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At least 235 records · Page 13

Diffusion Bonding of Silicon Carbide for a Micro-Electro-Mechanical Systems Lean Direct Injector

Robust approaches for joining silicon carbide (SiC) to silicon carbide sub-elements have been developed for a micro-electro-mechanical systems lean direct injector (MEMS LDI) application. The objective is to join SiC sub-elements to form a leak-free injector that has complex internal passages for the flow and mixing of fuel and air. Previous bonding technology relied upon silicate glass interlayers that were not uniform or leak free. In a newly developed joining approach, titanium foils and physically vapor deposited titanium coatings were used to form diffusion bonds between SiC materials during hot pressing. Microscopy results show the formation of well adhered diffusion bonds. Initial tests show that the bond strength is much higher than required for the component system. Benefits of the joining technology are fabrication of leak free joints with high temperature and mechanical capability.

Halbig, Michael C.↗

Releasable locking mechanisms

In the aerospace field spacecraft components are held together by separation systems until a specific time when they must be separated or deployed. Customarily a threaded joining bolt engages one of the components to be joined, and a threaded nut is placed on that bolt against the other component so they can be drawn together by a releasable locking assembly. The releasable locking assembly herein includes a plunger having one end coupled to one end of a plunger bolt. The other end is flanged to abut and compress a coil spring when the plunger is advanced toward the interface plane between the two components. When the plunger is so advanced toward the interface plane, the end of the plunger bolt can be connected to the joining bolt. Thus during retraction the joining bolt is drawn to one side of the interface plane by the force of the expanding spring.

Ahmed, Rafiq↗

Lead-acid battery

A sealed, low maintenance battery (10, 100) is formed of a casing (14, 102) having a sealed lid (12, 104) enclosing cell compartments (22, 110) formed by walls (24, 132). The cells comprise a stack (26) of horizontally disposed negative active plates (30) and positive active plates (28) interspersed with porous, resilient separator sheets (30). Each plate has a set of evenly spaced tigs (40, 41) disposed on one side thereof; like polarity tigs being disposed on one side and opposite polarity tigs on the other. Columns of tigs are electrically and mechanically joined by vertical bus bars (46). The bus bars contain outwardly projecting arms (56) of opposite polarity which are electrically joined at each partition wall (24) to electrically connect the cells in series. The stack is compressed by biasing means such as resilient pad (58) attached to the lid or by joining the tigs (52) to the post (48) at a distance less than the thickness of the mat (124). The end bus bars (46) are joined to straps (60, 62) which connect to the terminals (16, 18). The negative plates contain more capacity than the positive plates and the starved electrolyte imbibed in the separator sheets permits pressurized operation during which oxygen diffuses through the separator sheet to the negative plate where it recombines. Excess pressure is relieved through the vent and pressure relief valve (20).

Edwards, Dean B.↗

Development and Characterization of the Bonding and Integration Technologies Needed for Fabricating Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding technology, titanium interlayers (coatings and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness, and processing time were investigated. Electron microprobe analysis was used to identify the reaction formed phases. In the diffusion bonds, an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner interlayers of pure titanium and/or longer processing times resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Nondestructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig,Michael C.↗

Bonding and Integration Technologies for Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding, titanium interlayers (PVD and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness (10, 20, and 50 microns), processing time and temperature, and cooling rates were investigated. Microprobe analysis was used to identify the phases in the bonded region. For bonds that were not fully reacted an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner titanium interlayers and/or longer processing times resulted in stable and compatible phases that did not contribute to microcracking and resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Non-destructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig, Michael C.↗

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗

The Legacy and Future of the International Earth Science Constellation (ESC)

The most recent Decadal Survey placed high value on continuing constellation science. The ESC has evolved by seeing new missions joining and old missions retiring. Most recently, GCOM-W1, Landsat-8, and OCO-2 joined during 2012-2014. Landsat-9 is set to join in 2020. Each new mission provides new and improved suite of sensors. The new sensors also benefit both from the multitude of other existing on-orbit sensors as well as from the long-term cross-calibrated climate observations from the sensors that preceded them. At the same time, existing missions leave the constellation due to low fuel reserves or aging spacecraft subsystems. For example, CloudSat and CALIPSO left the ESC orbits in 2018, although they plan to continue making coordinated science observations at their new lower altitudes. This ESC evolution is expected to continue and this paper will discuss the opportunities for other new missions to join the ESC.

