A status review of Lewis Research Center supported protection system development
Superalloy dispersion strengthened and fused slurry silicide coatings for aircraft gas turbine engines and space shuttle heat shields
Grisaffe, S. J.↗
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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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Silver-chlorine fuel cell: A concept
Fuel cell regenerated by photochemical reduction enables novel slurry system to transport particles of reduced silver between regenerator section and anode. Fundamental reactions which provide electrical power from the fuel cell are given.
Lieberman, M.↗
Oxidation/vaporization of silicide coated columbium base alloys
Mass spectrometric and target collection experiments were made at 1600 K to elucidate the mode of oxidative vaporization of two columbium alloys, fused-slurry-coated with a complex silicide former (Si-20Cr-Fe). At oxygen pressures up to 0.0005 torr the major vapor component detected by mass spectrometry for oxidized samples was gaseous silicon monoxide. Analysis of condensates collected at oxygen pressures of 0.1, 1.0 and 10 torr revealed that chromium-, silicon-, iron- and tungsten- containing species were the major products of vaporization. Equilibrium thermochemical diagrams were constructed for the metal-oxygen system corresponding to each constituent metal in both the coating and base alloy. The major vaporizing species are expected to be the gaseous oxides of chromium, silicon, iron and tungsten. Plots of vapor phase composition and maximum vaporization rate versus oxygen pressure were calculated for each coating constituent. The major contribution to weight loss by vaporization at oxygen pressures above 1 torr was shown to be the chromium-containing species.
Kohl, F. J.↗
Exploratory screening tests of several alloys and coatings for automobile thermal reactors
A total of 23 materials (including uncoated ferritic and austenitic iron-base alloys, uncoated nickel and cobalt-base superalloys, and several different coatings on AISI 304 stainless steel) were screened as test coupons on a rack in an automobile thermal reactor. Test exposures were generally 51 hours including 142 thermal cycles of 10 minutes at 1010 + or - 30 C test coupon temperature and 7-minutes cool-down to about 510 C. Materials that exhibited corrosion resistance better than that of Hastelloy X include: a ferritic iron alloy with 6 weight percent aluminum; three nickel-base superalloys; two diffused-aluminum coatings on AISI 304; and a Ni-Cr slurry-sprayed coating on AISI 304. Preliminary comparison is made on the performance of the directly impinged coupons and a reactor core of the same material.
Oldrieve, R. E.↗
Hydrogen plasma tests of some insulating coating systems for the nuclear rocket thrust chamber
Several plasma-sprayed and slurry-coated insulating coating systems were evaluated for structural stability in a low-pressure hot hydrogen environment at a maximum heat flux of 19.6 million watts/sq meter. The heat was provided by an electric-arc plasma generator. The coating systems consisted of a number of thin layers of metal oxides and/or metals. The materials included molybdenum, nichrome, tungsten, alumina, zirconia, and chromia. The study indicates potential usefulness in this environment for some coatings, and points up the need for improved coating application techniques.
Current, A. N.↗
Protective coatings for columbium applied in the field.
The various aspects of field repair of columbium alloy panels with protective coatings designed as part of the Space Shuttle thermal protection system are examined. The field repair of the coatings is accomplished by employing ceramic cement repairs, and reapplying the fused slurry silicide coating. Techniques are described which improve the practicality of these repairs by employing torch heating. The repair coating quality is demonstrated by testing which simulates flight temperature, pressure, stress and acoustic vibration conditions as a function of time. Conclusions on the present status of field repair coatings are presented and recommendations are given for appropriate future activities relative to the use on an operational Space Shuttle system.
Carter, J.↗
Development of uniform and predictable battery materials for nickel-cadmium aerospace cells
The objective of this study was to analyze battery materials and manufacturing methods with the aim of developing uniform and predictable battery plates for nickel cadmium aerospace cells. The results are presented of an extensive factorially-designed experiment aimed at illuminating, in a comparative study, the effect of plaque preparation, plaque thickness, impregnation process, and loading level with active material. The following impregnation processes were investigated: (1) chemical conversion, (2) electrochemical conversion, and (3) high temperature electrochemical impregnation. The test parameter on which the conclusion regarding the manufacturing variables are based was the capacity change during a simulated near-earth orbit cycle regime. As operational variables, the effect of various charge and discharge rates was investigated. During the 100 test cycles, overall capacity changes of positive plates and the differences between the various plates were found to be small. Plates prepared by the high temperature electrochemical impregnation of slurry-coated plaque (at the conditions used) showed surface buildup of active material. They also retained slightly less of their capacity during cycling compared to other plate preparations.
