Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “direct casting”

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 343 records · Page 19

Elevated temperature mechanical properties and residual tensile properties of two cast superalloys and several nickel-base oxide dispersion strengthened alloys

The elevated temperature tensile, stress-rupture and creep properties and residual tensile properties after creep straining have been determined for two cast superalloys and several wrought Ni-16Cr-4Al-yttria oxide dispersion strengthened (ODS) alloys. The creep behavior of the ODS alloys is similar to that of previously studied ODS nickel alloys. In general, the longitudinal direction is stronger than the long transverse direction, and creep is at least partially due to a diffusional creep mechanism as dispersoid-free zones were observed after creep-rupture testing. The tensile properties of the nickel-base superalloy B-1900 and cobalt-base superalloy MAR-M509 are not degraded by prior elevated temperature creep straining (at least up to 1 pct) between 1144 and 1366 K. On the other hand, the room temperature tensile properties of ODS nickel-base alloys can be reduced by prior creep strains of 0.5 pct or less between 1144 and 1477 K, with the long transverse direction being more susceptible to degradation than the longitudinal direction.

Whittenberger, J. D.↗

Patterns of discoloration and oxidation by direct and scattered fluxes on LDEF, including oxygen on silicon

A number of interesting discoloration patterns are clearly evident on MOOO2-1 which resides on the three faces of the Long Duration Exposure Facility (LDEF). Most interesting is the pattern of blue oxidation on polished single crystal silicon apparently produced by scattered or direct ram oxygen atoms along the earth face. A complete explanation for the patterns has not yet been obtained. All honeycomb outgassing holes have a small discoloration ring around them that varies in color. The shadow cast by a suspended wire on the earth face surface is not easily explained by either solar photons or by ram flux. The shadows and the dark/light regions cannot be explained consistently by the process of solar ultraviolet paint-darkening modulated by ram flux oxygen bleaching of the paint.

Frederickson, A. R.↗

Space facilities: Meeting future needs for research, development, and operations

The National Facilities Study (NFS) represents an interagency effort to develop a comprehensive and integrated long-term plan for world-class aeronautical and space facilities that meet current and projected needs for commercial and government aerospace research and development and space operations. At the request of NASA and the DOD, the National Research Council's Committee on Space Facilities has reviewed the space related findings of the NFS. The inventory of more than 2800 facilities will be an important resource, especially if it continues to be updated and maintained as the NFS report recommends. The data in the inventory provide the basis for a much better understanding of the resources available in the national facilities infrastructure, as well as extensive information on which to base rational decisions about current and future facilities needs. The working groups have used the inventory data and other information to make a set of recommendations that include estimates of cast savings and steps for implementation. While it is natural that the NFS focused on cost reduction and consolidations, such a study is most useful to future planning if it gives equal weight to guiding the direction of future facilities needed to satisfy legitimate national aspirations. Even in the context of cost reduction through facilities closures and consolidations, the study is timid about recognizing and proposing program changes and realignments of roles and missions to capture what could be significant savings and increased effectiveness. The recommendations of the Committee on Space Facilities are driven by the clear need to be more realistic and precise both in recognizing current incentives and disincentives in the aerospace industry and in forecasting future conditions for U.S. space activities.

Source record↗

Directional solidification of superalloys

This invention relates to the directional solidification of superalloys, in particular nickel-based superalloys, by imposition of a predetermined temperature profile in the solidification front and, depending on the desired results, a predetermined rate of advance of said solidification front, whereas castings of markedly superior fatigue resistance are produced.

Schmidt, Deborah Diane↗

Characterizing the Use of Ultrasonic Energy in Promoting Uniform Composite Growth in Immiscible Alloys

The results of experimental investigation and mathematical modeling for immiscible alloys subjected to ultrasonic influence are presented. It is known that in inoculated light alloy melts, ultrasonic treatment creates a new type of cast structure with extremely fine grains of uniform composition. This effect is produced across a wide range of freezing rates and technologies. However, it has not been demonstrated that the process can be successfully applied during controlled directional solidification processing. In this work we present the results from a set of directional solidification experiments and suggest describing the droplet size versus ultrasonic frequency and amplitude using an energy approach, followed with a more detailed analysis through numerical modeling of the ultrasonic field.

