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The size of aluminum oxide particles produced by small rocket motors is determined by tank collection and spectrophotometry. The size of the particulate determines loss in thrust due to particle lag, particulate radiant heat transfer, acoustic attenuation and impingement and rocket plume structure and properties.
Superalloys can be strengthened by oxide dispersions to potentially improve their mechanical properties at high temperatures. Additive manufacturing has opened new paths for introducing oxide particles into superalloys with increased processing flexibility, to potentially provide oxide dispersion strengthening. Numerically controlled electrical discharge machining (EDM) has often been used as a machining process for initial sectioning, detailed roughing, and even finishing operations of conventional superalloys. The objective of this study was to examine how additively manufactured superalloys containing oxide dispersions respond when sectioned using EDM. Consistent sections of several superalloys, two containing an oxide dispersion, were sliced using a typical EDM machine with standard brass wire and a typical roughing condition set. Roughness, microstructure, and residual stress at the EDM surfaces were compared for the varied superalloys.
The sintered aluminum powder (SAP) technique of dispersion strengthening (formation of an oxide dispersion by preoxidation of metal powders) was applied to atomized powder of a nickel alloy containing, by weight, 17% Cr, 5% Al, and 0.2% Y. The SAP-NiCrAl alloy (without the ytterbium removed by oxdation) was worked by extrusion and rod rolling at 1205 C and by swaging at 760 C. Annealing treatments were applied after working to determine the recrystallization response. The NiCrAlY alloy, similarly prepared from atomized powder, but without a preoxidation treatment, was examined for comparison. The SAP-NiCrAl alloy exhibited oxide particle size and spacing much larger than that usually observed in oxide dispersion strengthened alloys; nonetheless, it was possible to achieve abnormal (secondary) recrystallization in the SAP-NiCrAl alloy as has been reported for other oxide dispersion strengthened alloys. In contrast, the unoxidized NiCrAlY alloy exhibited only primary recrystallization.
The SAP technique of dispersion strengthening (formation of an oxide dispersion by preoxidation of metal powders) was applied to atomized powder of the alloy Ni-17Cr-5Al-0.2 Y. SAP-NiCrAl was worked by extrusion and rod rolling at 1205 C and by swaging at 760 C. A variety of annealing treatments were applied after working to determine the recrystallization response. NiCrAlY, similarly prepared from atomized powder, but without a preoxidation treatment, was examined for comparison. The SAP-NiCrAl of this study exhibited oxide particle size and spacing much larger than that usually observed in oxide dispersion strengthened alloys; nonetheless, it was possible to achieve abnormal (secondary) recrystallization in the SAP-NiCrAl as has been reported for other oxide dispersion strengthened alloys. In contrast, unoxidized NiCrAlY exhibited only primary recrystallization.
As part of a NASA funded contract to develop and demonstrate a gas generator cycle hybrid rocket motor for upper stage space motor applications, the development and demonstration of a low sensitivity, high performance fuel composition was undertaken. The ultimate goal of the development program was to demonstrate successful hybrid operation (start, stop, throttling) of the fuel with high concentration (90+%) hydrogen peroxide. The formulation development and lab-scale testing of a simple DOT Class 1.4c gas generator propellant is described. Both forward injected center perforated and aft injected end burner hybrid combustion behavior were evaluated with gaseous oxygen and catalytically decomposed 90% hydrogen peroxide. Cross flow and static environments were found to yield profoundly different combustion behaviors, which were further governed by binder type, oxidizer level and, significantly, oxidizer particle size. Primary extinguishment was accomplished via manipulation of PDL behavior and oxidizer turndown, which is enhanced with the hydrogen peroxide system. Laboratory scale combustor results compared very well with 11-inch and 24-inch sub-scale test results with 90% hydrogen peroxide.
