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High temperature polymer creep simulation of aluminum alloy stress-strain distribution using photoelastoplastic stress measurement
A new technique of high-temperature thermal-conductivity measurement is described. A CO2 gas laser is used to generate a low-frequency temperature wave at one face of a small disk-shaped sample, and an infrared detector views the opposite face to detect the phase of the emerging radiation. A mathematical expression is derived which enables phase data at several frequencies to be used for the simultaneous determination of thermal diffusivity and mean extinction coefficient. Lattice and radiative thermal conductivities are then calculated. Test results for sintered aluminum oxide at temperatures from 530 to 1924 K are within the range of error of previously existing data.
Strainrange Partitioning provides unifying framework for characterizing high-temperature, low-cycle, creep-fatigue properties of metals and alloys. Method offers distinct advantage to designers of immediately providing reliable upper and lower bounds on cyclic life for any type of inelastic strain cycle that may be encountered in service.
The realization of low cost, electric power from large-area silicon, photovoltaic arrays will depend on the development of new methods for large capacity production of solar grade (SG) silicon with a cost of less than $10 per kilogram by 1986 (established Department of Energy goal). The objective of the program is to develop a method to produce SG silicon in large quantities based on the high temperature-sodium reduction of silicon tetrachloride (SiCl4) to yield molten silicon and the coproduct salt vapor (NaCl). Commercial ac electric arc heaters will be utilized to provide a hyper-heated mixture of argon and hydrogen which will furnish the required process energy. The reactor is designed for a nominal silicon flow rate of 45 kg/hr. Analyses and designs have been conducted to evaluate the process and complete the initial design of the experimental verification unit.
Studies focused on the impact and mechanical behavior of SiC and Si3N4 at high temperatures are summarized. Instrumented Charpy impact testing is analyzed by a compliance method and related to strength; slow crack growth is related to processing, and creep is discussed. The transient nature of flaw populations during oxidation under load is emphasized for both SiC and Si3N4.
Measurements of surface pressure and heat flux at Mach 6.8 for a nonaxisymmetric body, typical of the forward fuselage of an entry vehicle, have been obtained in the Langley 8-ft high-temperature tunnel. Comparisons of these data with predictions obtained from two numerical methods, which treat the test medium as an ideal gas with a laminar boundary layer, are presented. In general, the numerical results are consistent with each other and follow the data in regions of laminar flow; however, the data for angle of attack 14.9 deg indicate transitional flow on most of the windward surface. Also, the two numerical methods disagree slightly in regions of zero or nearly zero pressure gradients.
Laser-induced plasmas in various gas mixtures were used to simulate lightning in other planetary atmospheres. This method of simulation has the advantage of producing short-duration, high-temperature plasmas free from electrode contamination. The laser-induced plasma discharges in air are shown to accurately simulate terrestrial lightning and can be expected to simulate lightning spectra in other planetary atmospheres. Spectra from 240 to 880 nm are presented for simulated lightning in the atmospheres of Venus, earth, Jupiter, and Titan. The spectra of lightning on the other giant planets are expected to be similar to that of Jupiter because the atmospheres of these planets are composed mainly of hydrogen and helium. The spectra of Venus and Titan show substantial amounts of radiation due to the presence of carbon atoms and ions and show CN Violet radiation. Although small amounts of CH4 and NH3 are present in the Jovian atmosphere, only emission from hydrogen and helium is observed. Most differences in the spectra can be understood in terms of the elemental ratios of the gas mixtures. Consequently, observations of the spectra of lightning on other planets should provide in situ estimates of the atmospheric and aerosol composition in the cloud layers in which lightning is occurring. In particular, the detection of inert gases such as helium should be possible and the relative abundance of these gases compared to major constituents might be determined.
Thrust losses due to the inability of dissociated combustion gases to recombine in exhaust nozzles are of primary interest for evaluating the performance of hypersonic ramjets. Some results for the expansion of hydrogen-air combustion products are described. Combustion air was preheated up to 33000 R to simulate high-Mach-number flight conditions. Static-temperature measurements using the line reversal method and wall static pressures were used to indicate the state of the gas during expansion. Results indicated substantial departure from the shifting equilibrium curve beginning slightly downstream of the nozzle throat at stagnation pressures of 1.7 and 3.6 atmospheres. The results are compared with an approximate method for determining a freezing point using an overall rate equation for the oxidation of hydrogen.
