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NASA NTRS1978

Development of Methods of Characterizing Coal in Its Plastic State

Coal in its plastic state (typically 400-460 C) was examined by the isothermal Gieseler plastometry of seven selected coals of widely varying plastic properties. Kinetic models were proposed for the isothermal plastometric curves. Plastic behavior was compared with a variety of laboratory analyses and characterizations of these coals, including classical coal analysis; mineral analysis; microstructural analysis (extractable fractions, surface area measurement, and petrographic analysis); and thermal analysis (thermogravimetric analysis, thermomechanical analysis, and differential scanning calorimetry). The phenomenon of a sharp, large, poorly reproducible exotherm in the differential scanning calorimetric analysis of coking coals was examined. Several coal extrudates show mineral distribution, organic maceral composition and overall calorific value to be little affected by 800 F extrusion. Volatile matter and plastic properties are moderately reduced, and the network structure (as gauged by extractables) appears to be slightly degraded in the extrusion process.

Lloyd, W. G.↗

NASA NTRS1981

Permanent magnet properties of Mn-Al-C between -50 C and +150 C

Anisotropic Mn-Al-C (Ni) magnets are potential substitutes for Alnico 5 and 8. The limited machinability of the alloy and the fact that it is cobalt-free made it particularly interesting. The low Curie point and the costly warm extrusion process needed for grain orientation are drawbacks. The objective of this study was a detailed magnetic characterization of the material for possible use in electric machinery. The principal subjects of the study were the largest extruded bars presently available, of 31 mm diameter. Easy and hard axis magnetization curves and second-quadrant recoil loop fields were measured at various temperatures ranging from -50 C to +150 C. Property variations over the cross section of a bar were also studied.

Abdelnour, Z. A.↗

NASA NTRS2000

Viscoelastic flow modeling in the extrusion of a dough-like fluid

This work attempts to investigate the effect of viscoelasticity and three-dimensional geometry in screw channels. The Phan-Thien Tanner (PTT) constitutive equation with simplified model parameters was solved in conjunction with the flow equations. Polyflow, a commercially available finite element code was used to solve the resulting nonlinear partial differential equations. The PTT model predicted one log scale lower pressure buildup compared to the equivalent Newtonian results. However, the velocity profile did not show significant changes for the chosen PTT model parameters. Past Researchers neglected viscoelastic effects and also the three dimensional nature of the flow in extruder channels. The results of this paper provide a starting point for further simulations using more realistic model parameters, which may enable the food engineer to more accurately scale-up and design extrusion processes.

NASA Discipline Life Support Systems↗

NASA NTRS2023

Moon-to-Mars Planetary Autonomous Construction Technology: MMPACT Material Screening

NASA’s Space Technology Mission Directorate “champions technologies needed to live on and explore the Moon” [1]. This includes capabilities that capitalize on existing lunar resources and carry out surface manufacturing and construction activities. The goal of the Moon-to-Mars Planetary Construction Technology (MMPACT) Project is to mature these two capabilities. The primary resource on the Moon and the primary feedstock for manufacturing and construction is regolith. In the past, astronauts launched, landed, and lived in a spacecraft. NASA envisions a future where we make living spaces on the lunar surface instead. The innovative technologies required for lunar surface construction may be something never seen before, or they may be adaptations of existing technologies. MMPACT must screen for the most feasible technologies with the earliest potential technology insertions given the ambitious goals of the Artemis campaign. This poster summarizes recent efforts to discover and document mechanical and thermal capabilities of various technologies: a laser-based vitreous material transformation from Texas-based ICON, a molten extrusion process from ICON, a mortar from MSFC, a mortar from an MSFC-Louisiana State University partnership, and a geopolymer from a MSFC-Pennsylvania State University partnership. Other testing and development activities are documented as well. [1] https://www.nasa.gov/directorates/spacetech/Lunar_Surface_Innovation_Initiative

In-situ Resource Utilization↗

NASA NTRS1989

Ultrasonic imaging of textured alumina

Ultrasonic images representing the bulk attenuation and velocity of a set of alumina samples were obtained by a pulse-echo contact scanning technique. The samples were taken from larger bodies that were chemically similar but were processed by extrusion or isostatic processing. The crack growth resistance and fracture toughness of the larger bodies were found to vary with processing method and test orientation. The results presented here demonstrate that differences in texture that contribute to variations in structural performance can be revealed by analytic ultrasonic techniques.

