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At least 271 records · Page 15

An Engineering Look at Space Shuttle and ISS Operations

This slide presentation, in Spanish, is an overview of NASA's Space Shuttle operations and preparations for serving the International Space Station. There is information and or views of the shuttle's design, the propulsion system, the external tanks, the foam insulation, the reusable solid rocket motors, the vehicle assembly building (VAB), the mobile launcher platform being moved from the VAB to the launch pad. There is a presentation of some of the current issues with the space shuttle: cracks in the LH2 flow lines, corrosion and pitting, the thermal protection system, and inspection of the thermal protection system while in orbit. The shuttle system has served for more than 20 years, it is still a challenge to re-certify the vehicles for flight. Materials and material science remain as chief concerns for the shuttle,

Hernandez, Jose M.↗

Grease-Resistant O Rings for Joints in Solid Rocket Motors

There is a continuing effort to develop improved O rings for sealing joints in solid-fuel rocket motors. Following an approach based on the lessons learned in the explosion of the space shuttle Challenger, investigators have been seeking O-ring materials that exhibit adequate resilience for effective sealing over a broad temperature range: What are desired are O rings that expand far and fast enough to maintain seals, even when metal sealing surfaces at a joint move slightly away from each other shortly after ignition and the motor was exposed to cold weather before ignition. Other qualities desired of the improved O rings include adequate resistance to ablation by hot rocket gases and resistance to swelling when exposed to hydrocarbon-based greases used to protect some motor components against corrosion. Five rubber formulations two based on a fluorosilicone polymer and three based on copolymers of epichlorohydrin with ethylene oxide were tested as candidate O-ring materials. Of these, one of the epichlorohydrin/ethylene oxide formulations was found to offer the closest to the desired combination of properties and was selected for further evaluation.

Harvey, Albert R.↗

Application of Emulsified Zero-Valent Iron to Marine Environments

Contamination of marine waters and sediments with heavy metals and dense non-aqueous phase liquids (DNAPLs) including chlorinated solvents, pesticides and PCBs pose ecological and human health risks through the contaminant's potential bioaccumulation in fish, shellfish and avian populations. The contaminants enter marine environments through improper disposal techniques and storm water run-off. Current remediation technologies for application to marine environments include costly dredging and off-site treatment of the contaminated media. Emulsified zero-valent iron (EZVI) has been proven to effectively degrade dissolved-phase and DNAPL-phase contaminants in freshwater environments on both the laboratory and field-scale level. However, the application to marine environments is only just being explored. This paper discusses the potential use of EZVI in brackish and saltwater environments, with supporting laboratory data detailed. Laboratory studies were performed in 2005 to establish the effectiveness of EZVI to degrade trichloroethylene (TCE) in saltwater. Headspace vials were setup to determine the kinetic rate of TCE degradation using EZVI in seawater. The reaction vials were analyzed by Gas Chromatographic/Flame Ionization Detection (GC/FID) for ethene production after a 48 day period using a GC/FID Purge and Trap system. Analytical results showed that EZVI was very effective at degrading TCE. The reaction by-products (ethene, acetylene and ethane) were produced at 71% of the rate in seawater as in the fresh water controls. Additionally, iron within the EZVI particles was protected from oxidation of the corrosive seawater, allowing EZVI to perform in an environment where zero-valent iron alone could not compete. Laboratory studies were also performed to establish the effectiveness of emulsified zero-valent metal (EZVM) to remove dissolved-phase cadmium and lead found in seawater. EZVM is comprised of a combination of magnesium and iron metal surrounded by the same oil/surfactant membrane used in EZVI. The removal of cadmium and lead from a seawater matrix is a unique challenge. It requires a system that is resistant to the corrosive nature of seawater while removing specific ions that are in a relatively low concentration compared to naturally occurring seawater salts. Laboratory studies conducted show greater than 99% removal of lead and 96% removal of cadmium from a seawater solution spiked at 5 mg/L that was treated with an Emulsified Zero-Valent Metal (EZVM). The cadmium and lead are removed from the solution as they transport across the emulsion membrane and plate out onto the zero-valent metal surface.

