Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “vacuum processes”

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 433 records · Page 24

Solubility and diffusion of hydrogen in IN-100 and Waspaloy

The solubility of hydrogen, at a fixed hydrogen pressure, was measured in two different heat treatment conditions in both IN-100 and Waspaloy by equilibrium and analysis. The diffusion coefficients were determined by measuring the rate of hydrogen evolution in a vacuum. Hydrogen evolution appeared to be a diffusion-controlled process in all cases. For hydrogen diffusion in Waspaloy, Delta H was 38.5 kJ and D0 was 2.6 x 10 to the -7th sq/s. For IN-100, Delta H was 68.2 kJ and D0 was 59 x 10 to the -7th sq/s. The values for Waspaloy are close to those for pure nickel. The values for IN-100 are more similar to high nickel alloys that show trapping or surface layer impedance.

Khan, A. S.↗

The Wake Shield Facility: A space experiment platform

Information is given in viewgraph form on Wakeshield, a space experiment platform. The Wake Shield Facility (WSF) flight program objectives, product applications, commercial development approach, and cooperative experiments are listed. The program objectives are to produce new industry-driven electronic, magnetic, and superconducting thin-film materials and devices both in terrestrial laboratories and in space; utilize the ultra-vacuum of space for thin film epitaxial growth and materials processing; and develop commercial space hardware for research and development and enhanced access to space.

Allen, Joseph P.↗

Fock State Generation From the Nonlinear Kerr Medium

We discuss a system comprising a nonlinear Kerr medium in a cavity driven by an external coherent field directly or through the parametric process. We assume that the system is initially in the vacuum state, and we show that under appropriate conditions, i.e., properly chosen detuning and intensity of the driving field, the one or two-photon Fock states of the electromagnetic field can be achieved.

Leonski, W.↗

Approaches to Design and Evaluation of Sandwich Composites

This report describes research during the period June 15, 1997 to October 31, 2000. This grant yielded a low cast manufacturing of composite sandwich structures technology and characterization interfacial and subinterfacial cracks in foam core sandwich panels. The manufacturing technology is called the vacuum assisted resin transfer (VARTM). The VARTM is suitable for processing composite materials both at ambient and elevated temperatures and of unlimited component size. This technology has been successfully transferred to a small business fiber preform manufacturing company 3TEX located in Cary, North Carolina. The grant also supported one Ph.D, one M.S and a number of under graduate students, and nine publications and Presentations.

Shivakumar, Kunigal↗

Plasma Interactions with High Voltage Solar Arrays for a Direct Drive Hall Effect Thruster System

The Environmental Effects Group of NASA s Marshall Space Flight Center (MSFC) is conducting research into the effects of plasma interaction with high voltage solar arrays. These high voltage solar arrays are being developed for a direct drive Hall Effect Thruster propulsion system. A direct drive system configuration will reduce power system mass by eliminating a conventional power-processing unit. The Environmental Effects Group has configured two large vacuum chambers to test different high-voltage array concepts in a plasma environment. Three types of solar arrays have so far been tested, an International Space Station (ISS) planar array, a Tecstar planar array, and a Tecstar solar concentrator array. The plasma environment was generated using a hollow cathode plasma source, which yielded densities between 10(exp 6) - 10(exp 7) per cubic centimeter and electron temperatures of 0.5-1 eV. Each array was positioned in this plasma and biased in the -500 to + 500 volt range. The current collection was monitored continuously. In addition, the characteristics of arcing, snap over, and other features, were recorded. Analysis of the array performance indicates a time dependence associated with the current collection as well as a tendency for "conditioning" over a large number of runs. Mitigation strategies, to reduce parasitic current collection, as well as arcing, include changing cover-glass geometry and layout as well as shielding the solar cell edges. High voltage performance data for each of the solar array types tested will be presented. In addition, data will be provided to indicate the effectiveness of the mitigation techniques.