Grugel, Richard N.↗

Evaluating the bond strength and fracture mechanisms of cold-sprayed zinc coating on AZ91 magnesium substrate via a combined experimental and computational approach

Magnesium (Mg) alloys are ideal candidates for automotive applications due to their high strength to weight ratio, castability, recyclability etc., however, they lack corrosion and oxidation resistance. Solid-state deposition techniques, such as cold spray, have been demonstrated to enhance their corrosion resistance as it relies on the severe plastic deformation of powder particles upon impact with the substrate to form a metallurgical bond with the substrate and within the coating. At cold sprayed interfaces, a heterogeneous microstructure is formed that includes some porosity, oxides and intermetallics which can significantly affect coating performance. Thus, establishing a direct correlation between the interface microstructure and its properties can aid in designing optimal cold spray parameters. In this study, we investigated the microstructure and mechanical properties of a zinc (Zn) coating deposited on a high pressure die cast (HPDC) AZ91 Mg substrate via high resolution scanning transmission electron microscopy, in situ micro-tensile testing, and finite element method (FEM) modeling. Micro-tensile pillars fabricated using the plasma focused ion beam (PFIB) successfully isolates the coating-substrate interface within the gauge length. The average bond strength of Zn-Mg interface was determined to be ∼140 MPa with failure occurring partially at the interface and mostly into the coatings. A detailed microstructural characterization revealed evidence of a strong metallurgical bonding at the Zn-Mg interface and formation of the C14 MgZn 2 laves phase interlayer resulting in a mixed mode of fracture during the micro-tensile experiments. FEM modeling reveals the stress distribution along the interfaces and suggests that a MgZn 2 layer thickness between 200–400 nm is optimum to increase the bond strength and minimize the triaxiality. Such a site-specific interfacial analysis with correlative computational modeling provides crucial insight into the overall performance of cold spray interfaces.

Bond strength↗

Apollo 14 composite casting demonstration

This program assisted in the design and implementation of the composite casting demonstration for the Apollo 14 mission. Both flight and control samples were evaluated. Some conclusions resulting from a comparison of the flight and control samples were: (1) Solidification in neither the flight nor control samples was truly directional. (2) Apparent intermittent contact of the melt with the container in the flight samples led to unusual nucleation and growth structures. (3) There was greater uniformity, on a macro scale, of both pores and structural features in the flight sample; presumably the result of the reduced gravity conditions. (4) It seems quite feasible to produce enhanced dispersions of gases and dense phases in a melt which is solidified in reduced gravity. (5) A two-stage heating/cooling cycle may help directional solidification. (6) Sample materials should be selected from materials in which the dispersant fully wets the matrix material. (7) Experiments should be conducted in two modes: (1) where the melt is in good thermal contact with the container, and (2) where the melt is in a free-float condition.

Source record↗

Improved Estimate of Phobos Secular Acceleration from MOLA Observations

We report on new observations of the orbital position of Phobos, and use them to obtain a new and improved estimate of the rate of secular acceleration in longitude due to tidal dissipation within Mars. Phobos is the inner-most natural satellite of Mars, and one of the few natural satellites in the solar system with orbital period shorter than the rotation period of its primary. As a result, any departure from a perfect elastic response by Mars in the tides raised on it by Phobos will cause a transfer of angular momentum from the orbit of Phobos to the spin of Mars. Since its discovery in 1877, Phobos has completed over 145,500 orbits, and has one of the best studied orbits in the solar system, with over 6000 earth-based astrometric observations, and over 300 spacecraft observations. As early as 1945, Sharpless noted that there is a secular acceleration in mean longitude, with rate (1.88 + 0.25) 10(exp -3) degrees per square year. In preparation for the 1989 Russian spacecraft mission to Phobos, considerable work was done compiling past observations, and refining the orbital model. All of the published estimates from that era are in good agreement. A typical solution (Jacobson et al., 1989) yields (1.249 + 0.018) 10(exp -3) degrees per square year. The MOLA instrument on MGS is a laser altimeter, and was designed to measure the topography of Mars. However, it has also been used to make observations of the position of Phobos. In 1998, a direct range measurement was made, which indicated that Phobos was slightly ahead of the predicted position. The MOLA detector views the surface of Mars in a narrow field of view, at 1064 nanometer wavelength, and can detect shadows cast by Phobos on the surface of Mars. We have found 15 such serendipitous shadow transit events over the interval from xx to xx, and all of them show Phobos to be ahead of schedule, and getting progressively farther ahead of the predicted position. In contrast, the cross-track positions are quite close to the predicted values. Assuming that the along-track discrepancy is small enough that we can linearize the corrections, we model the mean orbital longitude as a quadratic function of time, and solve for corrections to the constant, linear, and quadratic terms. The time span of the recent observations is insufficient to properly resolve this issue alone, but when the 127 years of prior observations are added, we find a solution which reduces misfit to the new observations considerably, and makes no significant change to the fit to earlier observations. Our estimate for the secular acceleration term is (1.367 + 0.006) degrees per square year. The corresponding rate of energy dissipation is 3.34 MW. From a geophysical perspective, a more interesting parameter than the secular acceleration itself is the tidal lag angle, or tidal quality factor Q, for Mars. Unfortunately, the limiting error source in that determination is remaining uncertainty in the tidal Love numbers at harmonic degrees 2,3, and even 4. Until those parameters are better constrained, improvement in the orbital model of Phobos will not provide corresponding benefits for understanding the interior of Mars.