Soot is an important unsolved problem of combustion science because it is present in most hydrocarbon-fueled flames and current understanding of the reactive and physical properties of soot in flame environments is limited. This lack of understanding affects progress toward developing reliable predictions of flame radiation properties, reliable predictions of flame pollutant emission properties and reliable methods of computational combustion, among others. Motivated by these observations, the present investigation extended past studies of soot formation in this laboratory, to consider soot oxidation in laminar diffusion flames using similar methods. Early work showed that O2 was responsible for soot oxidation in high temperature O2-rich environments. Subsequent work in high temperature flame environments having small O2 concentrations, however, showed that soot oxidation rates substantially exceeded estimates based on the classical O2 oxidation rates of Nagle and Strickland-Constable and suggests that radicals such as O and OH might be strong contributors to soot oxidation for such conditions. Neoh et al. subsequently made observations in premixed flames, supported by later work, that showed that OH was responsible for soot oxidation at these conditions with a very reasonable collision efficiency of 0.13. Subsequent studies in diffusion flames, however, were not in agreement with the premixed flame studies: they agreed that OH played a dominant role in soot oxidation in flames, but found collision efficiencies that varied with flame conditions and were not in good agreement with each other or with Neoh et al. One explanation for these discrepancies is that optical scattering and extinction properties were used to infer soot structure properties for the studies that have not been very successful for representing the optical properties of soot. Whatever the source of the problem, however, these differences among observations of soot oxidation in premixed and diffusion flames clearly must be resolved. Motivated by these findings, the present study undertook measurements of soot and flame properties within the soot oxidation region of some typical laminar diffusion flames and exploited the new measurements to identify soot oxidation mechanisms for these conditions. Present considerations were limited to the early stages of soot oxidation (carbon consumption less than 70%) where reactions at the surface of primary soot particles dominate the process, rather than the later stages when particle porosity and internal particle oxidation become important as discussed by Neoh et al.
Advanced aerospace systems occasionally require the use of very brittle materials such as sapphire and ultra-high temperature ceramics. Although great progress has been made in the development of methods and standards for machining, testing and design of component from these materials, additional development and dissemination of standard practices is needed. ASTM Committee C28 on Advanced Ceramics and ISO TC 206 have taken a lead role in the standardization of testing for ceramics, and recent efforts and needs in standards development by Committee C28 on Advanced Ceramics will be summarized. In some cases, the engineers, etc. involved are unaware of the latest developments, and traditional approaches applicable to other material systems are applied. Two examples of flight hardware failures that might have been prevented via education and standardization will be presented.
The space-time conservation element and solution element method is employed to numerically study the acoustic feedback system in a high temperature, high speed wind tunnel mixer. The computation captures the self-sustained feedback loop between reflecting Mach waves and the shear layer. This feedback loop results in violent instabilities that are suspected of causing damage to some tunnel components. The computed frequency is in good agreement with the available experimental data. The physical phenomena are explained based on the numerical results.
Thermally sprayed dielectric ceramic coatings are the primary means of attaching strain and temperature gauges to hot-section rotating parts of turbine engines. As hot-section temperatures increase, lifetimes of installed gauges decrease, and seldom exceed one hour above 2,000 F (approx.1,100 C). Advanced engine components are expected to operate at temperatures approaching 2,200 F (approx.1,200 C), and the required high-temperature lifetime is 10 hours minimum. Typically, to enable a ceramic coating to adhere to the smooth surface of an engine component, a thermally sprayed NiCrAlY or NiCoCrAlY bond coat is applied to the smooth surface, thereby providing a textured surface to which the ceramic coat can adhere. The main failure mechanism of this system is decohesion and/or delamination at the interface between the ceramic top coat and the bond coat, caused by oxidation of the bond coat and stresses from the mismatch between the coefficients of thermal expansion of the ceramic top coat and the metallic bond coat. The approach taken to increase the high-temperature lifetime of a gauge attached to an engine component by the method described above involves (1) selective oxidation of the bond coat by means of a heat treatment in reduced oxygen partial pressure followed by (2) the application of a noble-metal diffusion barrier. In experiments to test this approach, heat treatments of NiCoCrAlY bond coats were carried out in a tube furnace in which, in each case, the temperature was alternately (1) increased at a rate of 3 C per minute and (2) held steady for one hour until the desired temperature was reached. The tube furnace was continuously purged with dry nitrogen gas. A final heat-treatment temperature range of 1,600 to 1,800 F (871 to 982 C) proved most beneficial.
A circuit topography is presented which is used to create usable digital logic gates using N (negatively doped) channel Junction Field Effect Transistors (JFETs) and load resistors, level shifting resistors, and supply rails whose values are based on the direct current (DC) parametric distributions of those JFETs. This method has direct application to the current state of the art in high temperature, for example 300.degree. C. to 500.degree. C. and higher, silicon carbide (SiC) device production. The ability to produce inverting and combinatorial logic enables the production of pulse and edge triggered latches. This scale of logic synthesis would bring digital logic and state machine capabilities to devices operating in extremely hot environments, such as the surface of Venus, near hydrothermal vents, within nuclear reactors (SiC is inherently radiation hardened), and within internal combustion engines. The basic logic gate can be configured as a driver for oscillator circuits allowing for time bases and simple digitizers for resistive or reactive sensors. The basic structure of this innovation, the inverter, can be reconfigured into various analog circuit topographies through the use of feedback structures.
