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At least 451 records · Page 25

All sources NASA NTRS DOE OSTI

NASA NTRS1978

External insulator for liquid hydrogen tanks

With optimized insulation thickness, tank temperatures were always below 311 K (100 F). This conclusion indicated that an aluminum tank could be used with an optimized insulation system if desired. The N2 purged systems were always lighter than CO2 purged systems. The lower condensation temperature was the controlling factor. Closed cell foam systems were lightest. Closed cell foams, in spite of their need for protective outer insulation, produced insulation systems which were lighter than systems which allowed cryodeposition. Foam system durability established for TMAX = 316 K (110 F). Tests for a subsonic application established this durability; higher temperature limit foam durability was unknown at this. An increase in foam TMAX from 316 K (110 F) to 450 K (350 F) potentially decreased TPS mass by 25 percent.

Sharpe, E. L.↗

NASA NTRS1980

Ceramic regenerator systems development program

The DOE/NASA Ceramic Regenerator Design and Reliability Program aims to develop ceramic regenerator cores that can be used in passenger car and industrial/truck gas turbine engines. The major cause of failure of early gas turbine regenerators was found to be chemical attack of the ceramic material. Improved materials and design concepts aimed at reducing or eliminating chemical attack were placed on durability test in Ford 707 industrial gas turbine engines late in 1974. Results of 53,065 hours of turbine engine durability testing are described. Two materials, aluminum silicate and magnesium aluminum silicate, show promise. Five aluminum silicate cores attained the durability objective of 10,000 hours at 800 C (1472 F). Another aluminum silicate core shows minimal evidence of chemical attack after 8071 hours at 982 C (1800 F). Results obtained in ceramic material screening tests, aerothermodynamic performance tests, stress analysis, cost studies, and material specifications are included.

Fucinari, C. A.↗

NASA NTRS1980

Effects of commercial aircraft operating environment on composite materials

Long term effects of commercial aircraft operating environment on the properties and durability of composite materials are being systematically explored. Composite specimens configured for various mechanical property tests are exposed to environmental conditions on aircraft in scheduled airline service, on racks at major airports, and to controlled environmental conditions in the laboratory. Results of tests following these exposures will identify critical parameters affecting composite durability, and correlation of the data will aid in developing methods for predicting durability. Interim results of these studies show that mass change of composite specimens on commercial aircraft depends upon the regional climate and season, and that mass loss from composite surfaces due to ultraviolet radiation can be largely prevented by aircraft paint.

Chapman, A. J.↗

NASA NTRS1982

Evaluation of high temperature structural adhesives for extended service

The evaluation, selection, and demonstration of structural adhesive systems for supersonic cruise research applications, and establishment of environmental durability of selected systems for up to 20,000 hours is described. Ten candidate adhesives were initially evaluated. During screening and evaluation, these candidates were narrowed to three of the most promising for environmental durability testing. The three adhesives were LARC-13, PPQ, and NR056X. The LARC-13 was eliminated because of a lack of stability at 505 K. The NRO56X was removed from the market. The LARC-TPI was added after preliminary evaluation and an abbreviated screening test. Only PPQ and LARC-TPI remained as the reasonable candidates late into the durability testing. Large area bond panels were fabricated to demonstrate the processibility of the selected systems. Specifications were prepared to assure control over critical material and process parameters. Surface characterization concentrated primarily upon titanium surface treatments of 10 volt chronic acid anodize, 5 volt chromic acid anodize and PASA-JELL. Failure analysis was conducted on lap shear adhesive bond failures which occurred in PPQ and LARC-13 test specimens after 10,000 hours at 505 K.

Hill, S. G.↗

NASA NTRS1982

Effect of fuel to air ratio on Mach 0.3 burner rig hot corrosion of ZrO2-Y2O3 thermal barrier coatings

