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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Lubricant and additive effects on spur gear fatigue life

Spur gear endurance tests were conducted with six lubricants using a single lot of consumable-electrode vacuum melted (CVM) AISI 9310 spur gears. The sixth lubricants was divided into four batches each of which had a different additive content. Lubricant tested with a phosphorus-type load carrying additive showed a statistically significant improvement in life over lubricants without this type of additive. The presence of sulfur type antiwear additives in the lubricant did not appear to affect the surface fatigue life of the gears. No statistical difference in life was produced with those lubricants of different base stocks but with similar viscosity, pressure-viscosity coefficients and antiwar additives. Gears tested with a 0.1 wt pct sulfur and 0.1 wt pct phosphorus EP additives in the lubricant had reactive films that were 200 to 400 (0.8 to 1.6 microns) thick.

Townsend, D. P.↗
NASA NTRS2018

Systems and Methods for Additive Manufacturing Processes that Strategically Buildup Objects

Systems and methods in accordance with embodiments of the invention implement additive manufacturing techniques that employ different sets of deposition characteristics and/or material formation characteristics during the additive manufacture of an object so as to strategically build up the object. In many embodiments, material used to build up an object is deposited at different deposition rates during the additive manufacture of the object, and the object is thereby strategically built up. In one embodiment, a method of additively manufacturing an object includes: depositing material onto a surface at a first deposition rate so as to define a first region of the object to be additively manufactured; and depositing material onto a surface at a second deposition rate so as to define a second region of the object to be additively manufactured; where the second deposition rate is different from the first deposition rate.

Hofmann, Douglas C.↗
NASA NTRS2015

A Decision-Support Model for Selecting Additive Manufacturing Versus Subtractive Manufacturing Based on Energy Consumption

This paper presents a simple computational model for determining whether additive manufacturing or subtractive manufacturing is more energy efficient for production of a given metallic part. The key discriminating variable is the fraction of the bounding envelope that contains material – i.e. the volume fraction of solid material. For both the additive process and the subtractive process, the total energy associated with the production of a part is defined in terms of the volume fraction of that part. The critical volume fraction is that for which the energy consumed by subtractive manufacturing equals the energy consumed by additive manufacturing. For volume fractions less than the critical value, additive manufacturing is more energy efficient. For volume fractions greater than the critical value, subtractive manufacturing is more efficient. The model considers the entire manufacturing lifecycle – from production and transport of feedstock material through processing to return of post-production scrap for recycling. Energy consumed by processing equipment while idle is also accounted for in the model. Although the individual energy components in the model are identified and accounted for in the expressions for additive and subtractive manufacturing, values for many of these components may not be currently available. Energy values for some materials’ production and subtractive and additive manufacturing processes can be found in the literature. However, since many of these data are reported for a very specific application, it may be difficult, if not impossible, to reliably apply these data to new process-material manufacturing scenarios since, very often, insufficient information is provided to enable extrapolation to broader use. Consequently, this paper also highlights the need to develop improved knowledge of the energy embodied in each phase of the manufacturing process. To be most valuable, users of the model should determine the energy consumed by their manufacturing process equipment on the basis of energy-per-unit-volume of production for each material of interest – considering both alloy composition and form. Energy consumed during machine idle per unit time should also be determined by the user then scaled to specific processing scenarios. Energy required to generate feedstock material (billet, plate, bar, wire, powder) must be obtained from suppliers.

J K Watson↗
NASA NTRS2024

Effects of Oxide Dispersion on Failure Modes in an Additively Manufactured Superalloy

Additive manufacturing opens new paths for introducing oxide particles into superalloys, to potentially provide oxide dispersion strengthening (ODS) at high temperatures. This provides opportunities to study how such dispersions can influence failure modes for a given superalloy, after nearly identical material processing paths. The objective of this study was to compare monotonic failure modes for additively manufactured superalloys with versus without an introduced oxide dispersion. The superalloy for each case was produced by laser powder bed fusion additive manufacturing. Specimens were subsequently given consistent thermal treatment paths and then tested in tensile and creep tests at varied temperatures. Failure modes were then compared. Additively manufactured NiCrAl without ODS had randomly oriented equiaxed grains while this alloy with 0.25 wt% Y 2 O 3 ODS additions had elongated [001] oriented grains in the build direction. Material made without ODS (“No-ODS”) was nearly completely single phase gamma, while ODS additions resulted in gamma, chromium carbide, and Y-Al-Cr oxide phases, with carbide and oxide phases contents estimated at no more than 13 and 1 vol%, respectively. Compared to No-ODS, material made with ODS had higher tensile strengths at room, 760 and 1093 °C. The elongation of ODS material was lower than No-ODS at room temperature, but higher at 760 °C. At 1093 °C ODS material had higher elongation than No-ODS when tested in the build direction, however elongation was lower for ODS material in the transverse direction at 1093 °C. Creep rupture strain, life, and area reduction at 760 and 1093 °C were all much higher for ODS material compared to No-ODS; 760 °C rupture life was nearly 100 times longer for ODS material. The presence of Y in the ODS material significantly improved oxidation resistance.