A key technology element in Nuclear Thermal Propulsion is the development of fuel materials and components which can withstand extremely high temperatures while being exposed to flowing hydrogen. NTREES provides a cost effective method for rapidly screening of candidate fuel components with regard to their viability for use in NTR systems. The NTREES is designed to mimic the conditions (minus the radiation) to which nuclear rocket fuel elements and other components would be subjected to during reactor operation. The NTREES consists of a water cooled ASME code stamped pressure vessel and its associated control hardware and instrumentation coupled with inductive heaters to simulate the heat provided by the fission process. The NTREES has been designed to safely allow hydrogen gas to be injected into internal flow passages of an inductively heated test article mounted in the chamber.
Many different aerogel-based materials are now being used in thermal insulation systems for cryogenic applications. These materials include flexible composite blankets, bulk-fill particles, and polymer composites in both evacuated and non-evacuated environments. In ambient environments, aerogels provide superior thermal performance compared to conventional polymeric foam and cellular glass insulations while offering unique advantages in avoiding problems with weathering, moisture, and mechanical damage. Aerogels are also used as spacer materials in multilayer insulation systems. These layered systems provide combined structural-thermal capability for cryogenic systems in either vacuum-jacketed or externally-applied insulation designs. Test data (effective thermal conductivity) include a wide range of both commercial and experimental aerogel materials. Testing was performed using laboratory cryostats and standard methods including full range vacuum (from ambient pressure to high vacuum) and boundary temperatures 293 K and 78 K. Examples of aerogel-based insulation systems are given for both evacuated and non-evacuated applications.
Many different aerogel-based materials are now being used in thermal insulation systems for cryogenic applications. These materials include flexible composite blankets, bulk-fill particles, and polymer composites in both evacuated and non-evacuated environments. In ambient environments, aerogels provide superior thermal performance compared to conventional polymeric foam and cellular glass insulations while offering unique advantages in solving problems with weathering, moisture, and mechanical damage. Aerogels are also used as spacer materials in multilayer insulation systems. These layered systems provide combined structural-thermal capability for cryogenic systems in either vacuum-jacketed or externally-applied insulation designs. Test data (effective thermal conductivity) include a wide range of both commercial and experimental aerogel materials. Testing was performed using laboratory cryostats and standard methods including full range vacuum (from ambient pressure to high vacuum) and boundary temperatures 293 K and 78 K. Examples of aerogel-based insulation systems are given for both evacuated and non-evacuated applications.
The main purpose of this work has been in the development and characterization of materials for high temperature applications. Thermal Protection Systems (TPS) are constantly being tested, and evaluated for increased thermal shock resistance, high temperature dimensional stability, and tolerance to environmental effects. Materials development was carried out through the use of many different instruments and methods, ranging from extensive elemental analysis to physical attributes testing. The six main focus areas include: (1) protective coatings for carbon/carbon composites; (2) TPS material characterization; (3) improved waterproofing for TPS; (4) modified ceramic insulation for bone implants; (5) improved durability ceramic insulation blankets; and (6) ultra-high temperature ceramics. This report describes the progress made in these research areas during this contract period.
The objective of the work presented here is to quantify the effects of purge gas temperature, pressure, and mass flow rate on Hydrazine (Hz) decontamination rates of the Ares I Roll Control System and Reaction Control System. A survey of experts in this field revealed the absence of any decontamination rate prediction models. Three basic decontamination methods were identified for analysis and modeling. These include low pressure eduction, high flow rate purge, and pulse purge. For each method, an approach to predict the Hz mass transfer rate, as a function of system pressure, temperature, and purge gas mass flow rate, is developed based on the applicable physics. The models show that low pressure eduction is two orders of magnitude more effective than the high velocity purge, which in turn is two orders of magnitude more effective than the pure diffusion component of pulse purging of deadheads. Eduction subjects the system to low pressure conditions that promote the extraction of Hz vapors. At 120 F, Hz is saturated at approximately 1 psia. At lower pressures and 120 F, Hz will boil, which is an extremely efficient means to remove liquid Hz. The Hz boiling rate is predicted by equating the rate at which energy is added to the saturated liquid Hz through heaters at the tube outer wall with the energy removed from the liquid through evaporation. Boil-off fluxes were predicted by iterating through the range of local pressures with limits set by the minimum allowed pressure of 0.2 psia and maximum allowed wall temperature of 120 F established by the heaters, which gives a saturation pressure of approximately 1.0 psia. Figure 1 shows the resulting boil-off fluxes as a function of local eduction pressure. As depicted in figure 1, the flux is a strong inverse function of eduction pressure, and that minimizing the eduction pressure maximizes the boil-off flux. Also, higher outer wall temperatures lead to higher boil-off fluxes and allow for boil-off over a greater range of eduction pressures.