Schneider, T.↗

Design and Manufacturing Processes of Long-Life Hollow Cathode Assembles

A process for testing an impregnated insert of a Hollow Cathode Assembly (HCA) subsequent to every exposure of the HCA to air, and prior to ignition, using a heater and an oil-free assembly having a base pressure of less than 5.0 x 10(exp -6) torr. The process comprises the steps of: installing the HCA in a vacuum; energizing the heater to a particular current level; de-energizing the heater after one-half hour; again energizing the heater to a particular current level; and de-energizing the heater for at least one-half hour.

Michael J Patterson↗

Fabrication of a Kilopixel Array of Superconducting Microcalorimeters with Microstripline Wiring

A document describes the fabrication of a two-dimensional microcalorimeter array that uses microstrip wiring and integrated heat sinking to enable use of high-performance pixel designs at kilopixel scales (32 X 32). Each pixel is the high-resolution design employed in small-array test devices, which consist of a Mo/Au TES (transition edge sensor) on a silicon nitride membrane and an electroplated Bi/Au absorber. The pixel pitch within the array is 300 microns, where absorbers 290 microns on a side are cantilevered over a silicon support grid with 100-micron-wide beams. The high-density wiring and heat sinking are both carried by the silicon beams to the edge of the array. All pixels are wired out to the array edge. ECR (electron cyclotron resonance) oxide underlayer is deposited underneath the sensor layer. The sensor (TES) layer consists of a superconducting underlayer and a normal metal top layer. If the sensor is deposited at high temperature, the ECR oxide can be vacuum annealed to improve film smoothness and etch characteristics. This process is designed to recover high-resolution, single-pixel x-ray microcalorimeter performance within arrays of arbitrarily large format. The critical current limiting parts of the circuit are designed to have simple interfaces that can be independently verified. The lead-to-TES interface is entirely determined in a single layer that has multiple points of interface to maximize critical current. The lead rails that overlap the TES sensor element contact both the superconducting underlayer and the TES normal metal

Chervenak, James↗

Multi-Scale CNT-Based Reinforcing Polymer Matrix Composites for Lightweight Structures

Reinforcing critical areas in carbon polymer matrix composites (PMCs), also known as fiber reinforced composites (FRCs), is advantageous for structural durability. Since carbon nanotubes (CNTs) have extremely high tensile strength, they can be used as a functional additive to enhance the mechanical properties of FRCs. However, CNTs are not readily dispersible in the polymer matrix, which leads to lower than theoretically predicted improvement in mechanical, thermal, and electrical properties of CNT composites. The inability to align CNTs in a polymer matrix is also a known issue. The feasibility of incorporating aligned CNTs into an FRC was demonstrated using a novel, yet commercially viable nanofiber approach, termed NRMs (nanofiber-reinforcing mats). The NRM concept of reinforcement allows for a convenient and safe means of incorporating CNTs into FRC structural components specifically where they are needed during the fabrication process. NRMs, fabricated through a novel and scalable process, were incorporated into FRC test panels using layup and vacuum bagging techniques, where alternating layers of the NRM and carbon prepreg were used to form the reinforced FRC structure. Control FRC test panel coupons were also fabricated in the same manner, but comprised of only carbon prepreg. The FRC coupons were machined to size and tested for flexural, tensile, and compression properties. This effort demonstrated that FRC structures can be fabricated using the NRM concept, with an increased average load at break during flexural testing versus that of the control. The NASA applications for the developed technologies are for lightweight structures for in-space and launch vehicles. In addition, the developed technologies would find use in NASA aerospace applications such as rockets, aircraft, aircraft/spacecraft propulsion systems, and supporting facilities. The reinforcing aspect of the technology will allow for more efficient joining of fiber composite parts, thus offering additional weight savings. More robust structures capable of withstanding micrometeoroid and space debris impacts will be possible with the enhanced mechanical properties imparted by the aligned CNTs incorporated into the fiber composite structure, as well as the potential for improved electrical and thermal properties. The materials fabrication approach developed in the present effort is a platform for customer applications where additional reinforcement is required or would be beneficial, especially in FRC structures and component parts. Depending upon the specific customer application, the NRM could be tailored to the specific matrix resin and desired property enhancement.