Bills, Bruce↗

Bridging Current Indirect and Future Direct Estimates of Convective Mass Flux Toward Quantifying the Role of Convective Cores on Anvil Area Time Tendencies

Anvil cloud spatial extent is strongly driven by convective mass flux. However, the lack of convective mass flux observations precludes global analyses of the functional relationship between anvil cloud area growth tendencies and convective areal coverage and vertical mass flux. Partly informed by analyses of a hierarchy of WRF mesoscale convective system (MCS) simulations, in this presentation, we discuss new work on estimating convective mass flux by way of an approach that casts the problem of quantifying convective mass flux into terms related to diabatic heating vertical structure, convective area and tropospheric stability. We demonstrate the usefulness of this approach at the MCS spatial scale via development of a simple, robust model that analytically connects system-scale convective mass flux and anvil cloud area growth rates. We show that the model predicts anvil area size changes in agreement with those observed in a global convective system tracking database (TOOCAN). An additional advantage of this approach for estimating convective mass flux is that it bridges future satellite mission plans for directly observing convective mass flux (e.g., AOS) with longer-record observations made by TRMM, GPM and satellite sounder mission data (the latter used for estimating stability) that, when combined, can be used for inferring convective mass fluxes at the MCS spatial scale spanning slowly changing, diverse environments. An evaluation and bridging of both direct and indirect approaches supports convective process analyses varying over longer time periods in this “era of convection.”

convective mass flux↗

Bridging current indirect and future direct estimates of convective mass flux toward quantifying the role of convective cores on anvil area time tendencies

Anvil cloud spatial extent is strongly driven by convective mass flux. However, the lack of convective mass flux observations precludes global analyses of the functional relationship between anvil cloud area growth tendencies and convective areal coverage and vertical mass flux. Partly informed by analyses of a hierarchy of WRF mesoscale convective system (MCS) simulations, in this presentation, we discuss new work on estimating convective mass flux by way of an approach that casts the problem of quantifying convective mass flux into terms related to diabatic heating vertical structure, convective area and tropospheric stability. We demonstrate the usefulness of this approach at the MCS spatial scale via development of a simple, robust model that analytically connects system-scale convective mass flux and anvil cloud area growth rates. We show that the model predicts anvil area size changes in agreement with those observed in a global convective system tracking database (TOOCAN). An additional advantage of this approach for estimating convective mass flux is that it bridges future satellite mission plans for directly observing convective mass flux (e.g., AOS) with longer-record observations made by TRMM, GPM and satellite sounder mission data (the latter used for estimating stability) that, when combined, can be used for inferring convective mass fluxes at the MCS spatial scale spanning slowly changing, diverse environments. An evaluation and bridging of both direct and indirect approaches supports convective process analyses varying over longer time periods in this “era of convection.”

convective mass flux↗

Analysis, design, and test of a graphite/polyimide Shuttle orbiter body flap segment

For future missions, increases in Space Shuttle orbiter deliverable and recoverable payload weight capability may be needed. Such increases could be obtained by reducing the inert weight of the Shuttle. The application of advanced composites in orbiter structural components would make it possible to achieve such reductions. In 1975, NASA selected the orbiter body flap as a demonstration component for the Composite for Advanced Space Transportation Systems (CASTS) program. The progress made in 1977 through 1980 was integrated into a design of a graphite/polyimide (Gr/Pi) body flap technology demonstration segment (TDS). Aspects of composite body flap design and analysis are discussed, taking into account the direct-bond fibrous refractory composite insulation (FRCI) tile on Gr/Pi structure, Gr/Pi body flap weight savings, the body flap design concept, and composite body flap analysis. Details regarding the Gr/Pi technology demonstration segment are also examined.

