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At least 307 records · Page 17

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NASA NTRS1997

On-Board Chemical Propulsion

NASA Lewis Research Center's On-Board Propulsion program (OBP) is developing low-thrust chemical propulsion technologies for both satellite and vehicle reaction control applications. There is a vigorous international competition to develop new, highperformance bipropellant engines. High-leverage bipropellant systems are critical to both commercial competitiveness in the international communications market and to cost-effective mission design in government sectors. To significantly improve bipropellant engine performance, we must increase the thermal margin of the chamber materials. Iridium-coated rhenium (Ir/Re) engines, developed and demonstrated under OBP programs, can operate at temperatures well above the constraints of state-of-practice systems, providing a sufficient margin to maximize performance with the hypergolic propellants used in most satellite propulsion systems.

Schneider, Steven J.↗

NASA NTRS1999

Deleterious Phase Formation in Next- Generation Nickel-Base Superalloys Predicted

Nickel- (Ni-) base superalloy single crystals represent the state-of-the-art for turbine engine airfoil applications because they offer the best balance of properties under the high operating temperatures required for efficient engine operation. Current trends in alloy design take advantage of improved creep rupture strength with the addition of higher levels of refractory elements. In particular, the addition of significantly higher levels of rhenium in third-generation superalloys is key for both microstructural stability and creep rupture strength. Although refractories provide strength benefits, alloys tend to be unstable when their refractory content is high because of topologically close-packed (TCP) phases. The formation of these phases in sufficient amount is detrimental to the performance of these alloys because of their brittle nature and because they deplete the Nirich matrix of potent solid-solution strengthening elements.

Ritzert, Frank J.↗

NASA NTRS1998

Integrated Solar Upper Stage Technical Support

NASA Lewis Research Center is participating in the Integrated Solar Upper Stage (ISUS) program. This program is a ground-based demonstration of an upper stage concept that will be used to generate both solar propulsion and solar power. Solar energy collected by a primary concentrator is directed into the aperture of a secondary concentrator and further concentrated into the aperture of a heat receiver. The energy stored in the receiver-absorber-converter is used to heat hydrogen gas to provide propulsion during the orbital transfer portion of the mission. During the balance of the mission, electric power is generated by thermionic diodes. Several materials issues were addressed as part of the technical support portion of the ISUS program, including: 1) Evaluation of primary concentrator coupons; 2) Evaluation of secondary concentrator coupons; 3) Evaluation of receiver-absorber-converter coupons; 4) Evaluation of in-test witness coupons. Two different types of primary concentrator coupons were evaluated from two different contractors-replicated coupons made from graphite-epoxy composite and coupons made from microsheet glass. Specular reflectivity measurements identified the replicated graphite-epoxy composite coupons as the primary concentrator material of choice. Several different secondary concentrator materials were evaluated, including a variety of silver and rhodium reflectors. The specular reflectivity of these materials was evaluated under vacuum at temperatures up to 800 C. The optical properties of several coupons of rhenium on graphite were evaluated to predict the thermal performance of the receiver-absorber-converter. Finally, during the ground test demonstration, witness coupons placed in strategic locations throughout the thermal vacuum facility were evaluated for contaminants. All testing for the ISUS program was completed successfully in 1997. Investigations related to materials issues have proven helpful in understanding the operation of the test article, leading to a potential ISUS flight test in 2002.

Jaworske, Donald A.↗

NASA NTRS2004

Feasibility of EB Welded Hastelloy X and Combination of Refractory Metals

As NASA continues to expand its horizon, exploration and discovery creates the need of advancement in technology. The Jupiter Icy Moon Orbiter's (JIMO) mission to explore and document the outer surfaces, rate the possibility of holding potential life forms, etc. within the three moons (Callisto, Ganymede, and Europa) proves to be challenging. The orbiter itself consists of many sections including: the nuclear reactor and the power conversion system, the radiator panels, and the thrusters and antenna. The nuclear reactor serves as a power source, and if successfully developed, can operate for extended periods. During the duration of my tenure at NASA Glenn Research Center's (NASA GRC) Advanced Metallics Branch, I was assigned to assist Frank J. Ritzert on analyzing the feasibility of the Electron Beam Welded Hastelloy X (HX), a nickel-based superalloy, to Niobium- 1 %Zirconium (Nb-1 Zr) and other refractory metals/alloys including Tantalum, Molybdenum, Tungsten, and Rhenium alloys. This welding technique is going to be used for the nuclear reactor within JIMO.