Brooks, Kathleen B.↗

Analysis of Launch Vehicle Liftoff Debris: Historical Perspective from Space Shuttle and Application to Artemis I

Human exploration-class launch vehicles are inherently prone to debris due to the extreme environments generated during pre-launch operations, liftoff, and flight. The use of cryogenic propellants often requires thermal protection system (TPS) coatings, typically foam, to maintain the propellant conditions in the tank and prevent an accumulation ice on the external surface of the vehicle. Some ice growth is to be expected at umbilical interfaces, vents, flanges, or brackets where it is difficult to apply TPS. This ice may come loose at any time due to wind on the launch pad, structural vibration and acoustics after rocket ignition, or aerodynamic forces during flight. This phenomena is especially apparent on vehicles with no TPS, such as the Saturn V rockets used in the Apollo Program, see Figure 1. During propellant tanking, the thermal contraction of the underlying substrate may generate cracks in the TPS (Figure 1). Chunks of TPS can release due to the expansion of ingested gas from cryopumping or from aerodynamic forces if the crack creates an offset surface. Most foams will also have a certain amount of “popcorning” where small pieces of foam will pop off during flight because of the differential between the static surface pressure and the pressure of the gas trapped in the foam cell structure. There are a number of other coating or closeout materials that may be shed from the vehicle and become debris. During pre-launch operations and liftoff, the vehicle may also be exposed to debris originating from the launch pad or ground support equipment. This debris is separate from foreign object debris, or FOD, which is not intended to be present and is strictly controlled through operations and maintenance procedures. In this case, debris is generated from hardware and materials that are necessary for launch and are subject to the intense vibration, acoustics, and direct plume impingement of the launch environment. Examples include ice from umbilicals, tape and tie wraps that protect cables, and rust or corrosion from the launch platform. While NASA has historically been aware of debris as a potential issue that could cause a failure resulting in loss of mission, loss of vehicle, or loss of crew, the likelihood and severity of that risk was not always well understood or given sufficient weight in program and flight decisions. After the Space Shuttle Columbia accident (STS-107), the investigation found that foam TPS debris shed from the external tank was the proximate cause of the damage to the orbiter wing. Six previous observations of debris released from the foam ramp that covered the bipod connecting the forward end of the orbiter to the external tank resulted in minor changes or were determined to be accepted flight risks. Two occurrences of bipod ramp foam loss were not identified until the STS-107 investigation. Despite the damage inflicted by these debris strikes, the Shuttle Program Requirements Control Board deemed the vehicle safe to fly. During the Return to Flight effort following the Columbia disaster, NASA Engineering developed a process for the assessment of debris transport, impact, and damage tolerance to support independent assessments of risk by NASA Safety and Mission Assurance (S&MA). Under this system, each element (vehicle or ground system) defines a catalog of all expected debris based on launch history, component testing, or analysis. Debris transport analysis (DTA) is conducted using the debris catalog characteristics and potential flow transport mechanisms (e.g., vehicle aerodynamics, gravity, wind, plume-driven). The predicted debris impact locations and velocities are provided to the hardware owners, who use available test data and analysis to determine whether each component can withstand the impacts. In cases where the element hardware may be severely damaged or fail, the options are to mitigate the debris source through some change in design or operation, or to work with S&MA to try to characterize the probability of the impact and damage for program risk acceptance. Because of the differences in debris characteristics and transport, the DTA has been divided between the Liftoff and Ascent regimes. The development and application of Liftoff DTA methodology from the Shuttle Program to the current Artemis Program is the subject of this paper. Liftoff DTA covers the time from the start of pre-launch operations at the launch pad, up until the vehicle clears the launch tower and there is no longer any interaction with ground systems. Debris transport during this period is broadly classified as either gravity, wind, and plume-entrained (GWPE) or plume driven (PD). GWPE debris is generally lower speed, travelling in a forward-to-aft direction. PD transport includes flow features from the rocket ignition transient, as well as plume impingement and recirculation that occur as the vehicle lifts off the launch platform. In these cases, the debris typically moves in an aft-to-forward direction at higher speeds. The applicable transport mechanisms must be considered for each piece of debris depending on the material, and release location and time. For example, rust or metallic debris from the tower could fall (GWPE) and impact the vehicle before landing on the launch platform deck where it could be also be transported by plume impingement (PD). However, falling ice (GWPE) from an umbilical is unlikely to survive impact with the vehicle or launch platform and be available for PD transport. Modeling of debris transport is accomplished using a set of DTA tools which simulate debris trajectories subject to a reference frame acceleration (i.e., gravity) and aerodynamic drag. Where the trajectory encounters a solid surface, the debris is allowed to rebound with a specified coefficient of restitution. The drag is calculated by interpolating the fluid state at each point in the debris trajectory from high-fidelity computational fluid dynamics (CFD) simulations of the launch vehicle and pad. The CFD data may either be static (steady state or time averaged), typically for GWPE transport, or dynamic (time-accurate) for PD flow features like the ignition transient. Examples of the CFD flow field solutions for the Space Launch System (SLS) rocket and launch pad are shown in Figure 2. Typical SLS debris trajectory predictions from DTA are illustrated in Figure 3. The final version of this paper will include a more detailed examination of the Liftoff DTA process developed during the Shuttle Program, and how it has been augmented and applied to the SLS rocket under the Artemis Program. Comparisons with debris observations from the Artemis I launch will demonstrate validation of the tools and methodology.