supperalloys↗
NASA NTRS1972

Effects of additives on volume change on melting, surface tension, and viscosity of liquid aluminum oxide

The effects of various oxide additives on the volume change on melting, the surface tension, and the viscosity of liquid Al2O3 were studied. Additives of Sm2O3, MgO, and Y2O3 which form solid solutions, compounds, and multiphase solids with Al2O3 were studied. A review of the property data for Al2O3 and Al2O3 containing oxide additives is presented. Oxide additives to Al2O3 reduce the volume change on melting and with the exception of SiO2 lower the viscosity; surface tensions change with oxide additives, but changes vary with different container material. Viscosity and volume change on melting appeared to be significantly more important for studying the properties of liquid oxides than surface tension. Supercooling of 270 K of yttrium aluminum garnet was observed.

Bates, J. L.↗
NASA NTRS1979

Evaluation and auger analysis of a zinc-dialkyl-dithiophosphate antiwear additive in several diester lubricants

The wear of pure iron in sliding contact with hardened M-2 tool steel was measured for a series of synthetic diester fluids, both with and without a zinc dialkyl dithiophosphate (ZDP) antiwear additive, as test lubricants. Selected wear scars were analyzed by an Auger emission spectroscopy (AES) depth profiling technique in order to assess the surface film elemental composition. The ZDP was an effective antiwear additive for all the diesters except dibutyl oxalate and dibutyl sebacate. The high wear measured for the additive-containing oxalate was related to corrosion; the higher wear measured for the additive-containing sebacate was due to an oxygen interaction. The AES of dibutyl sebacate surfaces run in dry air and in dry nitrogen showed large differences only in the amount of oxygen present. The AES of worn surfaces where the additive was effective showed no zinc, only a little phosphorus, and large amounts of sulfur.

Brainard, W. A.↗
NASA NTRS1984

Effect of lubricant extreme-pressure additives on surface fatigue life of AISI 9310 spur gears

Surface fatigue tests were conducted with AISI 9310 spur gears using a formulated synthetic tetraester oil (conforming to MIL-L-23699 specifications) as the lubricant containing either sulfur or phosphorus as the EP additive. Four groups of gears were tested. One group of gears tested without an additive in the lubricant acted as the reference oil. In the other three groups either a 0.1 wt % sulfur or phosphorus additive was added to the tetraester oil to enhance gear surface fatigue life. Test conditions included a gear temperature of 334 K (160 F), a maximum Hertz stress of 1.71 GPa (248 000 psi), and a speed of 10,000 rpm. The gears tested with a 0.1 wt % phosphorus additive showed pitting fatigue life 2.6 times the life of gears tested with the reference tetraester based oil. Although fatigue lives of two groups of gears tested with the sulfur additive in the oil showed improvement over the control group gear life, the results, unlike those obtained with the phosphorus oil, were not considered to be statistically significant.

Scibbe, H. W.↗
NASA NTRS1986

Sintering and properties of Si3N4 with and without additives by HIP treatment

Hot Isostatic Pressing (HIP) of Si3N4 powders with and without additives was performed using a glass container, and various kinds of pressureless-sintered Si3N4 were HIP'ed without a container. The effects of HIP treatment on density, microstructure, flexural strength, microhardness, and fracture toughness on Si3N4 ceramics were studied. Using a glass container it was difficult to reach theoretical density. The microhardness of HIP'ed Si3N4 without additives was low, and the fracture toughness of HIP'ed Si3N4 with and without additives was 22 to 25 W/m-K, and it decreased with increasing the amount of additives. The density and flexural strength, and hardness of pressureless-sintered Si3N4 which contained Al2O and Y2O3 as oxide additives were remarkably improved by HIP treatment using nitrogen as a pressure transmitting gas. It is very important to select the sintering conditions for fabricating the presintered body of Si3N4 in order to improve the mechanical properties of Si3N4 by HIP treatment.