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The effect of residual stress on performance of high temperature coatings
Techniques for measurement of residual stress in MoSi2 coatings and the determination of stress in coatings prepared by metalliding, pack and slurry processes are discussed. The stress level can be determined by stress induced deflections or by X-ray techniques. The deflection method is most direct. It is based on the fact that a thin substrate, coated on one side only, is usually curved at room temperature. The radius of curvature is easily measured and readily related to residual stress.
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Development of an external ceramic insulation for the space shuttle orbiter. Part 2: Optimization
The basic insulation improvement study concentrated upon evaluating variables which could result in significant near-term gains in mechanical behavior and insulation effectiveness of the baseline system. The approaches undertaken included: evaluation of small diameter fibers, optimization of binder: slurry characteristics, evaluation of techniques for controlling fiber orientation, optimization of firing cycle, and the evaluation of methods for improving insulation efficiency. A detailed discussion of these basic insulation improvement studies is presented.
Tanzilli, R. A.↗
Modified fused silicide coatings for tantalum (Ta-10W) reentry heat shields
Results are presented of a program of research to develop a reliable, high performance, fused slurry silicide coating for the Ta-10W alloy. The effort was directed toward developing new and improved formulations for use at 2600 to 2800 F (1700 to 1811 K) in an atmospheric reentry thermal protection system with a 100-mission capability. Based on a thorough characterization of isothermal and cyclic oxidation behavior, bend transition temperatures, room- and elevated-temperature tensile properties, and creep behavior, a 2.5 Mn-33Ti-64.5Si coating (designated MTS) provides excellent protection for the Ta-10W alloy in simulated reentry environments. An extensive analysis of the oxidation behavior and characteristics of the MTS coating in terms of fundamental mechanisms also is presented.
Packer, C. M.↗
Application of EREP imagery to fracture-related mine safety hazards and environmental problems in mining
The author has identified the following significant results. Numerous fracture traces were detected on both the color transparencies and black and white spectral bands. Fracture traces of value to mining hazards analysis were noted on the EREP imagery which could not be detected on either the ERTS-1 or high altitude aircraft color infrared photography. Several areas of mine subsidence occurring in the Busseron Creek area near Sullivan, Indiana were successfully identified using color photography. Skylab photography affords an increase over comparable scale ERTS-1 imagery in level of information obtained in mined lands inventory and reclamation analysis. A review of EREP color photography permitted the identification of a substantial number of non-fuel mines within the Southern Indiana test area. A new mine was detected on the EREP photography without prior data. EREP has definite value for estimating areal changes in active mines and for detecting new non-fuel mines. Gob piles and slurry ponds of several acres could be detected on the S-190B color photography when observed in association with large scale mining operations. Apparent degradation of water quality resulting from acid mine drainage and/or siltation was noted in several ponds or small lakes and appear to be related to intensive mining activity near Sullivan, Indiana.
Wier, C. E.↗
Structure and function of an inorganic-organic separator for electrochemical cells: Preliminary study
The structure of a new separator material for electrochemical cells has been investigated. Investigation into details of the separator structure showed it to be multilayered and to consist mainly of a quasi-impervious organic skin, a porous region of mixed organic and inorganic material, and an area of nonuniformly treated substrate. The essential feature of the coating (slurry) is believed to be interconnected pores which allow ionic conductivity. The interconnected pores are believed to be formed by the interaction of the plasticizer and inorganic fibers. The major failure mode of silver zinc cells using such a separator (zinc nodules shorting adjacent plates) was investigated.