afternoon constellation↗

An Evening with NASA Scientists and Engineers: A Senior Living Community Outreach Program

Introduction: An Evening with NASA Scientists and Engineers is an outreach program for senior living communities, where participants learn from and interact with a scientist or engineer in a virtual setting. Participants learn about NASA science and engineering through a behind-the-scenes look from the people who work at NASA. The program focuses on both the stories behind the discoveries and the stories behind the people. The audience tunes in to the events via the NASA Zoom Webinar platform, where they have the opportunity to ask questions throughout the approximately 30-minute program. By bringing the audience into the conversation, we build rapport and thus improve their connection with NASA. Overview: An Evening with NASA Scientists and Engineers began in September 2020 when we identified a need for outreach to this particular demographic, as senior living communities had been hit especially hard by the COVID-19 pandemic. The program covers a wide range of topics, including heliophysics, astrophysics, planetary science, Earth science, planetary defense, and more, depending on what is topically appropriate at the time, and occurs on a roughly monthly basis. Each interactive presentation is between 20-25 minutes with 5-10 minutes of dedicated Q&A. Future dates and topics may change depending on new developments to NASA missions and stories. Audience: As of December 2021, we have four regularly attending senior living communities, spanning the East Coast from New Hampshire to Florida, with each joining the overall program at various stages of its development. The ability to reach many different senior living communities is crucial so that a diversity of people may benefit from this program. The audience consists of seniors with varying experience and comprehension levels – some are very familiar with the sciences while others are simply curious to learn more. Residents tune in to each event from their individual rooms or from their larger community rooms. RiverWoods Exeter. The RiverWoods Exeter community was our initial audience who acted as our “guinea pig” to see how this program might be implemented and to work out any major issues. They are located in Exeter, NH but also have two additional campuses in Durham, NH and Manchester, NH, that joined us a few months into the program. Culpepper Garden. Our second community to join the program was Culpepper Garden, a senior living community in Arlington, VA that provides both independent and assisted living housing to low-income seniors. Edinburgh Square. Our third community, Edinburgh Square, connected with us after hearing about the program through Culpepper Garden. Edinburgh Square is an HUD-subsidized retirement community in Roanoke, VA that houses both seniors and those living with disabilities. Moonstruck Astronomy Club. The Moonstruck Astronomy Club consists of residents from the On Top of the World retirement community in Ocala, FL and was the latest senior living community to join us. NASA Zoom Webinar: An Evening with NASA Scientists and Engineers reaches numerous senior living communities through live presentations that we host using the NASA Zoom Webinar virtual platform. Participants are typically already familiar with the Zoom platform which enables a lower barrier to entry. A recording of each talk is added to a designated video playlist on the NASA STEM YouTube channel so that audiences worldwide may view them [1]. These recordings began with our April 1, 2021 presentation, as this was when NASA Zoom Webinar was implemented, thus enabling us to record each talk. Metrics: We record attendance numbers from the senior living communities for each event as well as those from YouTube views after the presentation recording is posted online. Depending on which communities tune in, typical attendance numbers are between 60-100 people. RiverWoods Exeter has the most regularly attending residents, with an average of 55 attendees per event. As of December 2021, we have hosted fourteen events, nine of which were recorded and posted to our designated NASA STEM YouTube Channel playlist. The nine recordings combined have roughly 4,000 YouTube views thus far, with specific videos seeing higher view counts around launch dates (e.g. NASA’s DART mission) and trending topics (e.g. JWST). A list of speakers, topics, and links to presentation recordings is shown in Table 1. Future Program Expansion: Thus far, we have been adding communities on an individual basis. To make this process more streamlined, we are looking into working with senior living community networks and organizations such as LeadingAge [2]. In this manner, we will be able to reach more communities while also making it easier to send and receive relevant information.

