Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “MATERIALS EROSION”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Space Environmental Exposure of the MISSE 9-15 Polymers and Composites Experiment 1-4 (PCE 1-4)

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet (UV), x-ray and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation of susceptible materials threatening spacecraft performance and durability. To increase our understanding of effects such as AO erosion and radiation induced embrittlement of spacecraft materials, NASA Glenn Research Center has developed a series of experiments that were flown as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). These experiments have provided critical space environmental durability data such as AO erosion data of polymers and composites, and radiation induced mechanical property degradation of spacecraft insulation materials, after long term space exposure. Recently, four Glenn experiments with 365 flight samples were flown on ISS’s MISSE-Flight Facility (MISSE-FF). These experiments are the Polymers and Composites Experiment-1 (PCE-1) flown as part of the MISSE-9 mission, the PCE-2 flown as part of the MISSE-10 mission, the PCE-3 flown as part of the MISSE-12 and MISSE-15 missions, and the PCE-4 flown as part of the MISSE-13 mission. This paper provides details on the space environment exposure of Glenn’s PCE 1-4 flight samples. Passive samples were flown in each flight orientation for post-flight AO fluence determination and on-orbit contamination analyses. Solar exposure estimates were computed by Aegis Aerospace, Inc. The environment exposure details include the total space vacuum duration, time on the MISSE-FF, the direct space exposure duration, the AO fluence and the computed mission Equivalent Sun Hours (ESH) solar exposure. Typical on-orbit temperatures are also provided along with a summary of analyses of PCE 1-4 contamination witness samples. Knowledge of the space environmental exposure of the PCE 1-4 flight samples is crucial for flight data interpretation.

Atomic oxygen↗
NASA NTRSDate not supplied

Computational Investigation of Oxidative Etch Pitting in FiberForm and Its Impact on Material Properties

Oxidation-driven carbon erosion does not occur uniformly but rather through the development of localized etch pits at active surface sites. These active sites form due to atomic defects on the carbon surface, making them significantly more reactive than the surrounding, non-defective areas. As a result, these sites are the first to react during ablation, leading to their removal. This process creates new defects in neighboring atoms, increasing their reactivity and causing localized carbon removal around these active sites. In this way, the highly reactive defective areas serve as nucleation points for the formation and growth of etch pits, which can have adverse effects on structural integrity of FiberForm. To better understand how these etch pits impact the material properties of carbon fiber microstructures, we have developed a new capability within the direct simulation Monte Carlo (DSMC) framework to capture the etch pit formation process. This capability, integrated into the DSMC code SPARTA (Stochastic Parallel Rarefied-gas Time-accurate Analyzer), models material removal in the presence of active sites, leading to the formation of etch pits. The current work focuses on studying the effects of these etch pits on the material properties of FiberForm, a widely used base material in thermal protection systems (TPS). The microstructure of virgin FiberForm, obtained via X-ray microtomography, is imported into SPARTA to generate the ablated geometries with etch pits. These modified microstructures are then analyzed using the Porous Microstructure Analysis (PuMA) software to compute various material properties, including elasticity, thermal conductivity, and permeability. We investigate the variation of these properties due to the complex surface topology changes caused by etch pit formation. Additionally, we compare the effects of pitting with the conventional model of shrinking fibers, traditionally used to simulate the ablation of carbon structures. Significant differences emerge between the two approaches. Consequently, this physically realistic model of material removal through etch pit formation offers improved accuracy in predicting the degradation of carbon-based TPS during oxidation. It also provides insights into other mechanisms, such as spallation, where chunks of material are removed into the flow due to etch pit growth. Ultimately, this model enhances our understanding of failure modes in these materials during ablation.

PuMA↗
NASA NTRS1991

Effect of current ripple on cathode erosion in 30 kWe class arcjets

An investigation was conducted to study the effect of current ripple on cathode erosion in 30 kWe class arcjets to determine the change in the cathode erosion rate for high (11 percent) and low (4 percent) current ripple. The measurements were conducted using a copper-tungsten cathode material to accelerate the cathode erosion process. It is shown that the high ripple erosion rate was initially higher than the low ripple erosion rate, but decreased asymptotically with time to a level less than half that of the low ripple value. Results suggest that high ripple extends the cathode lifetime for long duration operation, and improves arc stability by increasing the cathode attachment area.