Martinez, Diana A.↗

NASA NTRS2006

Vacuum Plasma Spray (VPS) Material Applications for Thruster Components

A variety of vacuum plasma spray (VPS) material systems have been successfully applied to injector and thrust chamber components. VPS offers a versatile fabrication process with relatively low costs to produce near net shape parts. The materials available with VPS increase operating margins and improve component life by providing superior thermal and oxidation protection in specific engine environments. Functional gradient materials (FGM) formed with VPS allow thrust chamber liners to be fabricated with GRCop-84 (an alloy of copper, chrome, and niobium) and a protective layer of NiCrAlY on the hot wall. A variety of thrust chamber liner designs have been fabricated to demonstrate the versatility of the process. Hot-fire test results have confirmed the improved durability and high temperature performance of the material systems for thrust chamber liners. Similar FGM s have been applied to provide superior thermal protection on injector faceplates with NiCrAlY and zirconia coatings. The durability of the applied materials has been demonstrated with hot-fire cycle testing on injector faceplates in high temperature environments. The material systems can benefit the components used in booster and main engine propulsion systems. More recent VPS efforts are focused on producing rhenium based material systems for high temperature applications to benefit in-space engines like reaction control system (RCS) thrusters.

Elam, Sandra↗

NASA NTRS2006

Vacuum Plasma Spray (VPS) Material Applications for Thruster Components

A variety of vacuum plasma spray (VPS) material systems have been successfully applied to injector and thrust chamber components. VPS offers a versatile fabrication process with relatively low costs to produce near net shape parts. The materials available with VPS increase operating margins and improve component life by providing superior thermal and oxidation protection in specific engine environments. Functional gradient materials (FGM) formed with VPS allow thrust chamber liners to be fabricated with GRCop-84 (an alloy of copper, chrome, and niobium) and a protective layer of NiCrAlY on the hot wall. A variety of thrust chamber liner designs have been fabricated to demonstrate the versatility of the process. Hot-fire test results have confined the improved durability and high temperature performance of the material systems for thrust chamber liners. Similar FGM s have been applied to provide superior thermal protection on injector faceplates with NiCrAlY and zirconia coatings. The durability of the applied materials has been demonstrated with hot-fire cycle testing on injector faceplates in high temperature environments. The material systems can benefit the components used in booster and main engine propulsion systems. More recent VPS efforts are focused on producing rhenium based material systems for high temperature applications to benefit in-space engines like reaction control system (RCS) thrusters.

Elam, Sandra↗

NASA NTRS2006

Net Shaped Component Fabrication of Refractory Metal Alloys using Vacuum Plasma Spraying

The vacuum plasma spraying (VPS) technique was employed to produce dense and net shaped components of a new tungsten-rhenium (W-Re) refractory metal alloy. The fine grain size obtained using this technique enhanced the mechanical properties of the alloy at elevated temperatures. The alloy development also included incorporation of thermodynamically stable dispersion phases to pin down grain boundaries at elevated temperatures and thereby circumventing the inherent problem of recrystallization of refractory alloys at elevated temperatures. Requirements for such alloys as related to high temperature space propulsion components will be discussed. Grain size distribution as a function of cooling rate and dispersion phase loading will be presented. Mechanical testing and grain growth results as a function of temperature will also be discussed.

Sen, S.↗

NASA NTRS1998

High temperature thrust chamber for spacecraft

A high temperature thrust chamber for spacecraft (20) is provided herein. The high temperature thrust chamber comprises a hollow body member (12) having an outer surface and an internal surface (16) defining the high temperature chamber (10). The body member (12) is made substantially of rhenium. An alloy (18) consisting of iridium and at least alloying metal selected of the group consisting of rhodium, platinum and palladium is deposited on at least a portion of the internal surface (16) of the body member (12). The iridium and the alloying metal are electrodeposited onto the body member (12). A HIP cycle is performed upon the body member (12) to cause the coating of iridium and the alloying metal to form the alloy (18) which protects the body member (12) from oxidation.

