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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS1997

Videometric Applications in Wind Tunnels

Videometric measurements in wind tunnels can be very challenging due to the limited optical access, model dynamics, optical path variability during testing, large range of temperature and pressure, hostile environment, and the requirements for high productivity and large amounts of data on a daily basis. Other complications for wind tunnel testing include the model support mechanism and stringent surface finish requirements for the models in order to maintain aerodynamic fidelity. For these reasons nontraditional photogrammetric techniques and procedures sometimes must be employed. In this paper several such applications are discussed for wind tunnels which include test conditions with Mach number from low speed to hypersonic, pressures from less than an atmosphere to nearly seven atmospheres, and temperatures from cryogenic to above room temperature. Several of the wind tunnel facilities are continuous flow while one is a short duration blowdown facility. Videometric techniques and calibration procedures developed to measure angle of attack, the change in wing twist and bending induced by aerodynamic load, and the effects of varying model injection rates are described. Some advantages and disadvantages of these techniques are given and comparisons are made with non-optical and more traditional video photogrammetric techniques.

Burner, A. W.↗
NASA NTRS2008

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

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

Halbig,Michael C.↗
NASA NTRS2008

Bonding and Integration Technologies for Silicon Carbide Based Injector Components

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

Halbig, Michael C.↗
NASA NTRS2006

Optical Microscopy Techniques to Inspect for Metallic Whiskers

Metal surface finishes of tin, zinc and cadmium are often applied to electronic components, mechanical hardware and other structures. These finishes sometimes unpredictably may form metal whiskers over periods that can take from hours to months or even many years. The metal whiskers are crystalline structures commonly having uniform cross sectional area along their entire length. Typical whisker dimensions are nominally on the order of only a few microns (um) across while their lengths can extend from a few microns to several millimeters. Metal whiskers pose a reliability hazard to electronic systems primarily as an electrical shorting hazard. The extremely narrow dimensions of metal whiskers can make observation with optical techniques very challenging. The videos herein were compiled to demonstrate the complexities associated with optical microscope inspection of electronic and mechanical components and assemblies for the presence or absence of metal whiskers. The importance of magnification, light source and angle of illumination play critical roles in being able to detect metal whiskers when present. Furthermore, it is demonstrated how improper techniques can easily obscure detection. It is hoped that these videos will improve the probability of detecting metal whiskers with optical inspection techniques.

Brusse, Jay A.↗
NASA NTRS2009

NASA PS400: A New Temperature Solid Lubricant Coating for High Temperature Wear Applications

A new solid lubricant coating, NASA PS400, has been developed for high temperature tribological applications. This plasma sprayed coating is a variant of the patented PS304 coating and has been formulated to provide higher density, smoother surface finish and better dimensional stability than PS304. PS400 is comprised of a nickel-molybdenum binder that provides strength, creep resistance and extreme oxidative and dimensional stability. Chromium oxide, silver and barium-calcium fluoride eutectic are added to the binder to form PS400.Tribological properties were evaluated with a pin-on-disk test rig in sliding contact to 650 C. Coating material samples were exposed to air, argon and vacuum at 760 C followed by cross section microscopic analysis to assess microstructure stability. Oil-Free microturbine engine hot section foil bearing tests were undertaken to assess PS400 s suitability for hot foil gas bearing applications. The preliminary results indicate that PS400 exhibits tribological characteristics comparable to the PS304 coating but with enhanced creep resistance and dimensional stability suitable for demanding, dynamic applications.

DellaCorte, C.↗
NASA NTRS2009

An Investigation of Differential Deposition for Figure Corrections in Full-Shell Grazing-Incidents X-Ray Optics

We are investigating differential deposition as a way of correcting small figure errors inside full-shell grazing-incidence x-ray optics. The optics in our study are fabricated using the electroformed-nickel-replication technique, and the figure errors arise from fabrication errors in the mandrel, from which the shells are replicated, as well as errors induced during the electroforming process. Combined, these give sub-micron-scale figure deviations which limit the angular resolution of the optics to approx. 10 arcsec. Sub-micron figure errors can be corrected by selectively depositing (physical vapor deposition) material inside the shell. The requirements for this filler material are that it must not degrade the ultra-smooth surface finish necessary for efficient x-ray reflection (approx. 5 A rms), and must not be highly stressed. In addition, a technique must be found to produce well controlled and defined beams within highly constrained geometries, as some of our mirror shells are less than 3 cm in diameter.