Eberly, Daniel↗

Ames Engineering Directorate

The Ames Engineering Directorate is the principal engineering organization supporting aerospace systems and spaceflight projects at NASA's Ames Research Center in California's Silicon Valley. The Directorate supports all phases of engineering and project management for flight and mission projects-from R&D to Close-out-by leveraging the capabilities of multiple divisions and facilities.The Mission Design Center (MDC) has full end-to-end mission design capability with sophisticated analysis and simulation tools in a collaborative concurrent design environment. Services include concept maturity level (CML) maturation, spacecraft design and trades, scientific instruments selection, feasibility assessments, and proposal support and partnerships. The Engineering Systems Division provides robust project management support as well as systems engineering, mechanical and electrical analysis and design, technical authority and project integration support to a variety of programs and projects across NASA centers. The Applied Manufacturing Division turns abstract ideas into tangible hardware for aeronautics, spaceflight and science applications, specializing in fabrication methods and management of complex fabrication projects. The Engineering Evaluation Lab (EEL) provides full satellite or payload environmental testing services including vibration, temperature, humidity, immersion, pressure/altitude, vacuum, high G centrifuge, shock impact testing and the Flight Processing Center (FPC), which includes cleanrooms, bonded stores and flight preparation resources. The Multi-Mission Operations Center (MMOC) is composed of the facilities, networks, IT equipment, software and support services needed by flight projects to effectively and efficiently perform all mission functions, including planning, scheduling, command, telemetry processing and science analysis.

Small Satellites↗

Evaporation in equilibrium, in vacuum, and in hydrogen gas

Evaporation experiments were conducted for SiO2 in three different conditions: in equilibrium, in vacuum, and in hydrogen gas. Evaporation rate in vacuum is about two orders of magnitude smaller than that in equilibrium, which is consistent with previous works. The rate in hydrogen gas changes depending on hydrogen pressure. The rate at 10 exp -7 bar of hydrogen pressure is as small as that of free evaporation, but at 10 exp -5 bar of hydrogen pressure it is larger than that in equilibrium. In equilibrium and in vacuum, the evaporation rate is limited by decomposition of SiO2 on the crystal surface, but it is limited by a diffusion process for evaporation in hydrogen gas. Therefore, evaporation rate of minerals in the solar nebula can be shown neither by that in equilibrium nor by that in vacuum. The maximum temperature of the solar nebula at the midplane at 2-3 AU where chondrites are believed to have originated is calculated to be as low as 150 K, 1500 K, or in between them. The temperature is, in any case, not high enough for total evaporation of the interstellar materials. Therefore, evaporation of interstellar materials is one of the most important processes for the origin and fractionation of solid materials. The fundamental process of evaporation of minerals has been intensively studied for these several years. Those experiments were carried out either in equilibrium or in vacuum; however, evaporation in the solar nebula is in hydrogen (and much smaller amount of helium) gas. In order to investigate evaporation rate and compositional (including isotopic) fractionation during evaporation, vaporization experiments for various minerals in various conditions are conducted. At first, SiO2 was adopted for a starting material, because thermochemical data and its nature of congruent vaporization are well known. Experiments were carried out in a vacuum furnace system.

Nagahara, Hiroko↗

Simplified procedures for correlation of experimentally measured and predicted thrust chamber performance

Thrust chamber performance is evaluated in terms of an analytical model incorporating all the loss processes that occur in a real rocket motor. The important loss processes in the real thrust chamber were identified, and a methodology and recommended procedure for predicting real thrust chamber vacuum specific impulse were developed. Simplified equations for the calculation of vacuum specific impulse are developed to relate the delivered performance (both vacuum specific impulse and characteristic velocity) to the ideal performance as degraded by the losses corresponding to a specified list of loss processes. These simplified equations enable the various performance loss components, and the corresponding efficiencies, to be quantified separately (except that interaction effects are arbitrarily assigned in the process). The loss and efficiency expressions presented can be used to evaluate experimentally measured thrust chamber performance, to direct development effort into the areas most likely to yield improvements in performance, and as a basis to predict performance of related thrust chamber configurations.