Kuratani, S.↗
NASA NTRS1987

Polyimide processing additives

A method has been found for enhancing the melt flow of thermoplastic polyimides during processing. A high molecular weight 422 copoly(amic acid) or copolyimide was fused with approximately 0.05 to 5 pct by weight of a low molecular weight amic acid or imide additive, and this melt was studied by capillary rheometry. Excellent flow and improved composite properties on graphite resulted from the addition of a PMDA-aniline additive to LARC-TPI. Solution viscosity studies imply that amic acid additives temporarily lower molecular weight and, hence, enlarge the processing window. Thus, compositions containing the additive have a lower melt viscosity for a longer time than those unmodified.

Pratt, J. R.↗
NASA NTRS1991

Estimation of additive forces and moments for supersonic inlets

A technique for estimating the additive forces and moments associated with supersonic, external compression inlets as a function of mass flow ratio has been developed. The technique makes use of a low order supersonic paneling method for calculating minimum additive forces at maximum mass flow conditions. A linear relationship between the minimum additive forces and the maximum values for fully blocked flow is employed to obtain the additive forces at a specified mass flow ratio. The method is applicable to two-dimensional inlets at zero or nonzero angle of attack, and to axisymmetric inlets at zero angle of attack. Comparisons with limited available additive drag data indicate fair to good agreement.

Perkins, Stanley C., Jr.↗
NASA NTRS1992

The cyclic oxidation resistance at 1200 C of beta-NiAl, FeAl, and CoAl alloys with selected third element additions

The intermetallic compounds Beta-NiAl, FeAl, and CoAl were tested in cyclic oxidation with selected third element alloy additions. Tests in static air for 200 1-hr cycles at 1200 C indicated by specific weight change/time data and x-ray diffraction analysis that the 5 at percent alloy additions did not significantly improve the oxidation resistance over the alumina forming baseline alloys without the additions. Many of the alloy additions were actually deleterious. Ta and Nb were the only alloy additions that actually altered the nature of the oxide(s) formed and still maintained the oxidation resistance of the protective alumina scale.

Barrett, C. A.↗
NASA NTRS1954

Theoretical and experimental investigation of additive drag

The significance of additive drag is discussed and equations for determining its approximate value are derived for annular and open-nose inlets. Charts are presented giving values of additive drag coefficient over a range of free-stream Mach numbers for open and for annular-nose inlets with conical flow at the inlet. The effects on additive drag of variable inlet-total-pressure recovery and static pressures on the centerbody are investigated and an analytical method of predicting the variation of pressure on the centerbody with mass-flow ratio is given. Experimental additive-drag values are presented for a series of 20 degree and 25 degree cone half-angle inlets and one open-nose inlet operating at free-stream Mach numbers of 1.8 and 1.6. A comparison with the theoretical values of additive drag shows excellent agreement for the open-nose inlet and moderately good agreement for the annular inlets. (author)

Sibulkin, Merwin↗
NASA NTRS1996

Evaluation of Boundary-Enhancement Additives for Perfluoropolyethers

Six additives were synthesized and evaluated as boundary lubrication enhancers for perfluoropolyethers. These additives included a phosphonate, a thiophosphonate, a beta-diketone, a benzothiazole, an amide and a sulfite. These additives were evaluated in a vacuum four-ball apparatus, at a one weight percent concentration in a perfluoropolyether based on hexafluoropropene oxide. Tests were performed in vacuum (less than 5.0 x 10(exp 6) Torr), at room temperature (approx. 23 C), at an initial Hertzian stress of 3.5 GPa (200N load), and a sliding velocity of 28.8 mm/sec (100 rpm). Infrared (IR) and Raman spectroscopies were used to analyze the 440 C specimens after testing. Wear rates for each formulation were determined from the slope of wear volume as a function of sliding distance. All additives yielded reductions in mean wear rates of at least 55 percent, with the exception of the benzothiazole which had no effect. Two of the additives, an amide and a sulfite, reduced the mean wear rate by at least 80 percent. IR and Raman analysis indicated the severity of wear can be correlated to the amount of surface fluorinated polymeric acid species (R(sub f)COOH) and amorphous carbon, in and around the wear scar.