Gubarev, Mikhail V.↗
NASA NTRS2010

Toward Establishing a Realistic Benchmark for Airframe Noise Research: Issues and Challenges

The availability of realistic benchmark configurations is essential to enable the validation of current Computational Aeroacoustic (CAA) methodologies and to further the development of new ideas and concepts that will foster the technologies of the next generation of CAA tools. The selection of a real-world configuration, the subsequent design and fabrication of an appropriate model for testing, and the acquisition of the necessarily comprehensive aeroacoustic data base are critical steps that demand great care and attention. In this paper, a brief account of the nose landing-gear configuration, being proposed jointly by NASA and the Gulfstream Aerospace Company as an airframe noise benchmark, is provided. The underlying thought processes and the resulting building block steps that were taken during the development of this benchmark case are given. Resolution of critical, yet conflicting issues is discussed - the desire to maintain geometric fidelity versus model modifications required to accommodate instrumentation; balancing model scale size versus Reynolds number effects; and time, cost, and facility availability versus important parameters like surface finish and installation effects. The decisions taken during the experimental phase of a study can significantly affect the ability of a CAA calculation to reproduce the prevalent flow conditions and associated measurements. For the nose landing gear, the most critical of such issues are highlighted and the compromises made to resolve them are discussed. The results of these compromises will be summarized by examining the positive attributes and shortcomings of this particular benchmark case.

Khorrami, Mehdi R.↗
NASA NTRS2011

Technical Tension Between Achieving Particulate and Molecular Organic Environmental Cleanliness: Data from Astromaterial Curation Laboratories

NASA Johnson Space Center operates clean curation facilities for Apollo lunar, Antarctic meteorite, stratospheric cosmic dust, Stardust comet and Genesis solar wind samples. Each of these collections is curated separately due unique requirements. The purpose of this abstract is to highlight the technical tensions between providing particulate cleanliness and molecular cleanliness, illustrated using data from curation laboratories. Strict control of three components are required for curating samples cleanly: a clean environment; clean containers and tools that touch samples; and use of non-shedding materials of cleanable chemistry and smooth surface finish. This abstract focuses on environmental cleanliness and the technical tension between achieving particulate and molecular cleanliness. An environment in which a sample is manipulated or stored can be a room, an enclosed glovebox (or robotic isolation chamber) or an individual sample container.

Allton, J. H.↗
NASA NTRS2004

Joint Lead-Free Solder Test Program for High Reliability Military and Space Applications

Current and future space and defense systems face potential risks from the continued use of tin-lead solder, including: compliance with current environmental regulations, concerns about potential environmental legislation banning lead-containing products, reduced mission readiness, and component obsolescence with lead surface finishes. For example, the United States Environmental Protection Agency (USEPA) has lowered the Toxic Chemical Release reporting threshold for lead to 100 pounds. Overseas, the Waste Electrical and Electronic Equipment (WEEE) and the Restriction on Hazardous Substances (RoHS) Dicctives in Europe and similar mandates in Japan have instilled concern that a legislative body will prohibit the use of lead in aerospace/military electronics soldering. Any potential banning of lead compounds could reduce the supplier base and adversely affect the readiness of missions led by the National Aeronautics and Space Administration (NASA) and the U.S. Department of Defense (DoD). Before considering lead-free electronics for system upgrades or future designs, however, it is important for the DoD and NASA to know whether lead-free solders can meet their systems' requirements. No single lead-free solder is likely to qualify for all defense and space applications. Therefore, it is important to validate alternative solders for discrete applications. As a result of the need for comprehensive test data on the reliability of lead-free solders, a partnership was formed between the DoD, NASA, and several original equipment manufactures (OEMs) to conduct solder-joint reliability (laboratory) testing of three lead-free solder alloys on newly manufactured and reworked circuit cards to generate performance data for high-reliability (IPC Class 3) applications.