A Mach 0.3 burner rig test program was conducted to determine how the fuel to air mass ratio affects the durability of ZrO2-Y2O3/Ni-16Cr-6Al-0.31Y thermal barrier coating systems in combustion products containing 5 ppm Na and 2 ppm V. As the fuel to air mass ratio was increased from 0.039 to 0.049, the durability of ZrO2-6Y2O3, ZrO2-8Y2O3 and ZrO2-12Y2O3 coatings decreased. ZrO2-8Y2O3 coatings were approximately 2X and 1.3X more durable than ZrO2-12Y2O3 and ZrO2-6Y2O3 coatings respectively at the fuel to air mass ratio of 0.039. The number of one hour cycles endured by ZrO2-8Y2O3 coatings varied from averages of 53 to 200 for the fuel to air mass ratios of 0.049 and 0.039, respectively. At the fuel to air mass ratio of 0.049, all ZrO2-Y2O3 coated specimens failed in 40 to 60 one hour cycles

Hodge, P. E.↗

NASA NTRS1987

Heat flux calibration facility capable of SSME conditions

There is a need to more thoroughly characterize the hostile space shuttle main engine (SSME) turbopump environment. It has been estimated that component surface heat flux in the hot-gas environment is about 10 MW/square meter, and this is about 50 times that encountered in aircraft engines. Also, material temperature transients can be as high as 1000 K in about 1 second. These transients can cause durability problems such as material cracking. Heat flux sensors placed in the turbopump components can partially characterize this environment by measuring surface heat flux. These heat flux data can be used to verify analytical-stress, boundary-layer, and heat-transfer design models. Preliminary plans were discussed at the first SSME durablity conference for designing and fabricating a new facility for the calibration and durability testing of prototype heat flux sensors for the SSME. This facility, which is necessary for assessment of new heat flux gauge concepts needed in the hostile SSME turbopump environment, is described.

Liebert, Curt H.↗

NASA NTRS1989

Reusable high-temperature heat pipes and heat pipe panels

A reusable, durable heat pipe which is capable of operating at temperatures up to about 3000 F in an oxidizing environment and at temperatures above 3000 F in an inert or vacuum environment is produced by embedding a refractory metal pipe within a carbon-carbon composite structure. A reusable, durable heat pipe panel is made from an array of refractory-metal pipes spaced from each other. The reusable, durable, heat-pipe is employed to fabricate a hypersonic vehicle leading edge and nose cap.

Camarda, Charles J.↗

NASA NTRS1989

Analysis of the SSME HPOTP bearing inlet cavity

Analysis of the flow in the Space Shuttle Main Engine (SSME) high pressure oxygen turbopump (HPOTP) bearing no. 1 inlet cavity was completed in support of return-to-flight. With the incorporation of several design changes in the Phase 2 turbopump, rotordynamic stability of the pumps was enhanced, but the durability and life of the LOX-cooled bearings has decreased. During the post-Challenger SSME recertification, the causes of limited bearing durability were investigated. One topic addressed was the flow environment upstream of the pump-end bearing and the effect of seal exit swirl and a cavity anti-vortex rib on the bearing environment and life. The objective is to define the hydrodynamic environment upstream of the pump-end bearing and determine the effect of seal exit swirl and the anti-vortex rib on bearing inlet swirl. The problem was posed as an axisymmetric cavity flow with the computational domain extending from the seal exit to the bearing inlet. This domain was discretized with 22800 grid points. Boundary conditions were obtained from a 1-D model of the SSME coolant path. The inlet Mach number was 0.19 and the problem was solved with the CMINT code utilizing the Briley-McDonald/Beam-Warming algorithm with preconditioning to speed convergence at low Mach numbers. Three parametric cases with inlet swirl of 50 percent shaft speed (labyrinth seal), 20 percent shaft speed (damping seal), and no inlet swirl were considered. Computational results indicate large vortical flow structures in the cavity, with the labyrinth, damping, and no-swirl cases yielding bearing inlet swirl rates of 14, 10, and 9 percent of shaft speed, respectively. When these results were used as input to the SHABRETH bearing model, limited durability could not be explained by these small differences in swirl. Also, based on these results, a proposed design change for the cavity anti-vortex rib was not implemented by the SSME chief engineer.