Shogrin, Bradley A.↗
NASA NTRS2005

Thermodynamic Effect of Platinum Addition to beta-NiAl: An Initial Investigation

An initial investigation was conducted to determine the effect of platinum addition on the activities of aluminum and nickel in beta-NiAl(Pt) over the temperature range 1354 to 1692 K. These measurements were made with a multiple effusion-cell configured mass spectrometer (multi-cell KEMS). The results of this study show that Pt additions act to decreased alpha(Al) and increased the alpha(Ni) in beta-NiAl(Pt) for constant X(sub Ni)/X(sub Al) approx. = 1.13, while at constant X(sub Al) the affect of Pt on Al is greatly reduced. The measured partial enthalpies of mixing indicate Al-atoms have a strong self interaction while Ni- and Pt-atoms in have similar interactions with Al-atoms. Conversely the binding of Ni-atoms in beta-NiAl decreases with Pt addition independent of Al concentration. These initial results prove the technique can be applied to the Ni-Al-Pt system but more activity measurements are required to fully understand the thermodynamics of this system and how Pt additions improved the scaling behavior of nickel-based superalloys. In addition, with the choice of a suitable oxide material for the effusion-cell, the "closed" isothermal nature of the effusion-cell allows the direct investigation of an alloy-oxide equilibrium which resembles the "local-equilibrium" description of the metal-scale interface observed during high temperature oxidation. It is proposed that with an Al(l) + Al2O3(s) experimental reference state together with the route measurement of the relative partial-pressures of Al(g) and Al2O(g) allows the activities of O and Al2O3 to be determined along with the activities of Ni and Al. These measurements provide a direct method of investigating the thermodynamics of the metal-scale interface of a TGO-scale.

Source record↗
NASA NTRS2007

Lithium Dinitramide as an Additive in Lithium Power Cells

Lithium dinitramide, LiN(NO2)2 has shown promise as an additive to nonaqueous electrolytes in rechargeable and non-rechargeable lithium-ion-based electrochemical power cells. Such non-aqueous electrolytes consist of lithium salts dissolved in mixtures of organic ethers, esters, carbonates, or acetals. The benefits of adding lithium dinitramide (which is also a lithium salt) include lower irreversible loss of capacity on the first charge/discharge cycle, higher cycle life, lower self-discharge, greater flexibility in selection of electrolyte solvents, and greater charge capacity. The need for a suitable electrolyte additive arises as follows: The metallic lithium in the anode of a lithium-ion-based power cell is so highly reactive that in addition to the desired main electrochemical reaction, it engages in side reactions that cause formation of resistive films and dendrites, which degrade performance as quantified in terms of charge capacity, cycle life, shelf life, first-cycle irreversible capacity loss, specific power, and specific energy. The incidence of side reactions can be reduced through the formation of a solid-electrolyte interface (SEI) a thin film that prevents direct contact between the lithium anode material and the electrolyte. Ideally, an SEI should chemically protect the anode and the electrolyte from each other while exhibiting high conductivity for lithium ions and little or no conductivity for electrons. A suitable additive can act as an SEI promoter. Heretofore, most SEI promotion was thought to derive from organic molecules in electrolyte solutions. In contrast, lithium dinitramide is inorganic. Dinitramide compounds are known as oxidizers in rocket-fuel chemistry and until now, were not known as SEI promoters in battery chemistry. Although the exact reason for the improvement afforded by the addition of lithium dinitramide is not clear, it has been hypothesized that lithium dinitramide competes with other electrolyte constituents to react with lithium on the surface of the anode to form a beneficial SEI. Apparently, nitrides and oxides that result from reduction of lithium dinitramide on the anode produce a thin, robust SEI different from the SEIs formed from organic SEI promoters. The SEI formed from lithium dinitramide is more electronically insulating than is the film formed in the presence of an otherwise identical electrolyte that does not include lithium dinitramide. SEI promotion with lithium dinitramide is useful in batteries with metallic lithium and lithium alloy anodes.