S L Tiedeken↗

Welding in Space: Past, Present, and Future

It has been over fifty years since the first welds were made in space by Soviet cosmonauts on Soyuz-6 in October of 1969. The United States performed bead-on-plate welding, brazing, and metal melting experiments onboard the Skylab orbital space station several years later in 1973. Finally, Soviet cosmonauts departed their Salyut-7 capsule and made the first (and last) welds in open space in 1984. Progress on further demonstrations of welding in space stagnated, and subsequent microgravity welding research work shifted to lower-cost earth-based experiments that include drop towers and parabolic flights. With the advent of the International Space Station, relevant microgravity research was undertaken in the field of metal solidification science, and limited studies of brazing and soldering were undertaken; however, no welds have ever been on the Space Station. Therefore, it has been almost 40 years since a weld was made in space. Much like terrestrial construction and manufacturing industries, welding, joining, and allied processes will be enabling technologies for In-space Assembly and Manufacturing (ISAM) in the nascent “Space Economy”, a sector that is expected to approach a value of 10^12 USD within the next decade. It is critical that the welding and joining research community, along with the welding industry, engages the space industry to advance the understanding of those critical manufacturing processes which must be evaluated and matured in the extreme environments of space. Such environments include variable gravity (microgravity in low earth orbit, 0.17 gravity on the lunar surface, and 0.38 gravity on the martian surface), reduced pressure (extreme vacuum in space and the lunar surface to a predominantly CO2 atmosphere on Mars), and extreme temperatures (between 40 and 400 K). Past experiments and analyses are reviewed to suggest requirements that the welding and joining community should target to make strides on closing the current space welding gaps. Efforts to continue welding in space are currently underway at NASA in conjunction with academia and industry. Those are explored along with future agency goals which are seen as opportunities to engage the welding community on this historic effort.

in-space assembly and manufacturing↗

Development of dispersion-strengthened Ni-Cr-ThO2 alloys for the space shuttle thermal protection system.

An improved manufacturing process has been developed for TD-NiCr that provides sheet of improved quality, better gage control, and reproducible properties. A standard manufacturing process has been developed for the alternate alloy, DS-NiCr, produced by pack-chromizing Ni-2ThO2 sheet. Extension of forming and joining technology for TD-NiCr is in process. Formability criteria are being established for basic sheet forming processes related to the manufacture of Shuttle TPS panels. They include brake forming, corrugation forming, joggling, dimpling, and beading. Joining processes applicable to TPS panels are being optimized with emphasis on establishment of joint efficiencies. Resistance spot welding (fusion and solid state), resistance seam welding, solid-state diffusion welding, and brazing are included in the joining programs. Development of improved manufacturing technology for TD-NiCr fasteners is also being accomplished. Mechanical and physical properties of TD-NiCr are being characterized to provide design-allowable data.

Blankenship, C. P.↗

Self-adjusting assembly jig

Jig adjusts for thermal expansion and contraction to hold parts being joined under constant pressure and in correct alignment during entire joining operation. Jig is simple and easy to use, durable and maintenance free. Several methods may be used to join parts of many sizes and shapes.

Haaser, M. J.↗

Radial honeycomb core

Core alleviates many limitations of conventional nacelle construction methods. Radical core, made of metals or nonmetals, is fabricated either by joining nodes and then expanding, or by performing each layer and then joining nodes. Core may also be produced from ribbons or strips with joined nodes or ribbons oriented in longitudinal planes.

Cantley, R. B.↗

Compound solder joints

Joining technique prevents contamination, may be used to join dissimilar metal tubes, minimizes fluid and gas entrapment, expedites repairs, and can yield joints having leakage rates less than 0.000001 standard cubic cm He/min. Components of joint are solder sleeve, two solder rings, Teflon sleeve, and tubing to be joined.

Batista, R. I.↗

Reusable captive blind fastener

A one piece reusable fastener capable of joining materials together from one side (blind backside) comprises a screw driven pin ending in a wedge-shaped expander cone. The cone cooperates within a slotted collar end which has a number of tangs on a cylindrical body. The fastener is set by inserting it through aligned holes in the workpieces to be joined. Turning the pin in one direction draws the cone into the collar, deforming the tangs radially outward to mate with tapered back-tapered hold in the workpiece, thus fastening the two pieces together. Reversing the direction of the pin withdraws the cone from the collar, and allows the tangs to resume their contracted configuration without withdrawing the fastener from the insertion hole. The fastener is capable of joining materials together from only one side with substantial strength in tension and shear over many resue attachment cycles, with no special operations on the main assembly parts other than the tapering of the back end of the insertion hole.

