Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “metallic components”

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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
NASA NTRS2023

Reactive Additive Manufacturing for Fourth Industrial Revolution Exploration Systems (Ramfire) Aluminum 6061-Ram2 Nozzle Testing

The NASA Marshall Space Flight Center (MSFC) has applied various forms of metallic additive manufacturing (AM) in liquid rocket engine component design, development, and testing since 2010. These AM techniques reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing unconventional design. The RAMFIRE project, funded under Space Technology Mission Directorate (STMD) Game Changing Development (GCD) Program, has furthered the use of novel AM liquid rocket nozzles in collaboration with Elementum 3D. The project advanced novel large-scale AM aluminum material technology for significant weight savings in rocket engines and launch vehicles. Previously, aluminum alloys were difficult to weld and print using additive manufacturing. Elementum 3D’s patented Aluminum 6061-RAM2 alloy allows for aluminum alloys to be printed using various AM techniques and at various scales. The alloy can be leveraged for welding wire, showing drastic improvements in aluminum weldability. The RAMFIRE project focuses on five key areas: 1) Laser Powder Directed Energy Deposition (LP-DED) AL6061-RAM2 feedstock specification and verification, 2) LP-DED process development and validation, 3) LP-DED printed AL6061-RAM2 microstructural and mechanical property characterization, 4) Hot-fire test a 7k-lbf thrust class regeneratively cooled nozzle, 5) Print large scale regeneratively cooled nozzle. Hot-fire testing demonstrates potential of advanced space technologies to NASA and potential users by providing the relevant environments to advance TRL levels to the 5/6 range.

Al6061-RAM2↗
NASA NTRS2013

Thermal Imaging for Assessment of Electron-Beam Free Form Fabrication (EBF(sup 3)) Additive Manufacturing Welds

Additive manufacturing is a rapidly growing field where 3-dimensional parts can be produced layer by layer. NASA s electron beam free-form fabrication (EBF(sup 3)) technology is being evaluated to manufacture metallic parts in a space environment. The benefits of EBF(sup 3) technology are weight savings to support space missions, rapid prototyping in a zero gravity environment, and improved vehicle readiness. The EBF(sup 3) system is composed of 3 main components: electron beam gun, multi-axis position system, and metallic wire feeder. The electron beam is used to melt the wire and the multi-axis positioning system is used to build the part layer by layer. To insure a quality weld, a near infrared (NIR) camera is used to image the melt pool and solidification areas. This paper describes the calibration and application of a NIR camera for temperature measurement. In addition, image processing techniques are presented for weld assessment metrics.

Zalameda, Joseph N.↗
NASA NTRS1997

Surface Plasmon Resonance Evaluation of Colloidal Metal Aerogel Filters

We have fabricated aerogels containing gold, silver, and platinum nanoparticles for gas catalysis applications. By applying the concept of an average or effective dielectric constant to the heterogeneous interlayer surrounding each particle, we extend the technique of immersion spectroscopy to porous or heterogeneous media. Specifically, we apply the predominant effective medium theories for the determination of the average fractional composition of each component in this inhomogeneous layer. Hence, the surface area of metal available for catalytic gas reaction is determined. The technique is satisfactory for statistically random metal particle distributions but needs further modification for aggregated or surfactant modified systems. Additionally, the kinetics suggest that collective particle interactions in coagulated clusters are perturbed during silica gelation resulting in a change in the aggregate geometry.

Smith, David D.↗
NASA NTRS1982

Development of an advanced composite aileron for the L-1011 transport aircraft

Significant improvements in structural efficiency can be achieved by the utilization of advanced composites for construction of aircraft secondary structures. Careful evaluation of alternate designs and materials for the L-1011 advanced composite inboard aileron has led to the selection of several unique material combinations and easily manufactured structural configurations. The advanced composite aileron is a direct replacement for the metal aileron with a weight savings of 23 percent. Due to the configurational simplicity of the components within the composite aileron, and because it contains 50 percent fewer parts and fasteners than the metal aileron, it is predicted that the composite aileron will be cost competitive with the metal aileron in a production environment. Structural analysis of the composite aileron, in conjunction with the design data, concept verification, and ground tests, indicates that the composite aileron design meets or exceeds structural requirements.