Tank collection and spectrophotometric tests in determining aluminum oxide particle size produced by small rocket engine
Measurement data on the performance of Space Shuttle Solid Rocket Motor show wide variations in the head-end pressure changes and the total thrust build-up during the ignition transient periods. To analyze the flow and thermal behavior in the tested solid rocket motors, a 1-dimensional, ideal gas flow model via the SIMPLE algorithm was developed. Numerical results showed that burning patterns in the star-shaped head-end segment of the propellant and the erosive burning rate are two important factors controlling the ignition transients. The objective of this study is to extend the model to include the effects of aluminum particle commonly used in solid propellants. To treat the effects of aluminum-oxide particles in the combustion gas, conservation of mass, momentum, and energy equations for the particles are added in the numerical formulation and integrated by an inter-phase-slip algorithm.
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.
In friction stir welding (FSWing) the actual solid state joining takes place between the faying surfaces which form the weld seam. Thus the seam trace is often investigated for clues when the strength of the weld is reduced. Aluminum and its alloys are known to form a native, protective oxide on the surface. If these native surface oxides are not sufficiently broken up during the FSW process, they are reported to remain in the FSW interior and weaken the bond strength. This type of weld defect has been referred to as a lazy "S", lazy "Z", joint line defect, kissing bond, or residual oxide defect. Usually these defects are mitigated by modification of the process parameters, such as increased tool rotation rate, which causes a finer breakup of the native oxide particles. This study proposes that there may be an alternative mechanism for formation of oxides found within the weld nugget. As the oxidation rate increases at elevated temperatures above 400ºC, it may be possible for enhanced oxidation to occur on the interior surfaces during the FSW process from entrained air entering the seam gap. Normally, FSWs of aluminum alloys are made without a purge gas and it is unknown how process parameters and initial fit up could affect a potential air path into the interior during the processing. In addition, variations in FSW parameters, such as the tool rotation, are known to have a strong influence on the FSW temperature which may affect the oxidation rate if internal surfaces are exposed to entrained air. A series of FSWs were made in 3 different thickness panels of AA2219 (0.95, 1.27 and 1.56 cm) at 2 different weld pitches. As the thickness of the panels increased, there was an increased tendency for a gap to form in advance of the weld tool. If sufficient air is able to enter the workpiece gap prior to consolidation, the weld temperature can increase the oxidation rate on the interior surfaces. These oxidation rates would also be accelerated in areas of localized liquation. Metallographs from the weld panels showed indications of liquation at the grain boundaries. In FSWs of thicker panels, these regions of liquation were found to be heavily oxidized. The quality of the FSWs was evaluated from tensile testing at room temperature. As the panel thickness increased, a slight decrease in tensile strength was observed which was attributed to the presence of oxides. No oxide formation was observed in the thinner workpieces, although there were indications of localized liquation at the grain boundaries. Results from this study will assist in a better understand of the mechanisms of oxide formation in FSW interiors and provide methodology for minimizing their occurrence.
Tank collection and spectrophotometric tests in determining aluminum oxide particle size produced by small rocket engine
Temperature dependence of Mie scattering, covering absorption and scattering of electromagnetic radiation on spherical aluminum oxide particles
A method of making metal oxide clusters in a single stage by reacting a metal oxide with a substoichiometric amount of an acid in the presence of an oxide particle growth terminator and solubilizer. A method of making a ceramer is also disclosed in which the metal oxide clusters are reacted with a functionalized polymer. The resultant metal oxide clusters and ceramers are also disclosed.
A method of making metal oxide clusters in a single stage by reacting a metal oxide with a substoichiometric amount of an acid in the presence of an oxide particle growth terminator and solubilizer. A method of making a ceramer is also disclosed in which the metal oxide clusters are reacted with a functionalized polymer. The resultant metal oxide clusters and ceramers are also disclosed.