Mcconnaughey, P. K.↗

NASA NTRS1991

Low cost space power generation

The success of this study has given a method of fabricating durable copolymer films without size limitations. Previously, only compression molded samples were durable enough to generate electrical energy. The strengthened specimens are very long lived materials. The lifetime was enhanced at least a factor of 1,300 in full pyroelectric conversion cycle experiments compared with extruded, non-strengthened film. The new techniques proved so successful that the lifetime of the resultant copolymer samples was not fully characterized. The lifetime of these new materials is so long that accelerated tests were devised to probe their durability. After a total of more than 67 million high voltage electrical cycles at 100 C, the electrical properties of a copolymer sample remained stable. The test was terminated without any detectable degradation to allow for other experiments. One must be cautious in extrapolating to power cycle performance, but 67 million electrical cycles correspond to 2 years of pyroelectric cycling at 1 Hz. In another series of experiments at reduced temperature and electrical stress, a specimen survived over one-third of a billion electrical cycles during nearly three months of continuous testing. The radiation-limited lifetimes of the copolymer were shown to range from several years to millions of years for most earth orbits. Thus, the pyroelectric copolymer has become a strong candidate for serious consideration for future spacecraft power supplies.

Olsen, Randall B.↗

NASA NTRS1992

Tribological evaluation of an Al2O3-SiO2 ceramic fiber candidate for high temperature sliding seals

A test program to determine the relative sliding durability of an alumina-silica candidate ceramic fiber for high temperature sliding seal applications as described. This work represents the first reporting of the sliding durability of this material system. Pin-on-disk tests were used to evaluate the potential seal material by sliding a tow or bundle of the candidate ceramic fiber against a superalloy test disk. Friction was measured during the tests and fiber wear, indicated by the extent of fibers broken in the tow or bundle, was measured at the end of each test. Test variables studied included ambient temperatures from 25 C to 900 C, loads from 1.3 to 21.2 Newtons, and sliding velocities from 0.025 to 0.25 m/sec. In addition, the effects of fiber diameter, elastic modulus, and a pretest fiber heat treatment on friction and wear were measured. In most cases, wear increased with temperature. Friction ranged from about 0.36 at 500 C and low velocity (0.025 m/s) to over 1.1 at 900 C and high velocity (0.25 m/s). The pretest fiber heat treatment, which caused significant durability reductions for alumina-boria-silica ceramic fibers tested previously, had little effect on the alumina-silica fibers tested here. These results indicate that the alumina-silica (Al2O3-SiO2) fiber is a good candidate material system for high temperature sliding seal applications.

Dellacorte, Christopher↗

NASA NTRS1992

SiO(X) coatings for atomic oxygen protection of polyimide Kapton in low earth orbit

Sputter-deposited SiO(X) (where X between 1.9 and 2.0) thin film coatings have been found to be durable to atomic oxygen. Such coatings will be used to protect polyimide Kapton photovoltaic array blankets from atomic oxygen attack in low earth orbit (LEO) on the Space Station Freedom (SSF). Monte Carlo modeling of atomic oxygen attack at defect sites in protected Kapton exposed in laboratory RF plasma ashers and on solar tracking photovoltaic arrays in space has been conducted to enable understanding of degradation processes relevant to the durability of the SSF solar array blanket. SiO(X) protective coating performance data from RF plasma asher tests will be presented, along with Monte Carlo modeling considerations, to enable the projection of in-space durability of the SSF solar array blankets based on ground laboratory test results.

Banks, Bruce A.↗

NASA NTRS1993

Damage progression in stiffened composite panels

The design of composite structures requires an evaluation of their safety and durability under service loads and possible overload conditions. This paper presents a computational tool that has been developed to examine the response of stiffened composite panels via the simulation of damage initiation, growth, accumulation, progression, and propagation to structural fracture or co*lapse. The structural durability of a composite panel with a discontinuous stiffener is investigated under compressive loading induced by the gradual displacement of an end support. Results indicate damage initiation and progression to have significant effects on structural behavior under loading. Utilization of an integrated computer code for structural durability assessment is demonstrated.

Minnetyan, Levon↗

NASA NTRS1993

Brief summary of the evolution of high-temperature creep-fatigue life prediction models for crack initiation