Chazen, Melvin L.↗

NASA NTRS2009

Nano powders, components and coatings by plasma technique

Ultra fine and nanometer powders and a method of producing same are provided, preferably refractory metal and ceramic nanopowders. When certain precursors are injected into the plasma flame in a reactor chamber, the materials are heated, melted and vaporized and the chemical reaction is induced in the vapor phase. The vapor phase is quenched rapidly to solid phase to yield the ultra pure, ultra fine and nano product. With this technique, powders have been made 20 nanometers in size in a system capable of a bulk production rate of more than 10 lbs/hr. The process is particularly applicable to tungsten, molybdenum, rhenium, tungsten carbide, molybdenum carbide and other related materials.

McKechnie, Timothy N.↗

NASA NTRS2007

Coating Carbon Fibers With Platinum

A process for coating carbon fibers with platinum has been developed. The process may also be adaptable to coating carbon fibers with other noble and refractory metals, including rhenium and iridium. The coated carbon fibers would be used as ingredients of matrix/fiber composite materials that would resist oxidation at high temperatures. The metal coats would contribute to oxidation resistance by keeping atmospheric oxygen away from fibers when cracks form in the matrices. Other processes that have been used to coat carbon fibers with metals have significant disadvantages: Metal-vapor deposition processes yield coats that are nonuniform along both the lengths and the circumferences of the fibers. The electrical resistivities of carbon fibers are too high to be compatible with electrolytic processes. Metal/organic vapor deposition entails the use of expensive starting materials, it may be necessary to use a furnace, and the starting materials and/or materials generated in the process may be hazardous. The present process does not have these disadvantages. It yields uniform, nonporous coats and is relatively inexpensive. The process can be summarized as one of pretreatment followed by electroless deposition. The process consists of the following steps: The surfaces of the fiber are activated by deposition of palladium crystallites from a solution. The surface-activated fibers are immersed in a solution that contains platinum. A reducing agent is used to supply electrons to effect a chemical reduction in situ. The chemical reduction displaces the platinum from the solution. The displaced platinum becomes deposited on the fibers. Each platinum atom that has been deposited acts as a catalytic site for the deposition of another platinum atom. Hence, the deposition process can also be characterized as autocatalytic. The thickness of the deposited metal can be tailored via the duration of immersion and the chemical activity of the solution.

Effinger, Michael R.↗

NASA NTRS2009

Alloy Design Challenge: Development of Low Density Superalloys for Turbine Blade Applications

New low density single crystal (LDS) alloys have been developed for turbine blade applications, which have the potential for significant improvements in the thrust to weight ratio over current production alloys. An innovative alloying strategy was identified to achieve high temperature creep resistance, alloy density reductions, microstructural stability, and cyclic oxidation resistance. The approach relies on the use of molybdenum (Mo) as a potent solid solution strengthener for the nickel (Ni)-base superalloy; Mo has a density much closer to Ni than other refractory elements, such as rhenium (Re) or tungsten (W). A host of testing and microstructural examinations was conducted on the superalloy single crystals, including creep rupture testing, microstructural stability, cyclic oxidation, and hot corrosion. The paper will provide an overview of the single crystal properties that were generated in this new superalloy design space. The paper will also demonstrate the feasibility of this innovative approach of low density single crystal superalloy design. It will be shown that the best LDS alloy possesses the best attributes of three generations of single crystal alloys: the low density of first-generation single crystal alloys, the excellent oxidation resistance of second-generation single crystal alloys, and a creep strength which exceeds that of second and third generation alloys.