Debris↗

The corrosion mechanisms for primer coated 2219-T87 aluminum

To investigate metal surface corrosion and the breakdown of metal protective coatings, the ac Impedance Method was applied to zinc chromate primer coated 2219-T87 aluminum. The EG&GPARC Model 368 ac Impedance Measurement System, along with dc measurements with the same system using the Polarization Resistance Method, was used to monitor changing properties of coated aluminum disks immersed in 3.5 percent NaCl solutions buffered at pH 5.5 and pH 8.2 over periods of 40 days each. The corrosion system can be represented by an electronic analog called an equivalent circuit consisting of resistors and capacitors in specific arrangements. This equivalent circuit parallels the impedance behavior of the corrosion system during a frequency scan. Values for resistances and capacitances, that can be assigned in the equivalent circuit following a least squares analysis of the data, describe changes occurring on the corroding metal surface and in the protective coatings. A suitable equivalent circuit has been determined which predicts the correct Bode phase and magnitude for the experimental sample. The dc corrosion current density data are related to equivalent circuit element parameters.

Danford, Merlin D.↗

Environmental protection to 922K (1200 F) for titanium alloys

Evaluations are presented of potential coating systems for protection of titanium alloys from hot-salt stress-corrosion up to temperatures of 755 K (900 F) and from oxidation embrittlement up to temperature of 922 K (1200 F). Diffusion type coatings containing Si, Al, Cr, Ni or Fe as single coating elements or in various combinations were evaluated for oxidation protection, hot-salt stress-corrosion (HSSC) resistance, effects on tensile properties, fatigue properties, erosion resistance and ballistic impact resistance on an alpha and beta phase titanium alloy (Ti-6Al-2Sn-4Zr-2Mo). All of the coatings investigated demonstrated excellent oxidation protectiveness, but none of the coatings provided protection from hot-salt stress-corrosion. Experimental results indicated that both the aluminide and silicide types of coatings actually decreased the HSSC resistance of the substrate alloy. The types of coatings which have typically been used for oxidation protection of refractory metals and nickel base superalloys are not suitable for titanium alloys because they increase the susceptibility to hot-salt stress-corrosion, and that entirely new coating concepts must be developed for titanium alloy protection in advanced turbine engines.

Groves, M. T.↗

Environmentally Friendly Corrosion Preventative Compounds for Ground Support Structures

The need to use environmentally friendly technologies throughout future space-related launch programs prompted a study aimed at replacing current petroleum and solvent-based Corrosion Preventive Compounds (CPCs) with environmentally friendly alternatives. The work in this paper focused on the identification and evaluation of environmentally friendly CPCs for use in protecting flight hardware and ground support equipment from atmospheric corrosion. CPCs are used as temporary protective coatings and must survive in the aggressive coastal marine environment that exists throughout the Kennedy Space Center, Florida. The different protection behaviors of fifteen different oily film CPCs, both common petroleum-based and newer environmentally friendly types, were evaluated on various steel and aluminum substrates. CPC and substrate systems were subjected to atmospheric testing at the Kennedy Space Center's Beachside Atmospheric Corrosion Test Site, as well as cyclic accelerated corrosion testing. Each CPC also underwent physical characterization and launch-related compatibility testing. The results for the fifteen CPC systems are presented in this paper.