Harris, William J.↗
NASA NTRS2016

Post-Test Inspection of NASA's Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge and Neutralizer Cathodes

The NEXT Long-Duration Test is part of a comprehensive thruster service life assessment intended to demonstrate overall throughput capability, validate service life models, quantify wear rates as a function of time and operating condition, and identify any unknown life-limiting mechanisms. The test was voluntarily terminated in February 2014 after demonstrating 51,184 hours of high-voltage operation, 918 kg of propellant throughput, and 35.5 MN-s of total impulse. The post-test inspection of the thruster hardware began shortly afterwards with a combination of non-destructive and destructive analysis techniques, and is presently nearing completion. This paper presents relevant results of the post-test inspection for both discharge and neutralizer cathodes. Discharge keeper erosion was found to be significantly reduced from what was observed in the NEXT 2 kh wear test and NSTAR Extended Life Test, providing adequate protection of vital cathode components throughout the test with ample lifetime remaining. The area of the discharge cathode orifice plate that was exposed by the keeper orifice exhibited net erosion, leading to cathode plate material building up in the cathode-keeper gap and causing a thermally-induced electrical short observed during the test. Significant erosion of the neutralizer cathode orifice was also found and is believed to be the root cause of an observed loss in flow margin. Deposition within the neutralizer keeper orifice as well as on the downstream surface was thicker than expected, potentially resulting in a facility-induced impact on the measured flow margin from plume mode. Neutralizer keeper wall erosion on the beam side was found to be significantly lower compared to the NEXT 2 kh wear test, likely due to the reduction in beam extraction diameter of the ion optics that resulted in decreased ion impingement. Results from the post-test inspection have led to some minor thruster design improvements.

Electric Propulsion↗
NASA NTRS2021

Post-test Inspection of NASA’s Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge and Neutralizer Cathodes

The NEXT Long-Duration Test is part of a comprehensive thruster service life assessment intended to demonstrate overall throughput capability, validate service life models, quantify wear rates as a function of time and operating condition, and identify any unknown life-limiting mechanisms. The test was voluntarily terminated in February 2014 after demonstrating 51,184 h of high-voltage operation, 918 kg of propellant throughput, and 35.5 MN-s of total impulse. The post-test inspection of the thruster hardware began shortly afterwards with a combination of non-destructive and destructive analysis techniques, and is presently nearing completion. This paper presents relevant results of the post-test inspection for both discharge and neutralizer cathodes. Discharge keeper erosion was found to be significantly reduced from what was observed in the NEXT 2 kh wear test and NSTAR Extended Life Test, providing adequate protection of vital cathode components throughout the test with ample lifetime remaining. The area of the discharge cathode orifice plate that was exposed by the keeper orifice exhibited net erosion, leading to cathode plate material building up in the cathode-keeper gap and causing a thermally-induced electrical short observed during the test. Significant erosion of the neutralizer cathode orifice was also found and is believed to be the root cause of an observed loss in flow margin. Deposition within the neutralizer keeper orifice as well as on the downstream surface was thicker than expected, potentially resulting in a facility-induced impact on the measured flow margin from plume mode. Neutralizer keeper wall erosion on the beam side was found to be significantly lower compared to the NEXT 2 kh wear test, likely due to the reduction in beam extraction diameter of the ion optics that resulted in decreased ion impingement. Results from the post-test inspection have led to some minor thruster design improvements.

Ion engine↗
NASA NTRS1976

Energy Conversion Alternatives Study (ECAS), Westinghouse phase 1. Volume 2: Materials considerations

Extensive studies are presented which were carried out on materials behavior in nine advanced energy conversion systems employing coal and coal-derived fuels. The areas of materials behavior receiving particular attention in this regard are: (1) fireside corrosion and erosion in boiler and heat exchanger materials, (2) oxidation and hot corrosion of gas turbine materials, (3) liquid metal corrosion and mass transport, (4) high temperature steam corrosion, (5) compatability of materials with coal slag and MHD seed, (6) reaction of materials with impure helium, (7) allowable stresses for boiler and heat exchanger materials, (8) environmental effects on mechanical properties, and (9) liquid metal purity control and instrumentation. Such information was then utilized in recommending materials for use in the critical components of the power systems, and at the same time to identify materials problem areas and to evaluate qualitatively the difficulty of solving those problems. Specific materials recommendations for critical components of the nine advanced systems under study are contained in summary tables.