MacKay, Rebecca A.↗

NASA NTRS2011

Improved Rare-Earth Emitter Hollow Cathode

An improvement has been made to the design of the hollow cathode geometry that was created for the rare-earth electron emitter described in Compact Rare Earth Emitter Hollow Cathode (NPO-44923), NASA Tech Briefs, Vol. 34, No. 3 (March 2010), p. 52. The original interior assembly was made entirely of graphite in order to be compatible with the LaB6 material, which cannot be touched by metals during operation due to boron diffusion causing embrittlement issues in high-temperature refractory materials. Also, the graphite tube was difficult to machine and was subject to vibration-induced fracturing. This innovation replaces the graphite tube with one made out of refractory metal that is relatively easy to manufacture. The cathode support tube is made of molybdenum or molybdenum-rhenium. This material is easily gun-bored to near the tolerances required, and finish machined with steps at each end that capture the orifice plate and the mounting flange. This provides the manufacturability and robustness needed for flight applications, and eliminates the need for expensive e-beam welding used in prior cathodes. The LaB6 insert is protected from direct contact with the refractory metal tube by thin, graphite sleeves in a cup-arrangement around the ends of the insert. The sleeves, insert, and orifice plate are held in place by a ceramic spacer and tungsten spring inserted inside the tube. To heat the cathode, an insulating tube is slipped around the refractory metal hollow tube, which can be made of high-temperature materials like boron nitride or aluminum nitride. A screw-shaped slot, or series of slots, is machined in the outside of the ceramic tube to constrain a refractory metal wire wound inside the slot that is used as the heater. The screw slot can hold a single heater wire that is then connected to the front of the cathode tube by tack-welding to complete the electrical circuit, or it can be a double slot that takes a bifilar wound heater with both leads coming out the back. This configuration replaces the previous sheathed heater design that limited the cycling-life of the cathode.

Goebel, Dan M.↗

NASA NTRS2005

Modifications of a Composite-Material Combustion Chamber

Two short reports discuss modifications of a small, lightweight combustion chamber that comprises a carbon/carbon composite outer shell and an iridium/ rhenium inner liner. The first report discusses chamber design modifications made as results of hot-fire tests and post-test characterization. The Books & Reports 32 NASA Tech Briefs, June 2005 modifications were intended to serve a variety of purposes, including improving fabrication, reducing thermal-expansion mismatch stresses, increasing strength-to-weight ratios of some components, and improving cooling of some components. The second report discusses (1) the origin of stress in the mismatch between the thermal expansions of the Ir/Re liner and a niobium sleeve and flange attached to the carbon/ carbon shell and (2) a modification intended to relieve the stress. The modification involves the redesign of an inlet connection to incorporate a compressible seal between the Ir/Re liner and the Nb flange. A nickel alloy was selected as the seal material on the basis of its thermal-expansion properties and its ability to withstand the anticipated stresses, including the greatest stresses caused by the high temperatures to be used in brazing during fabrication.

Williams, Brian E.↗

NASA NTRS2010

A New Approach of Designing Superalloys for Low Density

New low-density single-crystal (LDS) alloy, have bee. developed for turbine blade applications, which have the potential for significant improvements in the thrust-to-weight ratio over current production superalloys. An innovative alloying strategy was wed to achieve alloy density reductions, high-temperature creep resistance, microstructural stability, and cyclic oxidation resistance. The alloy design relies on molybdenum as a potent. lower-density solid-solution strengthener in the nickel-based superalloy. Low alloy density was also achieved with modest rhenium levels tmd the absence of tungsten. Microstructural, physical mechanical, and environmental testing demonstrated the feasibility of this new LDS superalloy design.

MacKay, Rebecca A.↗

NASA NTRS2011

Improved Mo-Re VPS Alloys for High-Temperature Uses

Dispersion-strengthened molybdenum- rhenium alloys for vacuum plasma spraying (VPS) fabrication of high-temperature-resistant components are undergoing development. In comparison with otherwise equivalent non-dispersion-strengthened Mo-Re alloys, these alloys have improved high-temperature properties. Examples of VPS-fabricated high-temperature-resistant components for which these alloys are expected to be suitable include parts of aircraft and spacecraft engines, furnaces, and nuclear power plants; wear coatings; sputtering targets; x-ray targets; heat pipes in which liquid metals are used as working fluids; and heat exchangers in general. These alloys could also be useful as coating materials in some biomedical applications. The alloys consist of 60 weight percent Mo with 40 weight percent Re made from (1) blends of elemental Mo and Re powders or (2) Re-coated Mo particles that have been subjected to a proprietary powder-alloying-and-spheroidization process. For most of the dispersion- strengthening experiments performed thus far in this development effort, 0.4 volume percent of transition-metal ceramic dispersoids were mixed into the feedstock powders. For one experiment, the proportion of dispersoid was 1 volume percent. In each case, the dispersoid consisted of either ZrN particles having sizes <45 m, ZrO2 particles having sizes of about 1 m, HfO2 particles having sizes <45 m, or HfN particles having sizes <1 m. These materials were chosen for evaluation on the basis of previously published thermodynamic stability data. For comparison, Mo-Re feedstock powders without dispersoids were also prepared.

