Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “metallic components”

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 37 records · Page 2

Microelectronic components and metallic oxide studies and applications

The project involved work in two basic areas: (1) Evaluation of commercial screen printable thick film conductors, resistors, thermistors and dielectrics as well as alumina substrates used in hybird microelectronics industries. Results of tests made on materials produced by seven companies are presented. (2) Experimental studies on metallic oxides of copper and vanadium, in an effort to determine their electrochemical properties in crystalline, powder mixtures and as screen printable thick films constituted the second phase of the research effort. Oxide investigations were aimed at finding possible applications of these materials as switching devices memory elements and sensors.

Williams, L., Jr.↗

Long-life mission reliability for outer planet atmospheric entry probes

The results of a literature analysis on the effects of prolonged exposure to deep space environment on the properties of outer planet atmospheric entry probe components are presented. Materials considered included elastomers and plastics, pyrotechnic devices, thermal control components, metal springs and electronic components. The rates of degradation of each component were determined and extrapolation techniques were used to predict the effects of exposure for up to eight years to deep space. Pyrotechnic devices were aged under accelerated conditions to an equivalent of eight years in space and functionally tested. Results of the literature analysis of the selected components and testing of the devices indicated that no severe degradation should be expected during an eight year space mission.

Mccall, M. T.↗

The Significance of Small Cracks in Fatigue Design Concepts as Related to Rotorcraft Metallic Dynamic Components

In this paper the significance of the "small" crack effect as defined in fracture mechanics will be discussed as it relates to life managing rotorcraft dynamic components using the conventional safe-life, the flaw tolerant safe-life, and the damage tolerance design philosophies. These topics will be introduced starting with an explanation of the small-crack theory, then showing how small-crack theory has been used to predict the total fatigue life of fatigue laboratory test coupons with and without flaws, and concluding with how small cracks can affect the crack-growth damage tolerance design philosophy. As stated in this paper the "small" crack effect is defined in fracture mechanics where it has been observed that cracks on the order of 300 microns or less in length will propagate at higher growth rates than long cracks and also will grow at AK values below the long crack AK threshold. The small-crack effect is illustrated herein as resulting from a lack of crack closure and is explained based on continuum mechanics principles using crack-closure concepts in fracture mechanics.

Everett, R. A., Jr.↗

AMTEC cell testing, optimization of rhodium/tungsten electrodes, and tests of other components

Electrodes, current collectors, ceramic to metal braze seals, and metallic components exposed to the high 'hot side' temperatures and sodium liquid and vapor environment have been tested and evaluated in laboratory cells running for hundreds of hours at 1100-1200 K. Rhodium/tungsten electrodes have been selected as the optimum electrodes based on performance parameters and durability. Current collectors have been evaluated under simulated and actual operating conditions. The microscopic effects of metal migration between electrode and current collector alloys as well as their thermal and electrical properties determined the suitability of current collector and lead materials. Braze seals suitable for long term application to AMTEC devices are being developed.

Williams, Roger M.↗

Internal Electrostatic Discharge Testing of Inert Solid Rocket Motor Materials

Jupiter’s moon Europa is believed to have a global liquid-water ocean beneath its icy surface. As such, it is a highly interesting destination for explorers seeking signs of life outside of Earth. This interest has given rise to the Europa Lander Mission [Hand, et al., 2017]. The central goal of the Europa Lander Mission is to place a stationary lander on Europa and make surface and sub-surface measurements, dramatically improving understanding of this Jovian moon, and potentially detecting signs of life.Placing a lander on Europa will require multiple spacecraft elements deployed across a multi-year mission timeline. Some of the key elements include: a large payload capacity rocket, such as the Space Launch System (SLS), capable of providing direct Jupiter orbit insertion; a solar-powered carrier; a de-orbit system; a sky crane landing system; and, of course, the surface lander. A noteworthy fact is that the current design requires a large solid rocket motor to provide the necessary braking thrust for the de-orbit stage. While solid rocket motors have been used extensively by NASA during launch, in-space use has been limited. In addition to the normal challenges associated with a long-distance planetary mission, the Europa Lander Mission must also contend with the high-radiation environment associated with the Jovian system. The size of Jupiter, combined with its magnetic field strength, and rotation speed, result in a harsh radiation environment composed of high energy charged particles (ions and electrons) as well as high-temperature plasmas [de Soria-Santacruz Pich, 2016]. Due to this high-radiation environment, each component of the Europa Lander spacecraft must be evaluated to determine its radiation dose tolerance and its likelihood for experiencing electrostatic charging (and discharging). In general, metal components in a Jovian environment do not pose a concern for radiation degradation; in fact, metal structures and closeouts can act as radiation shielding for the more sensitive components. Charging of a metal component is only an issue if the component is not properly grounded to the spacecraft chassis. However, electrically insulating materials, such as polymers, are subject to radiation degradation as well as surface and internal charging, and therefore require extra scrutiny. The focus of this paper will be on the insulating materials that are commonly used inside solid rocket motors. The special application of a solid rocket motor used in space after a relatively long duration flight, combined with the high energy electron environment in the Jovian system, raises concerns about the possibility of significant charging and discharging leading to reduced performance.