The evolution of high-temperature, creep-fatigue, life-prediction methods used for cyclic crack initiation is traced from inception in the late 1940's. The methods reviewed are material models as opposed to structural life prediction models. Material life models are used by both structural durability analysts and by material scientists. The latter use micromechanistic models as guidance to improve a material's crack initiation resistance. Nearly one hundred approaches and their variations have been proposed to date. This proliferation poses a problem in deciding which method is most appropriate for a given application. Approaches were identified as being combinations of thirteen different classifications. This review is intended to aid both developers and users of high-temperature fatigue life prediction methods by providing a background from which choices can be made. The need for high-temperature, fatigue-life prediction methods followed immediately on the heels of the development of large, costly, high-technology industrial and aerospace equipment immediately following the second world war. Major advances were made in the design and manufacture of high-temperature, high-pressure boilers and steam turbines, nuclear reactors, high-temperature forming dies, high-performance poppet valves, aeronautical gas turbine engines, reusable rocket engines, etc. These advances could no longer be accomplished simply by trial and error using the 'build-em and bust-em' approach. Development lead times were too great and costs too prohibitive to retain such an approach. Analytic assessments of anticipated performance, cost, and durability were introduced to cut costs and shorten lead times. The analytic tools were quite primitive at first and out of necessity evolved in parallel with hardware development. After forty years more descriptive, more accurate, and more efficient analytic tools are being developed. These include thermal-structural finite element and boundary element analyses, advanced constitutive stress-strain-temperature-time relations, and creep-fatigue-environmental models for crack initiation and propagation. The high-temperature durability methods that have evolved for calculating high-temperature fatigue crack initiation lives of structural engineering materials are addressed. Only a few of the methods were refined to the point of being directly useable in design. Recently, two of the methods were transcribed into computer software for use with personal computers.

Halford, Gary R.↗

NASA NTRS1994

Transparent conducting thin films for spacecraft applications

Transparent conductive thin films are required for a variety of optoelectronic applications: automotive and aircraft windows, and solar cells for space applications. Transparent conductive coatings of indium-tin-oxide (ITO)-magnesium fluoride (MgF2) and aluminum doped zinc oxide (AZO) at several dopant levels are investigated for electrical resistivity (sheet resistance), carrier concentration, optical properties, and atomic oxygen durability. The sheet resistance values of ITO-MgF2 range from 10(exp 2) to 10(exp 11) ohms/square, with transmittance of 75 to 86 percent. The AZO films sheet resistances range from 10(exp 7) to 10(exp 11) ohms/square with transmittances from 84 to 91 percent. It was found that in general, with respect to the optical properties, the zinc oxide (ZnO), AZO, and the high MgF2 content ITO-MgF2 samples, were all durable to atomic oxygen plasma, while the low MgF2 content of ITO-MgF2 samples were not durable to atomic oxygen plasma exposure.

Perez-Davis, Marla E.↗

NASA NTRS1995

Damage-mitigating control of a reusable rocket engine for high performance and extended life

The goal of damage mitigating control in reusable rocket engines is to achieve high performance with increased durability of mechanical structures such that functional lives of the critical components are increased. The major benefit is an increase in structural durability with no significant loss of performance. This report investigates the feasibility of damage mitigating control of reusable rocket engines. Phenomenological models of creep and thermo-mechanical fatigue damage have been formulated in the state-variable setting such that these models can be combined with the plant model of a reusable rocket engine, such as the Space Shuttle Main Engine (SSME), for synthesizing an optimal control policy. Specifically, a creep damage model of the main thrust chamber wall is analytically derived based on the theories of sandwich beam and viscoplasticity. This model characterizes progressive bulging-out and incremental thinning of the coolant channel ligament leading to its eventual failure by tensile rupture. The objective is to generate a closed form solution of the wall thin-out phenomenon in real time where the ligament geometry is continuously updated to account for the resulting deformation. The results are in agreement with those obtained from the finite element analyses and experimental observation for both Oxygen Free High Conductivity (OFHC) copper and a copper-zerconium-silver alloy called NARloy-Z. Due to its computational efficiency, this damage model is suitable for on-line applications of life prediction and damage mitigating control, and also permits parametric studies for off-line synthesis of damage mitigating control systems. The results are presented to demonstrate the potential of life extension of reusable rocket engines via damage mitigating control. The control system has also been simulated on a testbed to observe how the damage at different critical points can be traded off without any significant loss of engine performance. The research work reported here is built upon concepts derived from the disciplines of Controls, Thermo-fluids, Structures, and Materials. The concept of damage mitigation, as presented in this report, is not restricted to control of rocket engines. It can be applied to any system where structural durability is an important issue.