Hickman, Robert↗

NASA NTRS2011

Fischer-Tropsch Catalyst for Aviation Fuel Production

As the oil supply declines, there is a greater need for cleaner alternative fuels. There will undoubtedly be a shift from crude oil to non-petroleum sources as a feedstock for aviation (and other transportation) fuels. The Fischer-Tropsch process uses a gas mixture of carbon monoxide and hydrogen which is converted into various liquid hydrocarbons; this versatile gas-to-liquid technology produces a complex product stream of paraffins, olefins, and oxygenated compounds such as alcohols and aldehydes. The Fischer-Tropsch process can produce a cleaner diesel oil fraction with a high cetane number (typically above 70) without any sulfur and aromatic compounds. It is most commonly catalyzed by cobalt supported on alumina, silica, or titania or unsupported alloyed iron powders. Cobalt is typically used more often than iron, in that cobalt is a longer-active catalyst, has lower water-gas shift activity, and lower yield of modified products. Promoters are valuable in improving Fischer-Tropsch catalyst as they can increase cobalt oxide dispersion, enhance the reduction of cobalt oxide to the active metal phase, stabilize a high metal surface area, and improve mechanical properties. Our goal is to build up the specificity of the Fischer-Tropsch catalyst while adding less-costly transition metals as promoters; the more common promoters used in Fischer-Tropsch synthesis are rhenium, platinum, and ruthenium. In this report we will describe our preliminary efforts to design and produce catalyst materials to achieve our goal of preferentially producing C8 to C18 paraffin compounds in the NASA Glenn Research Center Gas-To-Liquid processing plant. Efforts at NASA Glenn Research Center for producing green fuels using non-petroleum feedstocks support both the Sub-sonic Fixed Wing program of Fundamental Aeronautics and the In Situ Resource Utilization program of the Exploration Technology Development and Demonstration program.

deLaRee, Ana B.↗

NASA NTRS2012

Materials Advance Chemical Propulsion Technology

In the future, the Planetary Science Division of NASA's Science Mission Directorate hopes to use better-performing and lower-cost propulsion systems to send rovers, probes, and observers to places like Mars, Jupiter, and Saturn. For such purposes, a new propulsion technology called the Advanced Materials Bipropellant Rocket (AMBR) was developed under NASA's In-Space Propulsion Technology (ISPT) project, located at Glenn Research Center. As an advanced chemical propulsion system, AMBR uses nitrogen tetroxide oxidizer and hydrazine fuel to propel a spacecraft. Based on current research and development efforts, the technology shows great promise for increasing engine operation and engine lifespan, as well as lowering manufacturing costs. In developing AMBR, ISPT has several goals: to decrease the time it takes for a spacecraft to travel to its destination, reduce the cost of making the propulsion system, and lessen the weight of the propulsion system. If goals like these are met, it could result in greater capabilities for in-space science investigations. For example, if the amount (and weight) of propellant required on a spacecraft is reduced, more scientific instruments (and weight) could be added to the spacecraft. To achieve AMBR s maximum potential performance, the engine needed to be capable of operating at extremely high temperatures and pressure. To this end, ISPT required engine chambers made of iridium-coated rhenium (strong, high-temperature metallic elements) that allowed operation at temperatures close to 4,000 F. In addition, ISPT needed an advanced manufacturing technique for better coating methods to increase the strength of the engine chamber without increasing the costs of fabricating the chamber.

Source record↗

NASA NTRS2012

Oxygen-Methane Thruster

An oxygen-methane thruster was conceived with integrated igniter/injector capable of nominal operation on either gaseous or liquid propellants. The thruster was designed to develop 100 lbf (approximately 445 N) thrust at vacuum conditions and use oxygen and methane as propellants. This continued development included refining the design of the thruster to minimize part count and manufacturing difficulties/cost, refining the modeling tools and capabilities that support system design and analysis, demonstrating the performance of the igniter and full thruster assembly with both gaseous and liquid propellants, and acquiring data from this testing in order to verify the design and operational parameters of the thruster. Thruster testing was conducted with gaseous propellants used for the igniter and thruster. The thruster was demonstrated to work with all types of propellant conditions, and provided the desired performance. Both the thruster and igniter were tested, as well as gaseous propellants, and found to provide the desired performance using the various propellant conditions. The engine also served as an injector testbed for MSFC-designed refractory combustion chambers made of rhenium.

Pickens, Tim↗