining large coaxial shells and liners in general.

Sobol, Paul J.↗
NASA NTRS1992

Formed platelet combustor liner construction feasibility, phase A

Environments generated in high pressure liquid rocket engines impose severe requirements on regeneratively cooled combustor liners. Liners fabricated for use in high chamber pressures using conventional processes suffer from limitations that can impair operational cycle life and can adversely affect wall compatibility. Chamber liners fabricated using formed platelet technology provide an alternative to conventional regeneratively cooled liners (an alternative that has many attractive benefits). A formed platelet liner is made from a stacked assembly of platelets with channel features. The assembly is diffusion bonded into a flat panel and then three-dimensionally formed into a section of a chamber. Platelet technology permits the liner to have very precisely controlled and thin hot gas walls and therefore increased heat transfer efficiency. Further cooling efficiencies can be obtained through enhanced design flexibility. These advantages translate into increased cycle life and enhanced wall compatibility. The increased heat transfer efficiency can alternately be used to increase engine performance or turbopump life as a result of pressure drop reductions within the regeneratively cooled liner. Other benefits can be obtained by varying the materials of construction within the platelet liner to enhance material compatibility with operating environment or with adjoining components. Manufacturing cost savings are an additional benefit of a formed platelet liner. This is because of reduced touch labor and reduced schedule when compared to conventional methods of manufacture. The formed platelet technology is not only compatible with current state-of-the art combustion chamber structural support and manifolding schemes, it is also an enabling technology that allows the use of other high performance and potentially low cost methods of construction for the entire combustion chamber assembly. The contract under which this report is submitted contains three phases: (1) phase A - feasibility study and technology development; (2) phase B - sub-scale fabrication feasibility; and (3) phase C - large scale fabrication validation. This report covers the Phase A activities, which began in December of 1988.

Hayes, W. A.↗
NASA NTRS1993

Using rapid infrared forming to control interfaces in titanium-matrix composites

Control of the fiber-matrix reaction during composite fabrication is commonly achieved by shortening the processing time, coating the reinforcement with relatively inert materials, or adding alloying elements to retard the reaction. To minimize the processing time, a rapid IR forming (RIF) technique for metal-matrix composite fabrication has been developed. Experiments have shown that the RIF technique is a quick, simple, and low-cost process to fabricate titanium-alloy matrix composites reinforced with either silicon carbide or carbon fibers. Due to short processing times (typically on the order of 1-2 minutes in an inert atmosphere for composites with up to eight-ply reinforcements), the interfacial reaction is limited and well controlled. Composites fabricated by this technique have mechanical properties that are comparable to (in several cases, superior to) those made with conventional diffusion-bonding techniques.

Warrier, Sunil G.↗
NASA NTRS1992

Materials technology for Stirling space power converters

This program was conducted in support of the NASA LeRC development of the Stirling power converter (SPC) for space power applications. The objectives of this contract were: (1) to perform a technology review and analyses to support the evaluation of materials issues for the SPC; (2) to evaluate liquid metal compatibility issues of the SPC; (3) to evaluate and define a transient liquid phase diffusion bonding (TLPDB) process for the SPC joints to the Udimet 720 heater head; and (4) to evaluate alternative (to the TLPDB) joining techniques. In the technology review, several aspects of the current Stirling design were examined including the power converter assembly process, materials joining, gas bearings, and heat exchangers. The supporting analyses included GLIMPS power converter simulation in support of the materials studies, and system level analysis in support of the technology review. The liquid metal compatibility study evaluated process parameters for use in the Stirling power converter. The alternative joining techniques study looked at the applicability of various joining techniques to the Stirling power converter requirements.

Baggenstoss, William↗