Griffin, C. F.↗
NASA NTRS2012

A Suzaku Study of Ejecta Structure and Origin of Hard X-ray Emission in the Supernova Remnant G156.2+5.7

We report an X-ray study of the evolved Galactic supernova remnant (SNR) G1S6.2+S.7 based on six pointing observations with Suzaku. The remnant's large extent (100' in diameter) allows us to investigate its radial structure in the northwestern and eastern directions from the apparent center. The X-ray spectra. were well fit with a two-component non-equilibrium ionization model representing the swept-up interstellar medium (ISM) and the metal-rich ejecta. We found prominent central concentrations of Si, S and Fe from the ejecta component; the lighter elements of O, Ne and Mg were distributed more uniformly. The temperature of the ISM component suggests a slow shock (610-960 km/s), hence the remnant's age is estimated to be 7,000-15,000 yr, assuming its distance to be approx. 1.1 kpc. G1S6.2+5.7 has also been thought to emit hard, non-thermal X-rays, despite being considerably older than any other such remnant. In response to a recent discovery of a background cluster of galaxies (2XMM J045637.2+522411), we carefully excluded its contribution, and reexamined the origin of the hard X-ray emission. We found that the residual hard X-ray emission is consistent with the expected level of the cosmic X-ray background. Thus, no robust evidence for the non-thermal emission was obtained from G156.2+5.7. These results are consistent with the picture of an evolved SNR.

Uchida, Hiroyuki↗
NASA NTRS1993

Damped Lyman-alpha absorption by disk galaxies with large redshifts. IV - More intermediate-resolution spectroscopy

Intermediate-resolution spectra of six QSOs exhibiting seven Ly-alpha absorption troughs that are candidates for damped Ly-alpha absorption lines are presented. The metal content of the confirmed damped systems is investigated by examining the metal-line velocity profiles, and by performing curve-of-growth analyses for four of the six confirmed damped systems. The low-ionization lines associated with the z(metals) = 2.0399 damped system toward Q0458-020 have velocity widths up to 10 times wider than the width of the 21-cm absorption feature found at the same redshift. Since the 21-cm absorption arises in a low velocity dispersion layer of H I that extends more than 8/h kpc transverse to the line of sight, the H I absorption cannot arise from the same clouds responsible for the bulk of the metal-line absorption. This is strong evidence for a two-component model consisting of high column density 'quiescent' gas which gives rise to damped Ly-alpha and 21-cm absorption, and low column density 'turbulent' gas which dominates equivalent widths of saturated metal lines.

Wolfe, Arthur M.↗
NASA NTRS1998

Noble Metal Immersion Spectroscopy of Silica Alcogels and Aerogels

We have fabricated aerogels containing gold and silver nanoparticles for gas catalysis applications. By applying the concept of an average or effective dielectric constant to the heterogeneous interlayer surrounding each particle, we extend the technique of immersion spectroscopy to porous or heterogeneous media. Specifically, we apply the predominant effective medium theories for the determination of the average fractional composition of each component in this inhomogeneous layer. Hence, the surface area of metal available for catalytic gas reaction is determined. The technique is satisfactory for statistically random metal particle distributions but needs further modification for aggregated or surfactant modified systems. Additionally, the kinetics suggest that collective particle interactions in coagulated clusters are perturbed during silica gelation resulting in a change in the aggregate geometry.

Smith, David D.↗
NASA NTRS1993

Component Selection, Accelerated Testing, and Improved Modeling of AMTEC Systems for Space Power

Alkali metal thermal to electric converter (AMTEC) designs for space power are numerous, but the selection of materials for construction of long-lived AMTEC devices has been limited to electrodes, current collectors, and the solid electrolyte. AMTEC devices with lifetimes greater than 5 years require careful selection and life testing of all hot-side components. The likely selection of a remote condensed design for initial flight test and probable use with a radioisotope heat source in AMTEC powered planet probes requires the device to be constructed to tolerate operating T greater than 1150K, as well as exposure to Na (g) , and Na (liq) on the high pressure side. The temperatures involved make the characterization of high strength and chemical resistance to Na containing Na 2 O critical. Selection among materials which can be worked should not be driven by ease of fabricablity, as high temperature stability is the critical issue. These concepts drive the selecton of Mo alloys for Na (liq) containment in AMTEC cells for T to 1150K operation, as they are significantly stronger than comparable Nb or Ta alloys, are less soluble in Na (liq) containing dissolved Na 2 O, are workable compared with W alloys (which might be used for certain components), and are ductile at the T greater than 500K of proposed AMTEC modules in space applications.