Schneider, Todd A.↗

Silicon Alignment Pins: An Easy Way to Realize a Wafer-To-Wafer Alignment

A silicon alignment pin is used to align successive layers of components made in semiconductor chips and/or metallic components to make easier the assembly of devices having a layered structure. The pin is made as a compressible structure which can be squeezed to reduce its outer diameter, have one end fit into a corresponding alignment pocket or cavity defined in a layer of material to be assembled into a layered structure, and then allowed to expand to produce an interference fit with the cavity. The other end can then be inserted into a corresponding cavity defined in a surface of a second layer of material that mates with the first layer. The two layers are in registry when the pin is mated to both. Multiple layers can be assembled to create a multilayer structure. Examples of such devices are presented.

Jung-Kubiak, Cecile↗

Wafer-To-Wafer Alignment Method

A silicon alignment pin is used to align successive layer of component made in semiconductor chips and/or metallic components to make easier the assembly of devices having a layered structure. The pin is made as a compressible structure which can be squeezed to reduce its outer diameter, have one end fit into a corresponding alignment pocket or cavity defined in a layer of material to be assembled into a layered structure, and then allowed to expand to produce an interference fit with the cavity. The other end can then be inserted into a corresponding cavity defined in a surface of a second layer of material that mates with the first layer. The two layers are in registry when the pin is mated to both. Multiple layers can be assembled to create a multilayer structure. Examples of such devices are presented.

Jung-Kubiak, Cecile↗

Utilizing Modal Testing for Monitoring the Structural Health of Wind Tunnel Facility Hardware

The 10- by 10-Foot Abe Silverstein Supersonic Wind Tunnel (10×10) is the largest and fastest wind tunnel facility at NASA’s Glenn Research Center(GRC) and is specifically designed to test supersonic propulsion components from inlets and nozzles to full-scale jet and rocket engines[1]. Recently, a critical part of the wind tunnel failed and required a redesign before reintegrating into the facility. The design requirements of this new component required that clearances between large metallic components exist, which have the potential for undesirable nonlinear dynamics to occur, in particular rattling. Rattling is feared to occur when the wind tunnel is being operated in certain flow regimes that induce cyclic aero loads on the new component near its natural frequencies. This paper describes the approach taken to better understand and resolve this vibration problem using modal testing. A modal test was developed and executed by GRC’s Structural Dynamics Lab to quantify the modal parameters of the structure, namely which specific excitation frequencies caused the structure to rattle. These results were shared with facility operators as frequency ranges that should be avoided to ensure maximum lifespan of the new structure. Additional means of structural health monitoring (SHM) as well as Vortex shedding are briefly discussed in this paper.

Pederson, Kenneth↗

Urban Biomining Meets Printable Electronics: End-To-End at Destination Biological Recycling and Reprinting

Space missions rely utterly on metallic components, from the spacecraft to electronics. Yet, metals add mass, and electronics have the additional problem of a limited lifespan. Thus, current mission architectures must compensate for replacement. In space, spent electronics are discarded; on earth, there is some recycling but current processes are toxic and environmentally hazardous. Imagine instead an end-to-end recycling of spent electronics at low mass, low cost, room temperature, and in a non-toxic manner. Here, we propose a solution that will not only enhance mission success by decreasing upmass and providing a fresh supply of electronics, but in addition has immediate applications to a serious environmental issue on the Earth. Spent electronics will be used as feedstock to make fresh electronic components, a process we will accomplish with so-called 'urban biomining' using synthetically enhanced microbes to bind metals with elemental specificity. To create new electronics, the microbes will be used as 'bioink' to print a new IC chip, using plasma jet electronics printing. The plasma jet electronics printing technology will have the potential to use martian atmospheric gas to print and to tailor the electronic and chemical properties of the materials. Our preliminary results have suggested that this process also serves as a purification step to enhance the proportion of metals in the 'bioink'. The presence of electric field and plasma can ensure printing in microgravity environment while also providing material morphology and electronic structure tunabiity and thus optimization. Here we propose to increase the TRL level of the concept by engineering microbes to dissolve the siliceous matrix in the IC, extract copper from a mixture of metals, and use the microbes as feedstock to print interconnects using mars gas simulant. To assess the ability of this concept to influence mission architecture, we will do an analysis of the infrastructure required to execute this concept on Mars, and additional opportunities it could offer mission design from the biological and printing technologies. In addition, we will do an analysis of the impact of this technology for terrestrial applications addressing in particular environmental concerns and availability of metals.