Powell, W. B.↗

High Temperature Transfer Molding Resins: Status of PETI-298 and PETI-330

Two phenylethynyl terminated oligomers designated PETI-298 and PETI-330 were developed at the NASA Langley Research Center and have emerged as leading candidates for composite applications requiring high temperature performance (i.e. greater than or equal to 288 C for 1000 hours) combined with the ability to be readily processed into composites without the use of an autoclave or complex/lengthy cure or post-cure cycle. These high performance/high temperature composites are potentially useful on advanced aerospace vehicles in structural applications and as aircraft engine components such as inlet frames and compressor vanes. The number designation (i.e. 298, 330) refers to the glass transition temperature in degrees Celsius as determined on neat resin cured for 1 hour at 371 C. The resins are processable by non-autoclave techniques such as resin transfer molding (RTM), vacuum assisted RTM (VARTM) and resin infusion (RI). Both resins exhibit low complex melt viscosities (0.1-10 poise) at 280 C and are stable for greater than or equal to 2 hours at this temperature. Typically, the resins are melted, de-gassed and infused or injected at 280 C and subsequently cured at 371 C for 1-2 hours. Virtually no volatiles are evolved during the cure process. The resin synthesis is straightforward and has been scaled-up to 25 kg batches. The chemistry of PETI-298 and PETI-330 and the RTM AS-4 and T-650 carbon fabric laminate properties, and those of BMI-5270 for comparison, are presented.

Connell, John W.↗

Cleaning process for contaminated superalloy powders

A cleaning process for removing interstitial contaminants from superalloy powders after wet grinding is described. Typical analyses of oxygen, carbon, nitrogen, and hydrogen in ball-milled WAZ-20 superalloy samples after hydrogen plus vacuum cleaning are presented. The hydrogen cleaning step involves heating retorts containing superalloy powder twice under flowing hydrogen with a 24-hour hold at each temperature. The vacuum step involves heating cold-pressed billets two hours at an elevated temperature at a pressure of 10 microPa. It is suggested that the hydrogen plus vacuum cleaning procedure can be applied to superalloys contaminated by other substances in other industrial processes.

Anglin, A. E.↗

WFC3 Calibration and Data Processing

Wide Field Camera 3 (WFC3), a panchromatic imager being developed for the Hubble Space Telescope (HST), is now fully integrated and over the past year has completed first rounds of extensive ground testing at Goddard Space Flight Center (GSFC), in both ambient and thermal-vacuum test environments. This report summarizes the results of those tests and describes the pipeline processing methods that will be used to calibrate WFC3 data. WFC3 is designed to ensure that the superb imaging performance of HST is maintained through the end of the mission and takes advantage of recent developments in detector technology to provide new and unique capabilities for HST. WFC3 contains ultraviolet/visible (UVIS) and near-infrared (IR) imaging channels, offering high sensitivity and wide field of view over the broadest wavelength range of any HST instrument. It is slated to replace the current Wide Field and Planetary Camera 2 during Servicing Mission 4. The WFC3 UVIS channel is based on elements from the Advanced Camera for Surveys (ACS)Wide Field Camera (WFC), with a 4096x4096 pixel Marconi CCD covering a 160x160 arcsecond field of view. The WFC3 UVIS channel is optimized for maximum sensitivity in the near-UV and contains a complement of 48 spectral filters and a grism. The WFC3 IR channel uses a 1024x1024 pixel HgCdTe Hawaii-1R detector array covering a 135x135 arcsecond field of view. The array sensitivity is optimized in the 0.8-1.7micron spectral range. The IR channel accomodates 15 filters and 2 grisms for slitless spectroscopy.