AMTEC↗
NASA NTRS1972

Investigation of gaseous nuclear rocket technology

The experimental and theoretical investigations conducted during the period from September 1969 through September 1972 are reported which were directed toward obtaining information necessary to determine the feasibility of the full-scale nuclear light bulb engine, and of small-scale nuclear tests involving fissioning uranium plasmas in a unit cell installed in a driver reactor, such as the Nuclear Furnace. Emphasis was placed on development of RF simulations of conditions expected in nuclear tests in the Nuclear Furnace. The work included investigations of the following: (1) the fluid mechanics and containment characteristics of one-component and two-component vortex flows, both unheated and RF-induction heated; (2) heating of particle-seeded streams by thermal radiation from a dc arc to simulate propellant heating; (3) condensation and separation phenomena for metal-vapor/heated-gas mixtures to provide information for conceptual designs of components of fuel exhaust and recycle systems; (4) the characteristics of the radiant energy spectrum emitted from the fuel region, with emphasis on definition of fuel and buffer-gas region seed systems to reduce the ultraviolet radiation emitted from the nuclear fuel; and (5) the effects of nuclear radiation on the optical transmission characteristics of transparent materials.

Kendall, J. S.↗
NASA NTRS2005

Lifing of Engine Components

The successful development of advanced aerospace engines depends greatly on the capabilities of high performance materials and structures. Advanced materials, such as nickel based single crystal alloys, metal foam, advanced copper alloys, and ceramics matrix composites, have been engineered to provide higher engine temperature and stress capabilities. Thermal barrier coatings have been developed to improve component durability and fuel efficiency, by reducing the substrate hot wall metal temperature and protecting against oxidation and blanching. However, these coatings are prone to oxidation and delamination failures. In order to implement the use of these materials in advanced engines, it is necessary to understand and model the evolution of damage of the metal substrate as well as the coating under actual engine conditions. The models and the understanding of material behavior are utilized in the development of a life prediction methodology for hot section components. The research activities were focused on determining the stress and strain fields in an engine environment under combined thermo-mechanical loads to develop life prediction methodologies consistent with the observed damage formation of the coating and the substrates.

Source record↗
NASA NTRS2000

Float processing of high-temperature complex silicate glasses and float baths used for same

A float glass process for production of high melting temperature glasses utilizes a binary metal alloy bath having the combined properties of a low melting point, low reactivity with oxygen, low vapor pressure, and minimal reactivity with the silicate glasses being formed. The metal alloy of the float medium is exothermic with a solvent metal that does not readily form an oxide. The vapor pressure of both components in the alloy is low enough to prevent deleterious vapor deposition, and there is minimal chemical and interdiffusive interaction of either component with silicate glasses under the float processing conditions. Alloys having the desired combination of properties include compositions in which gold, silver or copper is the solvent metal and silicon, germanium or tin is the solute, preferably in eutectic or near-eutectic compositions.

Cooper, Reid Franklin↗
NASA NTRS1993

Component Selection, Accelerated Testing, and Improved Modeling of AMTEC Systems for Space Power (abstract)