Peterson, S. A.↗

Practical small-scale explosive seam welding

A small-scale explosive seam welding process has been developed that can significantly contribute to remote metal joining operations under hazardous or inaccessible conditions, such as nuclear reactor repair and assembly of structure in space. This paper describes this explosive seam welding process in terms of joining principles, variables, types of joints created, capabilities, and applications. Very small quantities of explosive in a ribbon configuration are used to create narrow (less than 0.5 inch), long-length, uniform, hermetically sealed joints that exhibit parent metal properties in a wide variety of metals, alloys, and combinations. The practicality of this process has been demonstrated by its current acceptance, as well as its capabilities that are superior in many applications to the universally accepted joining processes, such as mechanical fasteners, fusion and resistance welding, and adhesives.

Bement, L. J.↗

Practical small-scale explosive seam welding

A small-scale explosive seam welding process has been developed that can significantly contribute to remote metal joining operations under hazardous or inaccessible conditions, such as nuclear reactor repair and assembly of structure in space. This paper describes this explosive seam welding process in terms of joining principles, variables, types of joints created, capabilities, and applications. Very small quantities of explosive in a ribbon configuration are used to create narrow (less than 0.5 inch), long-length, uniform, hermetically sealed joints that exhibit parent metal properties in a wide variety of metals, alloys, and combinations. The practicality of this process has been demonstrated by its current acceptance, as well as its capabilities that are superior in many applications to the universally accepted joining processes, such as mechanical fasteners, fusion and resistance welding, and adhesives. Previously announced in STAR as N83-24896

Bement, L. J.↗

Derivation and test of elevated temperature thermal-stress-free fastener concept

Future aerospace vehicles must withstand high temperatures and be able to function over a wide temperature range. New composite materials are being developed for use in designing high-temperature lightweight structures. Due to the difference between coefficients of thermal expansion for the new composite materials and conventional high-temperature metallic fasteners, innovative joining techniques are needed to produce tight joints at all temperatures without excessive thermal stresses. A thermal-stress-free fastening technique is presented that can be used to provide structurally tight joints at all temperatures even when the fastener and joined materials have different coefficients of thermal expansion. The derivation of thermal-stress-free fasteners and joint shapes is presented for a wide variety of fastener materials and materials being joined together. Approximations to the thermal-stress-free shapes that result in joints with low-thermal-stresses and that simplify the fastener/joint shape are discussed. The low-thermal-stress fastener concept is verified by thermal and shear tests in joints using oxide-dispersion-strengthened alloy fasteners in carbon-carbon material. The test results show no evidence of thermal stress damage for temperatures up to 2000 F and the resulting joints carried shear loads at room temperature typical of those for conventional joints.

Sawyer, J. W.↗

Kinetics and thermodynamics of ceramic/metal interface reactions related to high T(sub c) superconducting applications

Superconducting ceramic materials, no matter what their form, size or shape, must eventually make contact with non-superconducting materials in order to accomplish current transfer to other parts of a real operating system, or for testing and measurement of properties. Thus, whether the configuration is a clad wire, a bulk superconducting disc, tape, or a thick or thin superconducting film on a substrate, the physical and mechanical behavior of interface (interconnections, joints, etc.) between superconductors and normal conductor materials of all kinds is of extreme importance to the technological development of these systems. Fabrication heat treatments associated with the particular joining process allow possible reactions between the superconducting ceramic and the contact to occur, and consequently influence properties at the interface region. The nature of these reactions is therefore of great broad interest, as these may be a primary determinant for the real capability of these materials. Research related both to fabrication of composite sheathed wire products, and the joining contacts for physical property measurements, as well as, a review of other related literature in the field are described. Comparison are made between 1-2-3, Bi-, and Tl-based ceramic superconductors joined to a variety of metals including Cu, Ni, Fe, Cr, Ag, Ag-Pd, Au, In, and Ga. The morphology of reaction products and the nature of interface degradation as a function of time will be highlighted.

Notis, Michael R.↗