Thomas, D. E.↗
NASA NTRS1975

Solid rocket motor nozzles

The steps in the nozzle design process are examined. The nozzle designer's role in defining design requirements and constraints is included along with discussions of each of the three basic phases of the nozzle design process itself: (1) aerodynamic design, in which the gas-contacting surfaces are configured to produce the required performance within the envelope limits; (2) thermal design, in which termal liners and thermal insulators are selected and configured to maintain the surfaces as closely as practical against effects of erosion and to limit the structure temperature to acceptable levels; and (3) structural design, in which materials are selected and configured to support the thermal components and to sustain the predicted loads. Analytical techniques that are used to establish thermal and structural design integrity and to predict nozzle performance are discussed along with methods for nozzle quality assurance. Emphasis is placed on nozzle design and materials for modern high-temperature aluminized propellants. Recurring nozzle design problems of graphite cracking and ejection, differential erosion at material interfaces, lack of sufficient proven nondestructive testing (NDT) techniques, the uncertainty of adhesive bonding, and inadequate definition of material properties, particularly at high temperatures are considered.

Ellis, R. A.↗
NASA NTRS1988

Soil erosion and causative factors at Vandenberg Air Force Base, California

Areas of significant soil erosion and unvegetated road cuts were identified and mapped for Vandenberg Air Force Base. One hundred forty-two eroded areas (most greater than 1.2 ha) and 51 road cuts were identified from recent color infrared aerial photography and ground truthed to determine the severity and causes of erosion. Comparison of the present eroded condition of soils (as shown in the 1986 photography) with that in historical aerial photography indicates that most erosion on the base took place prior to 1928. However, at several sites accelerated rates of erosion and sedimentation may be occurring as soils and parent materials are eroded vertically. The most conspicuous erosion is in the northern part of the base, where severe gully, sheet, and mass movement erosion have occurred in soils and in various sedimentary rocks. Past cultivation practices, compounded by highly erodible soils prone to subsurface piping, are probably the main causes. Improper range management practices following cultivation may have also increased runoff and erosion. Aerial photography from 1986 shows that no appreciable headward erosion or gully sidewall collapse have occurred in this area since 1928.

Butterworth, Joel B.↗
NASA NTRS2018

Materials International Space Station Experiment-9 (MISSE-9) Polymers and Composites Experiment

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet, x-ray, and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation, threatening spacecraft performance and durability. To increase our understanding of effects such as AO erosion and radiation induced embrittlement of spacecraft materials, NASA Glenn has developed a series of experiments flown as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). These experiments have provided critical LEO space environment durability data such as AO erosion data for many materials and mechanical properties changes after long term space exposure. In continuing these studies, a new experiment called the Polymers and Composites Experiment has been selected for flight on the MISSE-Flight Facility (MISSE-FF). The Polymers and Composites Experiment will be flown as part of the MISSE-9 mission, the inaugural mission of MISSE-FF manifested on SpaceX-14. This experiment includes 138 samples being flown in ram, wake or zenith orientations for space environmental durability assessment. The primary objective is to determine the LEO AO erosion yield, Ey (the volume loss per incident oxygen atom (cm3/atom)), of polymers, composites, and coated samples, as a function of solar irradiation and AO fluence. In addition, epoxy samples with varying levels of ZnO powder are included to study the effect of filler quantity on AO erosion. An AO Scattering Chamber is included to help improve the understanding of AO scattering mechanisms for improved AO undercutting modeling. Indium tin oxide (ITO) coated samples are included to validate the durability of ITO conductive coatings in LEO. Tensile samples of Teflon fluorinated ethylene propylene (FEP) of varying thicknesses and back-surface coatings will be flown in wake and zenith orientations to study radiation embrittlement versus thickness, and the effect of heating on FEP embrittlement. Finally, shape memory composite and cosmic ray shielding samples will be flown for LEO durability assessment. This paper presents an overview of the MISSE-9 Polymers and Composites Experiment.