Gorkovenko, Alexander A.↗
NASA NTRS2010

Lithium-Ion Electrolytes Containing Phosphorous-Based, Flame-Retardant Additives

Future NASA missions aimed at exploring Mars, the Moon, and the outer planets require rechargeable batteries that can operate over a wide temperature range (-60 to +60 C) to satisfy the requirements of various applications. In addition, many of these applications will require improved safety, due to their use by humans. Currently, the state-of-the-art lithium-ion (Li-ion) system has been demonstrated to operate over a wide range of temperatures (-40 to +40 C); however, abuse conditions can often lead to cell rupture and fire. The nature of the electrolyte can greatly affect the propensity of the cell/battery to catch fire, given the flammability of the organic solvents used within. Li-ion electrolytes have been developed that contain a flame-retardant additive in conjunction with fluorinated co-solvents to provide a safe system with a wide operating temperature range. Previous work incorporated fluorinated esters into multi-component electrolyte formulations, which were demonstrated to cover a temperature range from 60 to +60 C. This work was described in Fluoroester Co-Solvents for Low-Temperature Li+ Cells (NPO-44626), NASA Tech Briefs, Vol. 33, No. 9 (September 2009), p. 37; and Optimized Li-Ion Electrolytes Con tain ing Fluorinated Ester Co-Solvents (NPO-45824), NASA Tech Briefs, Vol. 34, No. 3 (March 2010), p. 48. Other previous work improved the safety characteristics of the electrolytes by adding flame-retardant additives such as triphenyl phosphate (TPhPh), tri-butyl phosphate (TBuPh), triethyl phosphate (TEtPh), and bis(2,2,2-trifluoroethyl) methyl phosphonate (TFMPo). The current work involves further investigation of other types of flame-retardant additives, including tris(2,2,2-trifluoroethyl) phosphate, tris(2,2,2-trifluoroethyl) phosphite, triphenylphosphite, diethyl ethylphosphonate, and diethyl phenylphosphonate added to an electrolyte composition intended for wide operating temperatures. In general, many of the formulations investigated in this study displayed good performance over a wide temperature range, good cycle life characteristics, and are expected to have improved safety characteristics, such as low flammability. Of the electrolytes studied, 1.0 M LiPF6 in EC+EMC+DEP (20:75:5 v/v %) and 1.0 M LiPF6 in EC+EMC+DPP (20:75:5 v/v %) displayed the best operation at low temperatures, whereas the electrolyte containing triphenylphosphite displayed the best cycle life performance compared to the baseline solution. It is anticipated that further improvements can be made to the life characteristics with the incorporation of a SET promoters (such as VC, vinylene carbonate), which will likely inhibit the decomposition of the flame-retardant additives.

Smart, Marshall C.↗
NASA NTRS2011

Fire-Retardant Polymeric Additives

Polyhydroxyamide (PHA) and polymethoxyamide (PMeOA) are fire-retardant (FR) thermoplastic polymers and have been found to be useful as an additive for imparting fire retardant properties to other compatible, thermoplastic polymers (including some elastomers). Examples of compatible flammable polymers include nylons, polyesters, and acrylics. Unlike most prior additives, PHA and PMeOA do not appreciably degrade the mechanical properties of the matrix polymer; indeed, in some cases, mechanical properties are enhanced. Also, unlike some prior additives, PHA and PMeOA do not decompose into large amounts of corrosive or toxic compounds during combustion and can be processed at elevated temperatures. PMeOA derivative formulations were synthesized and used as an FR additive in the fabrication of polyamide (PA) and polystyrene (PS) composites with notable reduction (>30 percent for PS) in peak heat release rates compared to the neat polymer as measured by a Cone Calorimeter (ASTM E1354). Synergistic effects were noted with nanosilica composites. These nanosilica composites had more than 50-percent reduction in peak heat release rates. In a typical application, a flammable thermoplastic, thermoplastic blend, or elastomer that one seeks to render flame-retardant is first dry-mixed with PHA or PMeOA or derivative thereof. The proportion of PHA or PMeOA or derivative in the mixture is typically chosen to lie between 1 and 20 weight percent. The dry blend can then be melt-extruded. The extruded polymer blend can further be extruded and/or molded into fibers, pipes, or any other of a variety of objects that may be required to be fire-retardant. The physical and chemical mechanisms which impart flame retardancy of the additive include inhibiting free-radical oxidation in the vapor phase, preventing vaporization of fuel (the polymer), and cooling through the formation of chemical bonds in either the vapor or the condensed phase. Under thermal stress, the cyclic hydroxyl/ methoxy component forms polybenzoxazole (PBO) in a reaction that absorbs heat from its surroundings. PBO under thermal stress cross-links, forming a protective char layer, which thermally insulates the polymer. Thus, the formation of the char layer further assists to extinguish the fire by preventing vaporization of the polymeric fuel.

Williams, Martha K.↗
NASA NTRS2014

Additive Manufacturing Infrared Inspection

Additive manufacturing is a rapid prototyping technology that allows parts to be built in a series of thin layers from plastic, ceramics, and metallics. Metallic additive manufacturing is an emerging form of rapid prototyping that allows complex structures to be built using various metallic powders. Significant time and cost savings have also been observed using the metallic additive manufacturing compared with traditional techniques. Development of the metallic additive manufacturing technology has advanced significantly over the last decade, although many of the techniques to inspect parts made from these processes have not advanced significantly or have limitations. Several external geometry inspection techniques exist such as Coordinate Measurement Machines (CMM), Laser Scanners, Structured Light Scanning Systems, or even traditional calipers and gages. All of the aforementioned techniques are limited to external geometry and contours or must use a contact probe to inspect limited internal dimensions. This presentation will document the development of a process for real-time dimensional inspection technique and digital quality record of the additive manufacturing process using Infrared camera imaging and processing techniques.

Gaddy, Darrell↗