Bozek, J. M.↗
Development of sputtered techniques for thrust chambers, task 1
Filler materials proposed for use in the sputter fabrication regeneratively cooled thrust chambers were evaluated. Low melting castable alloys, CERROBEND. CERROCAST, and CERROTRU, slurry applied SERMETEL 481 and flame-sprayed aluminum were investigated as filler materials. Sputter deposition from a cylindrical cathode inverted magnestron was used to apply an OFHC copper closeout layer to filled OFHC copper ribbed-wall cylindrical substrates. The sputtered closeout layer structure was evaluated with respect to filler material contamination, predeposition machining and finishing operations, and deposition parameters. The application of aluminum by flame-spraying resulted in excessiver filler porosity. Though the outgassing from this porosity was found to be detrimental to the closeout layer structure, bond strengths in excess of 10,500 psi were achieved. Removal of the aluminum from the grooves was readily accomplished by leaching in a 7.0 molar solution of sodium hydroxide at 353 K. Of the other filler materials evaluated, CERROTRU was found to be the most suitable material with respect to completely filling the ribbed-wall cylinders and vacuum system compatibility. However, bond contamination resulted in low closeout layer bond strength with the CERROTRU filler. CERROBEND, CERROCAST, and SERMETEL 481 were found to be unacceptable as filler materials.
Mullaly, J. R.↗
Processing for obtaining good quality water from sewage
Sewage treatment method incorporates aqueous slurry of activated carbon and ash. Process eliminates smell and greatly reduces amounts of solids requiring disposal. Solids consist only of sterile ash.
Humphrey, M. F.↗
Manufacture and static firing of X259-E6 rocket motor serial number XJ04/0001
A single motor was cast and static fired to demonstrate the performance of high energy crosslinked double base (XLDB) propellant in standard X259 rocket motor hardware. Prior to motor fabrication, the motor was analyzed to predict the results of static firing the X259 motor loaded with XLDB propellant. As a result of the analyses, a forward dome shrinkage liner was added to the design. With this design change it was determined that adequate margins of safety existed. The motor, designated the X259-E6 model with serial number XJ04/0001, was fabricated using a slurry-casting technique and was assembled with a standard X259-B4 nozzle which had the nozzle throat machined to a smaller inside diameter than the B4 model and the exit cone cut short for Bacchus Works altitude expansion. The motor was static fired on 20 February 1974 with the nozzle failing during motor operation. Nozzle failure was attributed to spalling of the throat material leading to complete nozzle break-up. However, the propellant functioned as predicted in the motor chamber, ignition was normal, and char and erosion of the internal insulator were as expected.
Robertson, D. R.↗
Bonding of sapphire to sapphire by eutectic mixture of aluminum oxide and zirconium oxide
Bonding of an element comprising sapphire, ruby or blue sapphire to another element of such material with a eutectic mixture of aluminum oxide and zirconium oxide is discussed. The bonding mixture may be applied in the form of a distilled water slurry or by electron beam vapor deposition. In one embodiment the eutectic is formed in situ by applying a layer of zirconium oxide and then heating the assembly to a temperature above the eutectic temperature and below the melting point of the material from which the elements are formed. The formation of a sapphire rubidium maser cell utilizing eutectic bonding is shown.
Deluca, J. J.↗
Design, fabrication and testing of a wet oxidation waste processing system
The wet oxidation of sewage sludge during space flight was studied for water and gas recovery, and the elimination of overboard venting. The components of the system are described. Slurry and oxygen supply modules were fabricated and tested. Recommendations for redesign of the equipment are included.
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Aerosols at 20 kilometers altitude
Stratospheric aerosols were collected at the 20 km altitude zone by direct impaction on 0.2mm palladium wires in view of the previously observed minimum in particle size frequency distribution between 0.1 and 0.2 microns. Since no minimum in size distribution around 0.2 microns was found, it is concluded that previous equipment was inefficient in collection in this range. Concentration results suggest that low particle concentrations result from small particles agglomerating to form larger ones. Since no indentations were found on the wires used in this experiment, and since there were no differences in the number of particles found on oil-coated surfaces vs uncoated surfaces, the particles in the stratosphere must be liquid, liquid coated, or a slurry.
Ferry, G. V.↗