Embrittlement↗
NASA NTRS1991

Effects of LDEF flight exposure on selected polymeric films and thermal control coatings

The characterization of polymeric films and thermal control coatings which were exposed for five years and ten months to the low-Earth environment is reported. Changes in solar absorptance, thermal emittance, and transmission are compared to laboratory control specimens. Sputter-deposited metallic coatings are shown to eliminate atomic oxygen erosion of resin matrix composite materials. The effects of long-term atomic oxygen exposure to metallized FEP Teflon film is characterized. Chemical characterization of polymeric films indicates that although surface erosion occurs, the molecular structure of the basic polymeric film has not changed significantly in response to this exposure.

Slemp, Wayne S.↗
DOE OSTI2019

Modeling of inter- and intra-edge-localized mode tungsten erosion during DIII-D H-mode discharges

The relationship between the tungsten gross erosion and the ELM characteristics is investigated for high performance (H-mode) discharges during the dedicated Metal Rings Campaign in DIII-D, using the one-dimensional ‘free-streaming’ ELM model, coupled to a simple analytical TRIM.SP sputtering model, while the OEDGE code is employed to calculate the inter-ELM impurity distribution and tungsten gross erosion. A carbon-tungsten mixed target material is used for both inter- and intra-ELM simulations. The OEDGE results reveal that the inter-ELM tungsten gross erosion rate is not sensitive to the carbon fraction on the tungsten surface layer; a wider range of carbon fractions from 0.3 to 0.6 give similar tungsten gross erosion profiles and match the diagnostic data, which is consistent with the simple analytical model. However, the intra-ELM simulation indicates that the value of surface carbon fraction can be as low as 0.3 to reproduce the measured tungsten gross erosion during ELMs, based on the effective ionizations/photon (S/XB) value of WI emissions. Finally, for both inter- and intra-ELM cases, carbon is predicted to dominate the tungsten erosion. However, in contrast to the inter-ELM tungsten erosion, which is dominated by locally redeposited C 2+ , the energetic C 6+ originating from the pedestal can contribute substantial tungsten erosion in the near-separatrix region during ELMs, and the width of this C 6+ dominated region exhibits a negative correlation with the heat flux density carried by ELMs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2002

Thermostructural Analysis of Carbon Cloth Phenolic Material Tested at the Laser Hardened Material Evaluation Laboratory

RSRM nozzle liner components have been analyzed and tested to explore the occurrence of anomalous material performance known as pocketing erosion. Primary physical factors that contribute to pocketing seem to include the geometric permeability, which governs pore pressure magnitudes and hence load, and carbon fiber high temperature tensile strength, which defines a material limiting capability. The study reports on the results of a coupled thermostructural finite element analysis of Carbon Cloth Phenolic (CCP) material tested at the Laser Hardened Material Evaluation Laboratory (the LHMEL facility). Modeled test configurations will be limited to the special case of where temperature gradients are oriented perpendicular to the composite material ply angle. Analyses were conducted using a transient, one-dimensional flow/thermal finite element code that models pore pressure and temperature distributions and in an explicitly coupled formulation, passes this information to a 2-dimensional finite element structural model for determination of the stress/deformation behavior of the orthotropic fiber/matrix CCP. Pore pressures are generated by thermal decomposition of the phenolic resin which evolve as a multi-component gas phase which is partially trapped in the porous microstructure of the composite. The nature of resultant pressures are described by using the Darcy relationships which have been modified to permit a multi-specie mass and momentum balance including water vapor condensation. Solution to the conjugate flow/thermal equations were performed using the SINDA code. Of particular importance to this problem was the implementation of a char and deformation state dependent (geometric) permeability as describing a first order interaction between the flow/thermal and structural models. Material property models are used to characterize the solid phase mechanical stiffness and failure. Structural calculations were performed using the ABAQUS code. Iterations were made between the two codes involving the dependent variables temperature, pressure and across-ply strain level. Model results comparisons are made for three different surface heat rates and dependent variable sensitivities discussed for the various cases.