Structurally stable and mechanically strong ceramic oxide aerogels are provided. The aerogels are cross-linked via organic polymer chains that are attached to and extend from surface-bound functional groups provided or present over the internal surfaces of a mesoporous ceramic oxide particle network via appropriate chemical reactions. The functional groups can be hydroxyl groups, which are native to ceramic oxides, or they can be non-hydroxyl functional groups that can be decorated over the internal surfaces of the ceramic oxide network. Methods of preparing such mechanically strong ceramic oxide aerogels also are provided.
Structurally stable and mechanically strong ceramic oxide aerogels are provided. The aerogels are cross-linked via organic polymer chains that are attached to and extend from surface-bound functional groups provided or present over the internal surfaces of a mesoporous ceramic oxide particle network via appropriate chemical reactions. The functional groups can be hydroxyl groups, which are native to ceramic oxides, or they can be non-hydroxyl functional groups that can be decorated over the internal surfaces of the ceramic oxide network. Methods of preparing such mechanically strong ceramic oxide aerogels also are provided.
Mullite bond coats filled with silicon particles have recently been proposed for the next generation of environmental barrier coatings (EBCs). The sacrificial oxidation of the silicon particles eliminates some of the environmental durability issues associated with traditional EBC designs. To investigate this novel design approach, a mathematical formulation and resulting numerical method have been developed for simulating the oxidation of silicon particles embedded in a mullite matrix. The focus is on the oxidation of the silicon in a dry oxygen environment where the oxidant is presumably oxygen. Oxygen transport from the exterior environment through the mullite is assumed to occur via two lattice defect diffusion mechanisms. As a result, the rate of oxygen transport is dictated by the self-diffusivity of the lattice defects. The numerical method is implemented using the COMSOL Multiphysics® program (COMSOL, Inc.). The method is applied to simulate the oxidation of silicon particles in a mullite pellet in recent oxidation experiments. Numerical results compare favorably with the oxidation behavior observed in the oxidation experiments. The numerical method is also used to investigate the effects of various features of the mullite-silicon particle system on the oxidation behavior.
Palagonitic materials from Mauna Kea, Hawaii, were identified as Mars analogs based on their spectral and magnetic properties. These materials probably resulted from hydrothermal alteration during eruption of the volcano and/or from weathering under ambient conditions. The reflectance spectra of the Mars surface obtained by Earth-based telescopes and the reflectance spectra of analogs obtained in the laboratory show features due to electronic transitions of Fe(III) in oxide particles that range in size from nanometer (nanophase) to micrometer sized or larger. The presence of Fe(III) suggests oxidizing conditions during the alteration process in Mars that may have occurred in the past or during a slow ongoing process. Two naturally altered basaltic samples from Hawaii (HWMK12 and HWMK13) and a laboratory-altered (PH-13-DCGT2) basaltic glass similar in elemental composition to the above two samples was examined. All three samples exhibited spectral characteristics similar to martian bright-region spectra. Chemical and mineralogical changes occurring at the surface of these basalts were studied in order to understand the basis for their Mars-like properties. The spectral properties of the three samples were examined after the removal of Fe oxides by chemical extractants.
The objective of this research is to create combustion data for gelled and metallized gelled fuels using unique nanometer-sized gellant particles and/or nanometer-sized aluminum particles. Researchers at the NASA Glenn Research Center are formulating the fuels for both gas turbine and pulsed detonation engines. We intend to demonstrate metallized gelled fuel ignition characteristics for pulse detonation engines with JP/aluminum fuel and for gas turbine engines with gelled JP, propane, and methane fuel. The fuels to be created are revolutionary as they will deliver the highest theoretically maximum performance of gelled and metallized gelled fuels. Past combustion work has used micrometer-sized particles, which have limited the combustion performance of gelled and metallized gelled fuels. The new fuel used nanometer-sized aluminum oxide particles, which reduce the losses due to mismatch in the gas and solid phases in the exhaust. Gelled fuels provide higher density, added safety, reduced fuel slosh, reduced leakage, and increased exhaust velocity. Altogether, these benefits reduce the overall size and mass of the vehicle, increasing its flexibility.