Montgomery Eliza L.↗

The Behavior of Environmentally Friendly Corrosion Preventative Compounds in an Aggressive Coastal Marine Environment

The shift to use environmentally friendly technologies throughout future space-related launch programs prompted a study aimed at replacing current petroleum and solvent-based Corrosion Preventive Compounds (CPCs) with environmentally friendly alternatives. The work in this paper focused on the identification and evaluation of environmentally friendly CPCs for use in protecting flight hardware and ground support equipment from atmospheric corrosion. The CPCs, while a temporary protective coating, must survive in the aggressive coastal marine environment that exists throughout the Kennedy Space Center, Florida. The different protection behaviors of fifteen different soft film CPCs, both common petroleum-based and newer environmentally friendly types, were evaluated on various steel and aluminum substrates. The CPC and substrate systems were subjected to atmospheric testing at the Kennedy Space Center's Beachside Atmospheric Corrosion Test Site, as well as cyclic accelerated corrosion testing. Each CPC also underwent physical characterization and launch-related compatibility testing . The initial results for the fifteen CPC systems are reported : Key words: corrosion preventive compound, CPC, spaceport, environmentally friendly, atmospheric exposure, marine, carbon steel, aluminum alloy, galvanic corrosion, wire on bolt.

Montgomery, Eliza L.↗

Pre-Demonstration Development of Controlled-Release Corrosion Inhibitors and Healing Agents as Alternatives to Hexavalent Chromium

This Limited Scope Study was directed to achieve the following objectives: (1) Scale-up of materials that can meet MIL-PRF-23377 (solvent-based primer). (2) Provide evidence of resistance to aircraft alkaline cleaners and deicing fluids. (3) Provide formulation for initial ecological and toxicity screening. (4) Submit an interim report that will provide the basis for a future ESTCP demonstration effort. The encapsulation procedure for two corrosion inhibitors was scaled up from lab scale to 2.0 kg. This scale will accommodate high volume production of coatings with encapsulated corrosion inhibitors for large surface areas during a follow on ESTCP demonstration effort. Test results provided evidence of resistance to alkaline cleaners and aircraft deicing fluids and compliance with MIL-PRF-23377. All the MIL-PRF-23377 requirements were met with the exception of the adhesion requirement, in top coated panels, and the flexibility requirement. Work on solving these two problems will be done prior to validation and demonstration of the technology. An initial ecological and toxicity screening identified several factors that were not critical to the acceptance of the encapsulated corrosion inhibitor. This new technology will lead to environmentally friendly alternatives to hexavalent chromium that will enable DoD to protect its assets. Field demonstration, licensing, qualification, and commercialization will allow its real world utilization.

Alternatives to Hexavalent Chromium↗

Status of the DOE/NASA critical gas turbine research and technology project

Activities performed in order to provide an R&T data base for utility gas turbine systems burning coal-derived fuels are described. Experiments were run to determine the corrosivity effects of trace metal contaminants (and potential fuel additives) on gas turbine materials and these results were correlated in a corrosion-life prediction model. Actual fuels were burned in a burner rig hot corrosion test to verify the model. A deposition prediction model was assembled and compared with results of actual coal-derived fuel deposition tests. Thermal barrier coatings were tested to determine their potential for protecting gas turbine hardware from the corrosive contaminants. Several coatings were identified with significantly improved spallation-resistance (and, hence, corrosion resistance).

Clark, J. S.↗

Grease Inhibits Stress-Corrosion Cracking In Bearing Race

Coating with suitable grease found to inhibit stress-corrosion cracking in bore of inner race of ball-bearing assembly operating in liquid oxygen. Protects bore and its corner radii from corrosion-initiating and -accelerating substances like moisture and contaminants, which enter during assembly. Operating life extended at low cost, and involves very little extra assembly time.

Beatty, Robert F.↗

Method of protecting a surface with a silicon-slurry/aluminide coating

A low cost coating for protecting metallic base system substrates from high temperatures, high gas velocity oxidation, thermal fatigue and hot corrosion is described. The coating is particularly useful for protecting vanes and blades in aircraft and land based gas turbine engines. A lacquer slurry comprising cellulose nitrate containing high purity silicon powder is sprayed onto the superalloy substrates. The silicon layer is then aluminized to complete the coating. The Si-Al coating is less costly to produce than advanced aluminides and protects the substrate from oxidation and thermal fatigue for a much longer period of time than the conventional aluminide coatings. While more expensive Pt-Al coatings and physical vapor deposited MCrAlY coatings may last longer or provide equal protection on certain substrates, the Si-Al coating exceeded the performance of both types of coatings on certain superalloys in high gas velocity oxidation and thermal fatigue. Also, the Si-Al coating increased the resistance of certain superalloys to hot corrosion.