Clayton, J. Louie↗
DOE OSTI2021

Control of the Plasma-Material Interface for Long Pulse Optimization in EAST and KSTAR

This project's major goal was to understand and control the plasma-material interface to improve long pulse discharge and performance in the EAST and KSTAR devices, emphasizing the unique strengths of each machine. In particular, MIT has developed implanted depth markers to diagnose the net erosion of high-Z materials. The goals included the characterization and utilization of these markers in various high-Z materials of interest, including TZM, tungsten, and refractory metal base high entropy alloys.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1986

Contribution to the study of the electric arc: Erosion of metallic electrodes

A procedure is described for determining the extent of arc electrode erosion (excluding erosion due to transfer of material) from measurements of emitted spectral beam intensity. The relation between emission intensity and plasma temperature is ascertained. Experimental study of several combinations of monometallic electrodes shows that the method is suitable for determining cathode erosion, although the anode metal affects the extent of erosion. Combinations of electrodes which lead to low erosion of silver are reported.

Castro, A.↗
NASA NTRS2024

Analyses of the MISSE 9-15 Polymers and Composites Experiment 1-4 (PCE 1-4) Contamination Samples

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet (UV), x-ray and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation of susceptible materials threatening spacecraft performance and durability. To increase our understanding of environmental effects such as AO erosion and radiation induced embrittlement of spacecraft materials, NASA Glenn Research Center developed a series of experiments that were flown as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). Recently, four Glenn experiments with 365 flight samples were flown on ISS’s MISSE-Flight Facility (MISSE-FF). These experiments are the Polymers and Composites Experiment-1 (PCE-1) flown as part of the MISSE-9 mission, the PCE-2 flown as part of the MISSE-10 mission, the PCE-3 flown as part of the MISSE-12 and MISSE-15 missions, and the PCE-4 flown as part of the MISSE-13 mission. Each of these experiments included passive contamination witness samples in each flight direction for post-flight molecular contamination analyses. A total of 13 contamination flight samples were flown. The post-flight analyses of the PCE 1-4 contamination samples include X-ray Photoelectron Spectroscopy (XPS) analyses (surface and ion sputter depth analyses) and optical properties (total reflectance, total transmittance and solar absorptance). This paper provides results of post-flight analyses of the PCE 1-4 contamination samples and their corresponding control samples. Knowledge of on-orbit contamination is important for the PCE 1-4 flight data interpretation.

Atomic Oxygen↗
DOE OSTI2026

Cr plasma-material-interaction in PISCES-RF: D thermal release, retention, and erosion

Pure chromium (Cr) targets were exposed to high-flux deuterium (D) plasmas in the Pisces-RF linear plasma device, and measurements of D retention, release, and erosion were subsequently performed. Post-exposure D retention was quantified using temperature-programmed desorption on Cr targets irradiated by 50 eV ions over a broad range of exposure temperatures (423–873 K) and ion fluences (3 × 10 24 – 3 × 10 26 m −2 ). The retained D inventory was observed to decrease rapidly with increased exposure temperature, from approximately ∼7 × 10 20 m −2 at ∼ 420 K, to then saturate near ∼ 10 20 m −2 for exposure temperatures above ∼550 K. Separately, at fixed exposure temperature (∼450 K), D retention was found to have only a weak dependence on increasing ion fluence. Lastly, the erosion of Cr in D plasma was investigated for ion impact energies in the range 40 ≤ E i ≤ 250 eV. Erosion was inferred using optical emission spectroscopy (OES) from the ratio of emission lines (Cr I (425.4 nm)/D I (656.1 nm)) measured close to the target. Conversion of the OES yield data to net erosion yield was made with singular ion energy target mass-loss measurements. These net erosion yield data were then further corrected to obtain gross erosion yield by accounting for a re-deposition factor, computed using a simple model. The gross erosion yield is found to be 2–4 times lower than predicted by SDTrimSP, consistent with that typically observed for light-ion sputtering under high-flux plasma conditions.

Chromium↗