Stang, David B.↗

NASA NTRS1990

Ultrasonic imaging of textured alumina

Stang, D. B.↗

NASA NTRS2006

Manufacture of Regularly Shaped Sol-Gel Pellets

An extrusion batch process for manufacturing regularly shaped sol-gel pellets has been devised as an improved alternative to a spray process that yields irregularly shaped pellets. The aspect ratio of regularly shaped pellets can be controlled more easily, while regularly shaped pellets pack more efficiently. In the extrusion process, a wet gel is pushed out of a mold and chopped repetitively into short, cylindrical pieces as it emerges from the mold. The pieces are collected and can be either (1) dried at ambient pressure to xerogel, (2) solvent exchanged and dried under ambient pressure to ambigels, or (3) supercritically dried to aerogel. Advantageously, the extruded pellets can be dropped directly in a cross-linking bath, where they develop a conformal polymer coating around the skeletal framework of the wet gel via reaction with the cross linker. These pellets can be dried to mechanically robust X-Aerogel.

Leventis, Nicholas↗

NASA NTRS1981

Applications of polymer extrusion technology to coal processing

Upon heating, many of the middle-aged bituminous coals exhibit a plasticity very similar to polyethylene for a few minutes. Plastic coal can be extruded, pelletized or molded using common plastics technology and equipment. Investigations concerning the plastic state of coals are conducted with the objective to develop techniques which will make useful commercial applications of this property possible. Experiments which show the characteristics of plastic-state coal are discussed, and problems related to a continuous extrusion of coal are considered. Probably the most significant difference between the continuous extrusion of coal and the extrusion of a thermoplastic polymer is that volatiles are continuously being released from the coal. Attention is given to aspects of dragflow, solids feeding, and melt pumping. Application potentials for plastic coal extrusion might be related to coal gasification, direct liquefaction, and coal combustion.

Lewis, D. W.↗

NASA NTRS1979

Experimental laboratory measurement of thermophysical properties of selected coal types

A number of bituminous coals of moderate to high plasticity were examined, along with portions of their extrudates from the JPL 1.5-inch 850 F screw extruder. Portions of the condensed pyrolysis liquids released during extrusion, and of the gaseous products formed during extrusion were also analyzed. In addition to the traditional determinations, the coals and extrudates were examined in terms of microstructure (especially extractable fractions), thermal analysis (especially that associated with the plastic state), and reactivity towards thermal and catalyzed hydroliquefaction. The process of extrusion increases the fixed carbon content of coals by about 5% and tends to increase the surface area. Coals contaning 25% or more DMF-extractable material show an increase in extractables as a result of extrusion; those initially containing less than 20% extractables show a decrease as a result of extrusion. Both the raw and extruded samples of Kentucky #9 coal are highly reactive towards hydroliquefaction, undergoing conversions of 75 to 80% in 15 min and 85-94% in 60 min in a stirred clave.

Lloyd, W. G.↗

NASA NTRS1970

Development of advanced high strength tantalum base alloys. Part 2: Scale-up investigation

Three experimental tantalum alloy compositions containing 14-16% W, 1% Re, 0.7% Hf, 0.025% C or 0.015% C and 0.015% N were prepared as two inch diameter ingots by consumable electrode vacuum arc melting. The as-cast ingots were processed by extrusion and swaging to one inch and 0.4 inch diameter rod and evaluated. Excellent high temperature forging behavior was exhibited by all three compositions. Creep strength at 2000 F to 2400 F was enhanced by higher tungsten additions as well as substitution of nitrogen for carbon. Weldability of all three compositions was determined to be adequate. Room temperature ductility was retained in the advanced tantalum alloy compositions as well as a notched/unnotched strength ratio of 1.4 for a notched bar having a K sub t = 2.9.

Ammon, R. L.↗

NASA NTRS1977

Fabrication of thin layer beta alumina

Beta alumina tubes having walls 700 microns, 300 microns, and 140 microns were processed by extrusion and sintering utilizing Ford proprietary binder and fabrication systems. Tubes prepared by this method have properties similar to tubes prepared by isostatic pressing and sintering, i.e. density greater than 98% of theoretical and a helium leak rate less than 3 x 10 to the -9th power cc/sq cm/sec. Ford ultrasonic bonding techniques were used for bonding beta alumina end caps to open ended beta -alumina tubes prior to sintering. After sintering, the bond was hermetic, and the integrity of the bonded area was comparable to the body of the tube.

Tennenhouse, G. J.↗

NASA NTRS1987

Powder processing of nickel and other aluminides by hot consolidation

Alloys based on FeAl, NiAl, and Ni3Al have been processed by extrusion of powders over a range of compositions, powder characteristics, and extrusion parameters. It is found that extrusion leads to dynamic recrystallization and that the grain size of the extrusions depends on the powder size, extrusion temperature, and extrusion ratio. Prior particle boundary oxides play an important role in controlling the grain size and uniformity by acting as obstacles to grain growth. Hot isostatic pressing and vacuum hot pressing can be used for powder densification, but prior particle oxides are not effectively broken up due to insufficient shearing deformation.