Brown, Christina↗
NASA NTRS2013

Castable Amorphous Metal Mirrors and Mirror Assemblies

A revolutionary way to produce a mirror and mirror assembly is to cast the entire part at once from a metal alloy that combines all of the desired features into the final part: optical smoothness, curvature, flexures, tabs, isogrids, low CTE, and toughness. In this work, it has been demonstrated that castable mirrors are possible using bulk metallic glasses (BMGs, also called amorphous metals) and BMG matrix composites (BMGMCs). These novel alloys have all of the desired mechanical and thermal properties to fabricate an entire mirror assembly without machining, bonding, brazing, welding, or epoxy. BMGs are multi-component metal alloys that have been cooled in such a manner as to avoid crystallization leading to an amorphous (non-crystalline) microstructure. This lack of crystal structure and the fact that these alloys are glasses, leads to a wide assortment of mechanical and thermal properties that are unlike those observed in crystalline metals. Among these are high yield strength, carbide-like hardness, low melting temperatures (making them castable like aluminum), a thermoplastic processing region (for improving smoothness), low stiffness, high strength-to-weight ratios, relatively low CTE, density similar to titanium alloys, high elasticity and ultra-smooth cast parts (as low as 0.2-nm surface roughness has been demonstrated in cast BMGs). BMGMCs are composite alloys that consist of a BMG matrix with crystalline dendrites embedded throughout. BMGMCs are used to overcome the typically brittle failure observed in monolithic BMGs by adding a soft phase that arrests the formation of cracks in the BMG matrix. In some cases, BMGMCs offer superior castability, toughness, and fatigue resistance, if not as good a surface finish as BMGs. This work has demonstrated that BMGs and BMGMCs can be cast into prototype mirrors and mirror assemblies without difficulty.

Hofmann, Douglas C.↗
NASA NTRS2013

Correlation of Gear Surface Fatigue Lives to Lambda Ratio (Specific Film Thickness)

The effect of the lubrication regime on gear performance has been recognized, qualitatively, for decades. Often the lubrication regime is characterized by the specific film thickness being the ratio of lubricant film thickness to the composite surface roughness. Three studies done at NASA to investigate gearing pitting life are revisited in this work. All tests were done at a common load. In one study, ground gears were tested using a variety of lubricants that included a range of viscosities, and therefore the gears operated with differing film thicknesses. In a second and third study, the performance of gears with ground teeth and superfinished teeth were assessed. Thicker oil films provided longer lives as did improved surface finish. These datasets were combined into a common dataset using the concept of specific film thickness. This unique dataset of more 258 tests provides gear designers with some qualitative information to make gear design decisions.

gear↗
NASA NTRS2014

Additive Manufacturing Design Considerations for Liquid Engine Components

The Marshall Space Flight Center's Propulsion Systems Department has gained significant experience in the last year designing, building, and testing liquid engine components using additive manufacturing. The department has developed valve, duct, turbo-machinery, and combustion device components using this technology. Many valuable lessons were learned during this process. These lessons will be the focus of this presentation. We will present criteria for selecting part candidates for additive manufacturing. Some part characteristics are 'tailor made' for this process. Selecting the right parts for the process is the first step to maximizing productivity gains. We will also present specific lessons we learned about feature geometry that can and cannot be produced using additive manufacturing machines. Most liquid engine components were made using a two-step process. The base part was made using additive manufacturing and then traditional machining processes were used to produce the final part. The presentation will describe design accommodations needed to make the base part and lessons we learned about which features could be built directly and which require the final machine process. Tolerance capabilities, surface finish, and material thickness allowances will also be covered. Additive Manufacturing can produce internal passages that cannot be made using traditional approaches. It can also eliminate a significant amount of manpower by reducing part count and leveraging model-based design and analysis techniques. Information will be shared about performance enhancements and design efficiencies we experienced for certain categories of engine parts.