Bushouse, H.↗

Experimental study of solar simulator mirror cryocontamination

The background and tasks formulation of the study of Solar Simulator collimation mirror cryocontamination in Large Thermal Vacuum Facility are outlined, research methods and experiment procedures are described, experimental relationships obtained are analyzed and practical recommendations are given. The accepted procedure of thermal vacuum tests as a rule defines the sequence of operations for verifying the spacecraft under test without taking into account measures for preventing Solar Simulator collimation mirror contamination and degradation. On the other hand, evacuation procedures is defined for conditions of achieving the required vacuum in the shortest possible time with using the available evacuation equipment at a regime close to the optimum one. Similarly, cryopanel cooling down cyclogram and test object preparation process are not analyzed from the viewpoint of ways of reducing environmental detrimental effects on thermal vacuum facility contamination-sensitive systems. Solar Simulator mirror contamination and its reflective characteristics change results in degradation of solar flux parameters and reduction of simulator continuous operation time. Methods of consideration of optical effects due to mirror surface contamination are actually missing. The effects themselves are not quite understood and data cited in literature as a rule, were obtained under conditions different from real thermal vacuum facility and therefore should be subjected to additional experimental verification. Only in the last few years contamination effect on optical surfaces degradation has been considered with using empirical relations. Mirror reflective properties degradation leads to the increase of Solar Simulator errors. This ultimately has an adverse effect on S/C ground development, schedule and cost of thermal vacuum tests. Besides, the mirror maintenance in operable state becomes more expensive. The present paper is dedicated to the study of Solar Simulator collimation mirror contamination and to the search of ways for improving the mirror design and thermal vacuum test procedure. On the basis of tests performed, recommendations are devised on reducing chamber inner-optical surfaces cryocontamination and degradation.

Galjaev, V. L.↗

Vacuum plasma spray coating

Currently, protective plasma spray coatings are applied to space shuttle main engine turbine blades of high-performance nickel alloys by an air plasma spray process. Originally, a ceramic coating of yttria-stabilized zirconia (ZrO2.12Y2O3) was applied for thermal protection, but was removed because of severe spalling. In vacuum plasma spray coating, plasma coatings of nickel-chromium-aluminum-yttrium (NiCrAlY) are applied in a reduced atmosphere of argon/helium. These enhanced coatings showed no spalling after 40 MSFC burner rig thermal shock cycles between 927 C (1700 F) and -253 C (-423 F), while current coatings spalled during 5 to 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2.8Y2O3 to the turbine blades of first-stage high-pressure fuel turbopumps utilizing the enhanced NiCrAlY bond-coating process. NiCrAlY bond coating is applied first, with ZrO2.8Y2O3 added sequentially in increasing amounts until a thermal barrier coating is obtained. The enchanced thermal barrier coating has successfully passed 40 burner rig thermal shock cycles.

Holmes, Richard R.↗

Crystal nucleation and glass formation in metallic alloy melts

Homogeneous nucleation, containerless solidification, and bulk formation of metallic glasses are discussed. Homogeneous nucleation is not a limiting factor for metallic glass formation at slow cooling rates if the reduced glass transition temperature is high enough. Such glasses can be made in bulk if heterogeneous nucleants are removed. Containerless processing eleminates potential sources of nucleants, but as drop tube experiments on the Pd-Si alloys show, the free surface may still be a very effective heterogeneous nucleant. Combination of etching and heating in vacuum or fluxing can be effective for cleaning fairly large ingots of nucleants. Reduced gravity processing has a potentially useful role in the fluxing technique, for example to keep large metallic ingots surrounded by a low density, low fluidity flux if this proved difficult under ground conditions. For systems where heterogeneous nucleants in the bulk of the ingot need gravity to segregate to the flux-metal interface, reduced gravity processing may not be appropriate for bulk glass formation.