Alkali metal thermal to electric converter (AMTEC) designs for space power are numerous, but selection of materials for construction of long-lived AMTEC devices has been limited to electrodes, current collectors, and the solid electrolyte. AMTEC devices with lifetimes greater than 5 years require careful selection and life testing of all hot-side components. The likely selection of a remote condensed design for initial flight test and probable use with a GPHS in AMTEC powered outer planet probes requires the device to be constructed to tolerate T greater than 1150K, as well as exposure to Na(sub (g)), and Na(sub (liq)) on the high pressure side. The temperatures involved make critical high strength and chemical resistance to Na containing Na(sub 2)O. Selection among materials which can be worked should not be driven by ease of fabricability, as high temperature stability is the critical issue. These concepts drive the selection of Mo alloys for Na(sub (liq)) containment in AMTEC cells for T to 1150K operation, as they are significantly stronger than comparable NB or Ta alloys, are less soluble in Na(sub (liq)) containing dissolved Na(sub 2)O, are workable compared to W alloys (which might be used for certain components), and are ductile at the T greater than 500K of proposed AMTEC modules in space applications.

AMTEC thermal to electric conversion↗
NASA NTRS2000

Erosion Coatings for High-Temperature Polymer Composites: A Collaborative Project With Allison Advanced Development Company

The advantages of replacing metals in aircraft turbine engines with high-temperature polymer matrix composites (PMC's) include weight savings accompanied by strength improvements, reduced part count, and lower manufacturing costs. Successfully integrating high-temperature PMC's into turbine engines requires several long-term characteristics. Resistance to surface erosion is one rarely reported property of PMC's in engine applications because PMC's are generally softer than metals and their erosion resistance suffers. Airflow rates in stationary turbine engine components typically exceed 2.3 kg/sec at elevated temperatures and pressures. In engine applications, as shown in the following photos, the survivability of PMC components is clearly a concern, especially when engine and component life-cycle requirements become longer. Although very few publications regarding the performance of erosion coatings on PMC's are available particularly in high-temperature applications the use of erosion-resistant coatings to significantly reduce wear on metallic substrates is well documented. In this study initiated by the NASA Glenn Research Center at Lewis Field, a low-cost (less than $140/kg) graphite-fiber-reinforced T650 35/PMR 15 sheet-molding compound was investigated with various coatings. This sheet-molding compound has been compression molded into many structurally complicated components, such as shrouds for gas turbine inlet housings and gearboxes. Erosion coatings developed for PMC s in this study consisted of a two-layered system: a bondcoat sprayed onto a cleaned PMC surface, followed by an erosion-resistant, hard topcoat sprayed onto the bondcoat as shown in following photomicrograph. Six erosion coating systems were evaluated for their ability to withstand harsh thermal cycles, erosion resistance (ASTM G76 83 "Standard Practice for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets") using Al2O3, and adhesion to the graphite fiber polyimide composite (ASTM D 4541 95 "Pull Off Strength of Coatings"). Glenn and Allison Advanced Development Company collaborated to optimize erosion coatings for gas turbine fan and compressor applications. All the coating systems survived aggressive thermal cycling without spalling. During erosion tests (see the final photo), the most promising coating systems tested had Cr3C2-NiCr and WC-Co as the hard topcoats. In all cases, these coating systems performed significantly better than that with a TiN hard topcoat. When material depth (thickness) loss is considered, the Cr3C2-NiCr and WC-Co coating systems provided, on average, an erosion resistance 8.5 times greater than that for the uncoated PMR 15/T650 35 composite. Similarly, Cr3C2-NiCr and WC-Co coating systems adhered to the PMC substrate during tensile tests significantly better than systems containing a TiN topcoat. Differences in topcoats of Cr3C2-NiCr and WC-Co were determined by considering issues such as cost and environmental impact. The preferred erosion-resistant coating system for PMR 15/T650 35 has WC-Co as the hard topcoat. This system provides the following benefits in comparison to the coating system with Cr3C2-NiCr topcoat: lower powder material cost (15 to 20 percent), environmentally friendly materials (Cr3C2-NiCr is hazardous), and higher deposition yield (10 to 15 percent), which results in less waste.