Whitten, Dave↗
NASA NTRS2016

Cleaning Genesis Sample Return Canister for Flight: Lessons for Planetary Sample Return

Sample return missions require chemical contamination to be minimized and potential sources of contamination to be documented and preserved for future use. Genesis focused on and successfully accomplished the following: - Early involvement provided input to mission design: a) cleanable materials and cleanable design; b) mission operation parameters to minimize contamination during flight. - Established contamination control authority at a high level and developed knowledge and respect for contamination control across all institutions at the working level. - Provided state-of-the-art spacecraft assembly cleanroom facilities for science canister assembly and function testing. Both particulate and airborne molecular contamination was minimized. - Using ultrapure water, cleaned spacecraft components to a very high level. Stainless steel components were cleaned to carbon monolayer levels (10 (sup 15) carbon atoms per square centimeter). - Established long-term curation facility Lessons learned and areas for improvement, include: - Bare aluminum is not a cleanable surface and should not be used for components requiring extreme levels of cleanliness. The problem is formation of oxides during rigorous cleaning. - Representative coupons of relevant spacecraft components (cut from the same block at the same time with identical surface finish and cleaning history) should be acquired, documented and preserved. Genesis experience suggests that creation of these coupons would be facilitated by specification on the engineering component drawings. - Component handling history is critical for interpretation of analytical results on returned samples. This set of relevant documents is not the same as typical documentation for one-way missions and does include data from several institutions, which need to be unified. Dedicated resources need to be provided for acquiring and archiving appropriate documents in one location with easy access for decades. - Dedicated, knowledgeable contamination control oversight should be provided at sites of fabrication and integration. Numerous excellent Genesis chemists and analytical facilities participated in the contamination oversight; however, additional oversight at fabrication sites would have been helpful.

Allton, J. H.↗
NASA NTRS2016

Hydrogen Embrittlement

Hydrogen embrittlement (HE) is a process resulting in a decrease in the fracture toughness or ductility of a metal due to the presence of atomic hydrogen. In addition to pure hydrogen gas as a direct source for the absorption of atomic hydrogen, the damaging effect can manifest itself from other hydrogen-containing gas species such as hydrogen sulfide (H2S), hydrogen chloride (HCl), and hydrogen bromide (HBr) environments. It has been known that H2S environment may result in a much more severe condition of embrittlement than pure hydrogen gas (H2) for certain types of alloys at similar conditions of stress and gas pressure. The reduction of fracture loads can occur at levels well below the yield strength of the material. Hydrogen embrittlement is usually manifest in terms of singular sharp cracks, in contrast to the extensive branching observed for stress corrosion cracking. The initial crack openings and the local deformation associated with crack propagation may be so small that they are difficult to detect except in special nondestructive examinations. Cracks due to HE can grow rapidly with little macroscopic evidence of mechanical deformation in materials that are normally quite ductile. This Technical Memorandum presents a comprehensive review of experimental data for the effects of gaseous Hydrogen Environment Embrittlement (HEE) for several types of metallic materials. Common material screening methods are used to rate the hydrogen degradation of mechanical properties that occur while the material is under an applied stress and exposed to gaseous hydrogen as compared to air or helium, under slow strain rates (SSR) testing. Due to the simplicity and accelerated nature of these tests, the results expressed in terms of HEE index are not intended to necessarily represent true hydrogen service environment for long-term exposure, but rather to provide a practical approach for material screening, which is a useful concept to qualitatively evaluate the severity of hydrogen embrittlement. The effects of hydrogen gas on mechanical properties such as tensile strength, ductility, fracture, low and high cycle fatigue, crack growth rate, and creep rupture are analyzed with respect to the general trends established from the HEE index values. It is observed that the severity of HE effects is also influenced by environmental factors such as pressure, temperature, and hydrogen gas purity. The severity of HE effects is also influenced by material factors such as surface finish, heat treatment, and product forms, compositions, grain direction, and crystal orientations.