Ray, Asok↗

NASA NTRS1996

Materials Assessment of Components of the Extravehicular Mobility Unit

Current research interests for Extravehicular Mobility Unit (EMU) design and development are directed toward enhancements of the Shuttle EMU, implementation of the Mark 3 technology for Shuttle applications, and development of a next generation suit (the X suit) which has applications for prolonged space flight, longer extravehicular activity (EVA), and Moon and Mars missions. In this research project two principal components of the EMU were studied from the vantage point of the materials and their design criteria. An investigation of the flexible materials which make up the lay-up of materials for abrasion and tear protection, thermal insulation, pressure restrain, etc. was initiated. A central focus was on the thermal insulation. A vacuum apparatus for measuring the flexibility of the materials was built to access their durability in vacuum. Plans are to include a Residual Gas Analyzer on the vacuum chamber to measure volatiles during the durability testing. These tests will more accurately simulate space conditions and provide information which has not been available on the materials currently used on the EMU. Durability testing of the aluminized mylar with a nylon scrim showed that the material strength varied in the machine and transverse directions. Study of components of the EMU also included a study of the EMU Bearing Assemblies as to materials selection, engineered materials, use of coatings and flammability issues. A comprehensive analysis of the performance of the current design, which is a stainless steel assembly, was conducted and use of titanium alloys or engineered alloy systems and coatings was investigated. The friction and wear properties are of interest as are the general manufacturing costs. Recognizing that the bearing assembly is subject to an oxygen environment, all currently used materials as well as titanium and engineered alloys were evaluated as to their flammability. An aim of the project is to provide weight reduction since bearing weights constitute 1/3 of the total EMU weight. Our investigations have shown favorable properties using a titanium or nickel base alloy in conjunction with a coating system. Interest lies in developing titanium as a more nonflammable material. Methodology for doing this lies in adding coatings and surface alloying the titanium. This report is brief and does not give all necessary details. The reader should contact the authors as to the detailed study and for viewing of raw data.

Olivas, John D.↗

NASA NTRS1995

Discontinuously Stiffened Composite Panel under Compressive Loading

The design of composite structures requires an evaluation of their safety and durability under service loads and possible overload conditions. This paper presents a computational tool that has been developed to examine the response of stiffened composite panels via the simulation of damage initiation, growth, accumulation, progression, and propagation to structural fracture or collapse. The structural durability of a composite panel with a discontinuous stiffener is investigated under compressive loading induced by the gradual displacement of an end support. Results indicate damage initiation and progression to have significant effects on structural behavior under loading. Utilization of an integrated computer code for structural durability assessment is demonstrated.

Minnetyan, Levon↗

NASA NTRS1997

Plasma-Sprayed Refractory Oxide Coatings on Silicon-Base Ceramics

Silicon-base ceramics are promising candidate materials for high temperature structural applications such as heat exchangers, gas turbines and advanced internal combustion engines. Composites based on these materials are leading candidates for combustor materials for HSCT gas turbine engines. These materials possess a combination of excellent physical and mechanical properties at high temperatures, for example, high strength, high toughness, high thermal shock resistance, high thermal conductivity, light weight and excellent oxidation resistance. However, environmental durability can be significantly reduced in certain conditions such as when molten salts, H2 or water vapor are present. The oxidation resistance of silicon-base materials is provided by SiO2 protective layer. Molten salt reacts with SiO2 and forms a mixture of SiO2 and liquid silicate at temperatures above 800C. Oxygen diffuses more easily through the chemically altered layer, resulting in a catastrophic degradation of the substrate. SiC and Si3N4 are not stable in pure H2 and decompose to silicon and gaseous species such as CH4, SiH, SiH4, N2, and NH3. Water vapor is known to slightly increase the oxidation rate of SiC and Si3N4. Refractory oxides such as alumina, yttria-stabilized zirconia, yttria and mullite (3Al2O3.2SiO2) possess excellent environmental durability in harsh conditions mentioned above. Therefore, refractory oxide coatings on silicon-base ceramics can substantially improve the environmental durability of these materials by acting as a chemical reaction barrier. These oxide coatings can also serve as a thermal barrier. The purpose of this research program has been to develop refractory oxide chemical/thermal barrier coatings on silicon-base ceramics to provide extended temperature range and lifetime to these materials in harsh environments.

Tewari, Surendra↗