Space mission↗

Method of making bearing materials

A method is described for making a composite material which provides low friction surfaces for materials in rolling or sliding contact. The composite material which is self-lubricating and oxidation resistant up to and in excess of about 930 C is comprised of a metal component which lends strength and elasticity to the structure and a fluorine salt component which provides oxidation protection to the metal but may also enhance the lubrication qualities of the composite.

Sliney, H. E.↗

Automated Eddy Current Inspection on Space Shuttle Hardware

Over the life time of the Space Shuttle program, metal parts used for the Reusable Solid Rocket Motors (RSRMs) have been nondestructively inspected for cracks and surface breaking discontinuities using magnetic particle (steel) and penetrant methods. Although these inspections adequately screened for critical sized cracks in most regions of the hardware, it became apparent after detection of several sub-critical flaws that the processes were very dependent on operator attentiveness and training. Throughout the 1990's, eddy current inspections were added to areas that had either limited visual access or were more fracture critical. In the late 1990's. a project was initiated to upgrade NDE inspections with the overall objective of improving inspection reliability and control. An automated eddy current inspection system was installed in 2001. A figure shows one of the inspection bays with the robotic axis of the system highlighted. The system was programmed to inspect the various case, nozzle, and igniter metal components that make up an RSRM. both steel and aluminum. For the past few years, the automated inspection system has been a part of the baseline inspection process for steel components. Although the majority of the RSRM metal part inventory ts free of detectable surface flaws, a few small, sub-critical manufacturing defects have been detected with the automated system. This paper will summarize the benefits that have been realized with the current automated eddy current system, as well as the flaws that have been detected.

Hartmann, John↗

Bearing material

A composite material is described which will provide low friction surfaces for materials in rolling or sliding contact and is self-lubricating and oxidation resistant up to and in excess of about 930 C. The composite is comprised of a metal component which lends strength and elasticity to the structure, a fluoride salt component which provides lubrication and, lastly, a glass component which not only provides oxidation protection to the metal but may also enhance the lubrication qualities of the composite.

Sliney, H. E.↗

Method of making bearing material

A composite material is described which will provide low friction surfaces for materials in rolling or sliding contact and is self lubricating and oxidation resistant up to and in excess of about 930 C. The composite is comprised of a metal component which lends strength and elasticity to the structure, a fluoride salt component which provides lubrication and, lastly, a glass component which not only provides oxidation protection to the metal but may also enhance the lubrication qualities of the composite.

Sliney, H. E.↗

Advanced Material Developments with Laser Engineered Net Shaping

The Laser Engineered Net Shaping (LENS(Trademark)) process is a new technology to fabricate three-dimensional metallic components directly from CAD solid models. It directly fabricates metal hardware by injecting the metal powder of choice into the focal point of a 700W Nd:Yag laser as it traces the perimeter and fills of a part. The Rapid Prototype Laboratory at Marshall Space Flight Center is currently operating a OPTOMEC 750 LENS machine in evaluation experiments involving integration of this technology into various manufacturing processes associated with aerospace applications. This paper will cover our research finding about properties of samples created from Inconel 718 & SS316 using this process versus the same materials in cast & wrought conditions.

Williams, Glenn A.↗

Development of nonmetallic solar collector and solar-powered pump

Design and building of two unique components for solar heating (1. flatplate solar collector using no metal components, and 2. solar powered pump for heating and cooling systems are outlined in report. Report also discusses hardware, deliverable end items, problems encountered during fabrication and testing, and performance certification.

Parker, J. C.↗

Ceramic Matrix Composites for Rotorcraft Engines

Ceramic matrix composite (CMC) components are being developed for turbine engine applications. Compared to metallic components, the CMC components offer benefits of higher temperature capability and less cooling requirements which correlates to improved efficiency and reduced emissions. This presentation discusses a technology develop effort for overcoming challenges in fabricating a CMC vane for the high pressure turbine. The areas of technology development include small component fabrication, ceramic joining and integration, material and component testing and characterization, and design and analysis of concept components.

Halbig, Michael C.↗