Jonathan A. Lee↗
NASA NTRS1943

A Method for Removal of Bakelite-Impregnated Wire Strain Gages

An increasing interest is being shown in the use of wire-type strain gages to measure static and dynamic stresses in aircraft-engine parts. Bakelite cement has been found satisfactory as a bonding agent for attaching the strain gages to machine parts that must operate at elevated temperatures. On many occasions, it is desired to remove Bakelite-cemented gages from the test parts for the purpose of replacing faulty gages or of returning the parts to service after strain measurements have been completed. Removal of the gages by means of scraping without prior treatment is very unsatisfactory because it is tedious and almost invariably damages the finished surface. Various solvents have been tried, but all attempts in this direction have been unsuccessful inasmuch as Bakelite cement, when properly baked, forms a polymer of very high molecular weight that resists the action of solvents. This report presents a gas-flame method of removal that is rapid and does not inure the structural part.

Kemp, Richard H.↗
NASA NTRS2018

Residual Stress Mapping of As-Built and Hot Isostatic Pressure Treated GRCop-84 as Fabricated by Selective Laser Melting

GRCop-84, a copper alloy developed by NASA Glenn Research Center (GRC) with the starting At% (atomic percent) Cu-8 Cr-4 Nb, has a copper matrix with a fine intermetallic dispersion of Cr2Nb (cubic Laves phase C15). The alloy is being developed for high-heat-flux applications and has excellent high temperature properties including retention of tensile strength at high temperatures, high thermal conductivity, and excellent creep resistance. GRCop-84 has shown higher survivability rates than other metal additive alloys, good surface finish, and requires less operator tweaking for builds, and this is not fully understood. Neutron diffraction provides an accurate, non-destructive method of measuring the thermal stresses accumulated during production; the primary source of failure before annealing. The unstressed lattice spacing (d (sub 0)), residual stress, and distribution have been characterized for simple shapes in HIP (Hot Isostatic Pressing,) and as-built conditions made with SLM (Selective Laser Melting), a powder bed fusion method, with the HIP samples showing significantly reduced stresses concentrations than the as-built.

Minnecci, Robert↗
NASA NTRS2018

Antennas for Space Instruments from GHz to THz

In this paper we present an overview of different antenna technologies for space-based instruments. We show that some of the designs that work well at gigahertz frequencies are difficult to implement at terahertz frequencies due to tight tolerance and rms surface finish requirements. We also show that antenna designs are dictated not only by the frequency of operations but also by the space platform of choice. In this paper, we also present ideas for low-profile terahertz antennas for implementation on SmallSat and CubeSat platforms.

Chattopadhyay, Goutam↗
NASA NTRSDate not supplied

Supersonic Traveling Crossflow Wave Characteristics in Ground and Flight Tests

This paper continues analysis of data acquired in a series of supersonic crossflow transition experiments on a 65° swept- wing model tested in both wind tunnel and flight. Flow visualization data are summarized to provide context for the swept-wing instability mechanisms of interest. Unsteady pressure measurements obtained near the wing model leading edge (LE) are studied using 2nd- and 3rd-order statistical methods to extract traveling crossflow wave characteristics from these data. Comparisons between tunnel and flight data with boundary-layer (BL) Linear Stability Theory (LST) predictions provide insights into BL transition phenomena similarities and differences observed in tests using the same swept-wing model configurations. Comparisons of unsteady pressure data results for wing LE configurations with and without distributed-roughness-element (DRE) patterns installed, suggest traveling crossflow disturbance growth is reduced when this type of flow control is applied. A brief stud y of different background surface roughness levels on the wing LE suggests the potential for another flow control approach to promote laminar flow on swept wings using streamwise-biased surface finishes.

Lewis R Owens↗