Sutter, James K.↗
NASA NTRS2007

Assembly and Thermal Hydraulic Test of a Stainless Steel Sodium-Potassium Circuit

Early Flight Fission Test Facilities (EFF-TF) team has been tasked by the NASA Marshall Space Flight Center Nuclear Systems Office to design, fabricate, and test an actively pumped alkali metal flow circuit. The system was originally built for use with lithium, but due to a shift in focus, it was redesigned for use with a eutectic mixture of sodium potassium (NaK). Basic circuit components include: reactor segment, NaK to gas heat exchanger, electromagnetic (EM) liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and a spill reservoir. A 37-pin partial-array core (pin and flow path dimensions are the same as those in a full design) was selected for fabrication and test. This paper summarizes the first fill and checkout testing of the Stainless Steel NaK-Cooled Circuit (SNaKC).

Garber, A.↗
NASA NTRS1993

Proposed framework for thermomechanical life modeling of metal matrix composites

The framework of a mechanics of materials model is proposed for thermomechanical fatigue (TMF) life prediction of unidirectional, continuous-fiber metal matrix composites (MMC's). Axially loaded MMC test samples are analyzed as structural components whose fatigue lives are governed by local stress-strain conditions resulting from combined interactions of the matrix, interfacial layer, and fiber constituents. The metallic matrix is identified as the vehicle for tracking fatigue crack initiation and propagation. The proposed framework has three major elements. First, TMF flow and failure characteristics of in situ matrix material are approximated from tests of unreinforced matrix material, and matrix TMF life prediction equations are numerically calibrated. The macrocrack initiation fatigue life of the matrix material is divided into microcrack initiation and microcrack propagation phases. Second, the influencing factors created by the presence of fibers and interfaces are analyzed, characterized, and documented in equation form. Some of the influences act on the microcrack initiation portion of the matrix fatigue life, others on the microcrack propagation life, while some affect both. Influencing factors include coefficient of thermal expansion mismatch strains, residual (mean) stresses, multiaxial stress states, off-axis fibers, internal stress concentrations, multiple initiation sites, nonuniform fiber spacing, fiber debonding, interfacial layers and cracking, fractured fibers, fiber deflections of crack fronts, fiber bridging of matrix cracks, and internal oxidation along internal interfaces. Equations exist for some, but not all, of the currently identified influencing factors. The third element is the inclusion of overriding influences such as maximum tensile strain limits of brittle fibers that could cause local fractures and ensuing catastrophic failure of surrounding matrix material. Some experimental data exist for assessing the plausibility of the proposed framework.

Halford, Gary R.↗
NASA NTRS1971

Creep-fatigue analysis by strain-range partitioning.

The framework of a new method is outlined for treating creep-fatigue behavior of metals. Inelastic strain-ranges are partitioned into the components of (1) completely reversed plasticity, (2) tensile plasticity reversed by compressive creep, or tensile creep reversed by compressive plasticity, and (3) completely reversed creep. Each of these components is shown to be related to cyclic life by a Manson-Coffin type power-law equation. A linear life fraction rule is used to combine the damaging effects of the individual components enabling the prediction of life. Test results are presented for a 2.25 Cr-1 Mo steel as well as limited information for a Type 316 stainless steel.

Manson, S. S.↗
NASA NTRS1977

Apparatus for measuring the force of gravity on freely falling electrons

An apparatus and data analysis technique for measuring the gravitational force on freely falling electrons are described. The measurement required that all forces acting on the electrons be uniform and measurable to about ten to the negative 11th power eV/m. The electrical force along the axis of the 5-cm-diam, vertical copper tube used in the experiment was found to be about six times ten to the negative 11th power eV/m when the tube was cooled to 4.2 K. Forces on electrons due to magnetic field gradients were reduced well below the electrical ones by selecting only ground state electrons for measurement. The absence, at 4.2 K, of much stronger electric fields, which were expected to arise from the patch effect and from differential lattice components, contrasts strongly with measurements of electric fields near metal surfaces made at room temperature.

Witteborn, F. C.↗
NASA NTRS1985

Deployable M-Braced Truss

Tension/compression and shear separated structurally in deployable beam. M-Braced Sections Packaged using combination of hinges and telescoping sections. When upper sections telescope into base, diagonals hinge, telescope, and rotate along batten. Components of M-braced truss fabricated from conventional metallic materials or nonmetallic materials such as graphite/epoxy. Applications include masts for antenna feed horns and ribs for solar array blankets.

Mikulas, M. M., Jr.↗