Deadmore, D. L.↗

Hermetic Edge Seals for Photovoltaic Modules

Corrosive atmospheric agents excluded to prolong cell life. Combination of two sealing techniques makes possible to protect solar cells from water vapor, oxygen, and other corrosive atmospheric constituents. Using three-step process, glass-to-metal hermetic seal formed around edge of solar-cell module. Elastomer seals used previously not as effective because they are permeable to water vapor and atmospheric gases.

Nowlan, M. J.↗

LSP Composite Susbtrate Destructive Evaluation Test Assessment Manual

This document specifies the processes to perform post-strike destructive damage evaluation of tested CFRP panels.It is recognized that many factors besides lightning damage protection are involved in the selection of an appropriate Lightning Strike Protection (LSP) for a particular system (e.g., cost, weight, corrosion resistance, shielding effectiveness, etc.). This document strives primarily to address the standardized generation of damage protection performance data.

Kovach, Daniel J.↗

Liquid Coatings for Reducing Corrosion of Steel in Concrete

Inorganic coating materials are being developed to slow or stop corrosion of reinforcing steel members inside concrete structures. It is much simpler and easier to use these coating materials than it is to use conventional corrosion-inhibiting systems based on impressed electric currents. Unlike impressed electrical corrosion-inhibiting systems, these coatings do not require continuous consumption of electrical power and maintenance of power-supply equipment. Whereas some conventional systems involve the use of expensive arc-spray equipment to apply the metallic zinc used as the sacrificial anode material, the developmental coatings can be applied by use of ordinary paint sprayers. A coating material of the type under development is formulated as a liquid containing blended metallic particles and/or moisture-attracting compounds. The liquid mixture is sprayed onto a concrete structure. Experiments have shown that even though such a coat resides on the exterior surface, it generates a protective galvanic current that flows to the interior reinforcing steel members. By effectively transferring the corrosion process from the steel reinforcement to the exterior coating, the protective current slows or stops corrosion of the embedded steel. Specific formulations have been found to meet depolarization criteria of the National Association of Corrosion Engineers (NACE) for complete protection of steel reinforcing bars ("rebar") embedded in concrete.

MacDowell, Louis G.↗

Examination of the influence of coatings on thin superalloy sections

The effects of two coatings, Codep B-1 and CoCrAlY, with and without simulated engine exposures at 982 C (1800 F) and 1093 C (2000 F), were evaluated on cast sections of Rene 80. Section thicknesses were from 0.075 cm (0.030 inch) to 0.15 cm (0.060 inch). Tensile and stress rupture properties, mechanical fatigue, thermal fatigue, ballistic impact and hot corrosion at R. T. and elevated temperatures were investigated. Thin sections generally had poorer tensile strengths and lower stress rupture lives than standard 1/4 inch round gage bars. The coatings, as-applied, had little effect on tensile strengths, rupture lives and mechanical fatigue and they increased thermal fatigue, ballistic impact and hot corrosion resistance. By providing considerable exposure protection to the Rene 80, the coatings improved all properties compared to exposed bare specimens.

Kaufman, M.↗

Lightweight Long Life Heat Exchanger

A shuttle orbiter flight configuration aluminum heat exchanger was designed, fabricated, and tested. The heat exchanger utilized aluminum clad titanium composite parting sheets for protection against parting sheet pin hole corrosion. The heat exchanger, which is fully interchangeable with the shuttle condensing heat exchanger, includes slurpers (a means for removing condensed water from the downstream face of the heat exchanger), and both the core air passes and slurpers were hydrophilic coated to enhance wettability. The test program included performance tests which demonstrated the adequacy of the design and confirmed the predicted weight savings.

Moore, E. K.↗

Ampoule With Integral Feedthroughs

Bridgman-growth ampoule has molybdenum-to-quartz feedthroughs at both ends. Ampoule is vacuum-tight, protects exposed areas of furnace from corrosive vapors emanating from sample and at same time prevents changes in composition of melt due to preferential vaporization of one of components.

Crouch, R. K.↗