Spaepen, F.↗

X-Ray Computed Tomography During Preliminary Examination of Apollo Drive Tube 73001

Introduction: Starting in 2019, the Apollo Next Generation Sample Analysis (ANGSA) Program has enabled consortium studies of specially curated Apollo samples that were previously unstudied (or under studied). This began with unsealed core tube 73002 [1,2] that is the upper part of a station 3 double drive tube. More recently the pro-gram extended to the study of a variety of frozen Apollo 17 samples [3], as well as the gas extraction [4] and dis-section [5] of 73001, the lower half of the station 3 double drive tube, that was sealed under vacuum on the Moon. In this abstract we will examine the role of X-ray Computed Tomography (XCT) during the preliminary examination process for sealed core 73001, including: (1) engineering scans to aid in understanding the gas extraction process, whole-core scanning prior to opening to inform extrusion and dissection work, and (3) individual particle scanning to characterize rock fragment lithologies for follow on studies. Methodology: Sample 73001 is a 33 cm long, 4 cm diameter regolith sample collected inside a drive tube (~1 mm aluminum walls). That drive tube was sealed inside a 0.5 mm thick stainless steel (SS) Core Sample Vacuum Container (CSVC). XCT scans for engineering purposes were done on the Nikon XTH 320 system at Johnson Space Center using the 225 kV multi-metal reflection source at 215 kV, 179 A, and a 38.49 m voxel size. Individual >4 mm particles separated from the core during processing (then triply sealed in Teflon bags) were also scanned at JSC using the 180 kV source at 90 kV, 33 A, and a 2.98 – 10.65 m voxel size. Whole-core scans were done at the University of Texas High-Resolution X-ray Computed Tomography Facility (UTCT) on the 225 kV reflection source on the North Star Imaging cabinet XCT system. These scans included: (1) a series of 9 overlapping super-resolution scans each covering a ~4 cm length of the tube at 190 kV, 180 µA, and a 12.9 µm voxel size and (2) a lower resolution continuous helical scan of the entire core at 190 kV, 180 µA, and a 51.8 µm voxel size. Progress and Results: Before piercing and extracting the gas from sample 73001, an XCT scan of the bottom portion of the CSVC was used to confirm the location of the Teflon cap on the inner drive tube, to ensure it was not accidentally pierced during gas extraction. Similarly, after piercing, the bottom and top portions of the CSVC were scanned in order to capture engineering knowledge about the results of the piercing process, as well as the metal knife edge vacuum seal (SS into In-Ag alloy). Both scans will provide constraints on future work of this type, particularly for samples collected during the Artemis mission. Another finding from these "engineering" scans was that the device in the drive tube that immobilizes the regolith (the keeper) was not seated in the tube properly. This meant that (1) the drive tube could not be removed from the CSVC for the trip to UTCT, and (2) the procedure for opening and extruding the drive tube had to be modified. Had either of these things not been known prior to opening the CSVC, it could have led to an inability to XCT scan the whole core at high resolution and/or potential disruption of the core stratigraphy during extrusion. At UTCT, the entire length of the core was scanned at high resolution (12.9 microns per voxel). This scan serves multiple purposes: (1) A lower resolution (and uncorrected) version of these scans stitched together was used to help inform the processors of potential pitfalls during extrusion and dissection; and (2) the full resolution corrected data will serve as the permanent in situ record of the stratigraphy of the sample and will enable future researchers to perform a variety of analyses. So far, 92 of the 121 >4 mm particles separated during dissection pass 1 of sample 73001 have been individually scanned. These scans clearly show the lithology of each particle while keeping the particles in pristine condition. Because of the dust adhering to particle exteriors it would otherwise be impossible to determine lithologies in a non-contaminating way. Thus far the types of lithologies seen in sample 73001 (e.g., regolith breccias, impact-melt breccias, agglutinates, and basalts) are similar to those previously identified in sample 73002 [2]. By the time of the meeting, all particles from all 3 dissection passes will have been scanned and statistics on the different lithologies in 73001 compiled. References: [1] Shearer et al. (2020) 51st LPSC, abstract 1181. [2] Zeigler et al. (2020) 51st LPSC, abstract 3023. [3] Kent et al. (2022) This Volume. [4] McDonald et al. (2022) European Lunar Symposium. [5] Gross et al (2022) This volume.

Moon↗