Graves, S. R.↗

Methodology for Sensitivity Analysis, Approximate Analysis, and Design Optimization in CFD for Multidisciplinary Applications

An incremental iterative formulation together with the well-known spatially split approximate-factorization algorithm, is presented for solving the large, sparse systems of linear equations that are associated with aerodynamic sensitivity analysis. This formulation is also known as the 'delta' or 'correction' form. For the smaller two dimensional problems, a direct method can be applied to solve these linear equations in either the standard or the incremental form, in which case the two are equivalent. However, iterative methods are needed for larger two-dimensional and three dimensional applications because direct methods require more computer memory than is currently available. Iterative methods for solving these equations in the standard form are generally unsatisfactory due to an ill-conditioned coefficient matrix; this problem is overcome when these equations are cast in the incremental form. The methodology is successfully implemented and tested using an upwind cell-centered finite-volume formulation applied in two dimensions to the thin-layer Navier-Stokes equations for external flow over an airfoil. In three dimensions this methodology is demonstrated with a marching-solution algorithm for the Euler equations to calculate supersonic flow over the High-Speed Civil Transport configuration (HSCT 24E). The sensitivity derivatives obtained with the incremental iterative method from a marching Euler code are used in a design-improvement study of the HSCT configuration that involves thickness. camber, and planform design variables.

Taylor, Arthur C., III↗

A review of the effect of nanoclays on the fresh and hardened properties of cement-based materials

This paper provides an overview of the use of nanoclays in cement-based materials. The effect of nanoclays on shear rheological properties will be discussed, with a focus on structural build-up behavior. This macroscale flow behavior will then be tied to the effect of nanoclays on the fresh microstructure as characterized via in-situ particle size measurements and rheological techniques. This will provide insight on the mechanisms underlying the effect of nanoclays on fresh state properties through an improved understanding of their effect on flocculation and coagulation behavior. In addition, secondary effects nanoclays have on the hardening and hardened properties will also be discussed. Examples of casting applications in which nanoclays have been effectively utilized as rheological modifiers, i.e. reducing self-consolidating concrete formwork pressure, extrusion, semi-flowable concrete for slipform paving, and 3D concrete printing, will be presented. Finally, some thoughts on potential directions for future work will be shared.

36 MATERIALS SCIENCE↗

A finite element procedure for nonlinear prebuckling and initial postbuckling analysis

A procedure cast in a form appropriate to the finite element method is presented for geometrically nonlinear prebuckling and postbuckling structural analysis, including the identification of snap-through type of buckling. The principal features of this procedure are the use of direct iteration for solution of the nonlinear algebraic equations in the prebuckling range, an interpolation scheme for determination of the initial bifurcation point, a perturbation method in definition of the load-displacement behavior through the postbuckling regime, and extrapolation in determination of the limit point for snap-through buckling. Three numerical examples are presented in illustration of the procedure and in comparison with alternative approaches.

Mau, S. T.↗

Flight Validation of Atomic Oxygen Resistant Resistant Polymers

Because of its high reactivity, atomic oxygen causes surface erosion on polymeric materials. although the reaction efficiency depends on the chemical structure of the polymer. We have found an organotin compound, bis(triphenyltin) oxide (BTO), which has an unusually high solubility in solutions of a number of commercial high performance polymers. Films of these polymers containing BTO showed a substantial reduction in erosion by atomic oxygen when compared with films of the pure material. Analysis has shown that in the presence of atomic oxygen, erosion of the exposed surfaces of the BTO-containing films leaves a residual protective tin oxide coating . Since the additive is uniformly distributed throughout the polymeric material, any break or puncture in the protective coating is "healed" by the material below. Samples were exposed to the environment of the low earth orbit (LEO) on two Space Shuttle flights, STS-46, in June of 1992, and STS-51 in September of 1993. The analysis of these samples has been reported previously. For both flights, the samples were small (1.3 cm and 1.9 cm respectively) thus limiting the scope of analysis. In the research under this cooperative agreement, films of a polyetherimide, were exposed to the LEO environment on Space Shuttle flight STS-85 in August of 1997 as part of the Evaluation of Space Environment and Effects on Materials (ESEM) experiment. The polyetherimide chosen is available commercially as Ultem, registered to the General Electric Company. Films of pure Ultem, Ultem with 10% BTO by mass, and Ultem with 20% BTO by mass were exposed in the ram direction for 40 hours during STS-85. Ultem has a Tg of 215 deg C and is soluble in common chlorinated solvents. Granules of the polymer were dried at 120 deg C, but otherwise were used as received. Films were cast on a glass plate from a solution of the polymer in a 60/40 (w/w) mixture of chloroform and 1,1,2,2-tetrachloroethane. The plate was placed in a dust-free box for at least 24 hours to allow much of the solvent to evaporate, and then was moved to a vacuum oven and slowly heated from 20 to 220 deg C over a period of two weeks to completely remove all solvent. Each exposed sample was 7.6 cm long and 2.2 cm wide and about 0.025 mm thick. The structures of Ultem and bis(triphenyltin) oxide are shown.