Vedula, K.↗

NASA NTRS2002

Ceramic Inclusions In Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially as the material chosen for turbine disks. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that arise from the powder atomization process. These inclusions can have potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they usually don't reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where a known population of ceramic particles, whose composition and morphology are designed to mimic the 'natural' inclusions, are added to the precursor powder. Surface connected inclusions have been found to have a particularly large detrimental effect on fatigue life, therefore the volume of ceramic 'seeds' added is calculated to ensure that a minimum number will occur on the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface and embedded cross-sectional areas were needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macro slices from extrusions and forgings. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions.

Bonacuse, Pete↗

NASA NTRS2003

Development of a Novel Discontinuously Reinforced Aluminum for Space Applications

The present results indicated that: Al-Sc-Mg-X alloys were selected to provide higher strength from -423 to 450F. SiC and B4C were chosen as reinforcements. Fine spherical powder of Al-Sc-Mg-X was produced using helium gas atomization. Matrix alloy and DRA were processed using vacuum hot processing and extrusion. DRA showed very high strength 100ksi at cryo, RT and hydrogen. Ductility was low. Matrix alloy exhibited high strength and ductility. LCF of matrix was higher than DRA in high strain range.

Pandey, Awadh↗

NASA NTRS2004

Revisiting the Interpretation of Thorium Abundances at Hansteen Alpha

Hansteen Alpha is one of the few remaining locations on the Moon thought to be formed by highlands volcanism. Hansteen Alpha is a triangular shaped feature located in the southern portion of Oceanus Procellarum (12 degrees W, 50 degrees S) and its size is approximately 25 km on each side. As described by Hawke et al., there is clear evidence that: 1) Hansteen Alpha was emplaced by extrusive volcanic processes; and 2) it was formed by a viscous lava that should be enriched in Th. However, in the study of Hawke et al. using available Lunar Prospector (LP) Th data, it was concluded that the Hansteen Alpha region was not greatly enriched in Th as would be expected for a highly evolved, viscous lava. It was further concluded based on other compositional data that the magma that formed Hansteen Alpha did not correspond to any known rock type. Here we revisit the interpretation of Th abundances at Hansteen Alpha for a couple of reasons. First, the size of Hansteen Alpha is smaller than the spatial resolution of the LP Gamma-ray Spectrometer (LP-GRS) from which the Th abundances were derived. Therefore, the LP-GRS pixels covering Hansteen Alpha may not truly represent the Th abundance of the Hansteen Alpha feature. Second, recent work has led to a much greater understanding of the Th spatial distribution for small-area features on the lunar surface. In particular, using forward modeling techniques, we have developed the ability to obtain information about Th abundances for features that are at or smaller than the FWHM spatial resolution (approximately [80 square kilometers]) of the LP-GRS data.

Lawrence, D. J.↗

NASA NTRS2001

Ceramic Inclusions in Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially in turbine disk applications. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that are inherent to the powder atomization process. These inclusions can have a potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they typically do not reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where known populations of ceramic particles, whose composition and morphology are designed to mimic the "natural" inclusions, are added to the precursor powder. Surface-connected inclusions have been found to have a particularly large detrimental effect on fatigue life; therefore, the quantity of ceramic "seeds" added is calculated to ensure that a minimum number will intersect the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface area was needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macroscopic slices from extrusions and forgings. Fatigue specimens have been machined from Udimet 720 (a powder metallurgy superalloy) forgings, to determine the effects of the inclusions on fatigue life. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions. This work has been supported by the Ultra Safe and Ultra- Efficient Engine Technologies programs.

Bonacuse, Peter J.↗

NASA NTRS1986

Low-Flammability PTFE for High-Oxygen Environments

Modified forming process removes volatile combustible materials. Flammability of cable-wrapping tape reduced by altering tape-manufacturing process. In new manufacturing process, tape formed by proprietary process of screw extrusion, followed by washing in solvent and drying. Tape then wrapped as before. Spectrogram taken after extrusion, washing, and drying shows lower hydrocarbon content. PTFE formed by new process suited to oxygen-rich environments. Safe in liquid oxygen of Space Shuttle tank and in medical uses; thin-wall shrinkable tubing in hospital test equipment, surgical instruments, and implants.

Walle, E.↗

NASA NTRS1987

Systematic stratospheric-tropospheric exchange viewed from isentropic coordinates

Within the atmosphere's stratification, stratospheric-tropospheric exchange of mass and other properties occurs primarily through quasi-horizontal transport processes within baroclinic wave regimes and through diabatic processes either in the form of deep convection or through systematic meridional variation of incoming and outgoing radiation. These exchange processes include both extrusions of stratospheric air into the troposphere and intrusions of tropospheric air into the stratosphere. The physical processes that govern both meridional and vertical exchange processes within isentropic coordinates are summarized for the global circulation.

Johnson, Donald↗