Kiefer, Richard L.↗

Cold-Sprayed NMC622 Composite as a Cathode for Lithium-Ion Batteries

The growing demand for high-energy, low-cost lithium-ion batteries (LIBs) to power electric vehicles (EVs) necessitates advances in both materials and manufacturing processes. Conventional cathode fabrication methods, such as slurry casting and drying, are energy-intensive and pose challenges for scalability and environmental compliance. In this study, we propose cold-spray (CS) deposition as a solvent-free approach for fabricating LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) composite cathodes. Powder blends of NMC622, poly(vinylidene fluoride) (PVDF), and carbon black (CB) are directly deposited onto stainless steel and Inconel substrates under varied gas temperatures, pressures (and thus velocities), and standoff distances. The effects of temperature on the deposit morphology, coating density, and volume are systematically investigated. Computational fluid dynamics simulations reveal that increasing the gas temperature enhances the particle velocity, narrows the spray angle, and reduces the mass concentration radially at the nozzle outlet. CS deposition results in a dense cathode microstructure, accompanied by fracture in polycrystalline NMC622 particles. X-ray diffraction analysis further verifies that there are no phase changes during the deposition process. The electrochemical performance of the cold-sprayed cathodes reveals an initial capacity of approximately 96 mAh g –1 for single-crystal NMC622 and 167 mAh g –1 for polycrystalline NMC622. While these values are modest compared to state-of-the-art slurry-cast cathodes, which typically exhibit 180–200 mAh g –1 under optimized conditions. The results demonstrate a competitive performance given the solvent-free nature of the CS process and compare favorably with tape-cast samples made from identical feedstock. In conclusion, he CS process enables the formation of dense, binder-integrated cathode coatings without the need for solvent processing, offering a promising pathway for scalable, energy-efficient dry electrode manufacturing of next-generation LIBs.

Batteries↗

Effect of tool design and pass strategy on defect elimination and uniform, enhanced tensile properties of friction stir processed high-pressure die-cast A380 alloy

This work reports implementation of friction stir processing (FSP) to locally modify microstructure and create a defect-free processing zone with the aid of different tool designs and altering the passing strategy for two different process parameter combinations. Here, FSP is applied on high pressure die-cast (HPDC) A380 alloy, a widely used Al-Si alloy fabricated in the die casting sector for automotive and aerospace applications. However, the presence of gas and shrinkage porosity, brittle needle-shaped Fe-containing ß-FeSiAl 5 intermetallic compounds, Al-dendrites, coarse and acicular silicon particles, and large second-phase particulates have a detrimental influence on the uniformity of tensile properties across the thickness direction of an HPDC plate. FSP is able to eliminate porosity, refine microstructure and improve tensile properties. An FSP tool design and a passing strategy are identified for the best microstructure consolidation and uniform enhanced tensile properties. This study noted the importance of tool features such as scroll design and flats on tool pin and multiple pass orientation strategy to find best combination of defect-free refined microstructure and uniform tensile strength and ductility across the processing zone of HPDC Al alloys.

36 MATERIALS SCIENCE↗

Analysis and calculation of macrosegregation in a casting ingot. MPS solidification model. Volume 3: Operating manual

The operation of solidification model 1 is described. Model 1 calculates the macrosegregation in a rectangular ingot of a binary alloy as a result of horizontal axisymmetric bidirectional solidification. The calculation is restricted to steady-state solidification; there is no variation in final local average composition in the direction of isotherm movement. The physics of the model are given.

Maples, A. L.↗