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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗
NASA NTRS2001

Laser High-Cycle Thermal Fatigue of Pulse Detonation Engine Combustor Materials Tested

Pulse detonation engines (PDE's) have received increasing attention for future aerospace propulsion applications. Because the PDE is designed for a high-frequency, intermittent detonation combustion process, extremely high gas temperatures and pressures can be realized under the nearly constant-volume combustion environment. The PDE's can potentially achieve higher thermodynamic cycle efficiency and thrust density in comparison to traditional constant-pressure combustion gas turbine engines (ref. 1). However, the development of these engines requires robust design of the engine components that must endure harsh detonation environments. In particular, the detonation combustor chamber, which is designed to sustain and confine the detonation combustion process, will experience high pressure and temperature pulses with very short durations (refs. 2 and 3). Therefore, it is of great importance to evaluate PDE combustor materials and components under simulated engine temperatures and stress conditions in the laboratory. In this study, a high-cycle thermal fatigue test rig was established at the NASA Glenn Research Center using a 1.5-kW CO2 laser. The high-power laser, operating in the pulsed mode, can be controlled at various pulse energy levels and waveform distributions. The enhanced laser pulses can be used to mimic the time-dependent temperature and pressure waves encountered in a pulsed detonation engine. Under the enhanced laser pulse condition, a maximum 7.5-kW peak power with a duration of approximately 0.1 to 0.2 msec (a spike) can be achieved, followed by a plateau region that has about one-fifth of the maximum power level with several milliseconds duration. The laser thermal fatigue rig has also been developed to adopt flat and rotating tubular specimen configurations for the simulated engine tests. More sophisticated laser optic systems can be used to simulate the spatial distributions of the temperature and shock waves in the engine. Pulse laser high-cycle thermal fatigue behavior has been investigated on a flat Haynes 188 alloy specimen, under the test condition of 30-Hz cycle frequency (33-msec pulse period and 10-msec pulse width including a 0.2-msec pulse spike; ref. 4). Temperature distributions were calculated with one-dimensional finite difference models. The calculations show that that the 0.2-msec pulse spike can cause an additional 40 C temperature fluctuation with an interaction depth of 0.08 mm near the specimen surface region. This temperature swing will be superimposed onto the temperature swing of 80 C that is induced by the 10-msec laser pulse near the 0.53-mm-deep surface interaction region.

Zhu, Dong-Ming↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗
NASA NTRS1992

Projectile shape and material effects in hypervelocity impact response of dual-wall structures

All large spacecraft are susceptible to impacts by meteoroids and pieces of orbiting space debris. These impacts occur at extremely high speeds and can damage flight-critical systems, which can in turn lead to catastrophic failure of the spacecraft. A long-duration spacecraft developed for a mission into this environment must include adequate protection against perforation of pressurized components by such impacts. This paper presents the results of an investigation into the effects of projectile shape and material on the perforation of aluminum dual-wall structural systems. Impact damage is characterized according to the extent of perforation, crater, and spall damage in the structural systems as a result of hypervelocity projectile impact loadings. Analysis of the damage data shows that there are distinct differences in impact damage from cylindrical and spherical projectiles. Projectile density is also found to affect the type and extent of damage sustained by dual-wall structural systems.

Schonberg, William P.↗
DOE OSTI2022

Simulation of dislocation evolution in microparticle impacts over a wide range of impact velocities

We report the dynamic loading environment created by high velocity microparticle impacts is very difficult to model. The extremely high strain rates, large deformations, and high temperatures affect the flow stress of the material in ways that standard flow stress models cannot capture. Plastic deformation and strain hardening in metals is controlled by the motion of dislocations. Dislocations can be nucleated, stored as forest dislocations, or be annihilated as loading progresses. A comprehensive accounting of dislocation density change is needed to accurately describe rate and temperature dependent dislocation glide and evolution across the wide rage of loading conditions present in microparticle impact problems. Therefore, we implement and apply a newly proposed flow stress model (Hunter and Preston, 2015, 2022) that is then coupled with mobile and immobile dislocation density evolution equations. This model is implemented in Los Alamos National Laboratory’s hydrodynamics code, FLAG, to model copper-on-copper microparticle impacts. This new strength model allows for accurate simulation of particle rebound and flattening across a wide range of impact velocities.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Cation Short-Range Ordering of MgAl 2 O 4 and NiAl 2 O 4 Spinel Oxides at High Temperatures via In Situ Neutron Total Scattering

Complex oxides that adopt the isometric spinel structure (AB 2 O 4 ) are important for numerous technological applications and are relevant for certain geological processes, which involve exposure to extreme environments such as high pressures and temperatures. Recent studies have shown that the changes to the spinel structure caused by these environments are complex and depend on the material length scale under consideration. In this study we have expanded this approach to the behavior of spinels under high temperature. In situ neutron total scattering experiments, coupled with pair distribution function analysis, performed on two spinel compositions with various levels of pre-existing disorder (MgAl 2 O 4 and NiAl 2 O 4 ) revealed that both compositions trend to a state of maximum disorder where the A and B cations are randomly distributed amongst the two available sites. Temperature-induced cation inversion, conventionally understood as exchange of cations on the A and B sites, is locally expressed as an atomic rearrangement to a tetragonal symmetry, a correlation that is retained up to the maximum temperature studied (1000 °C). Furthermore, a complex thermal expansion behavior is revealed wherein the oxide materials expand heterogeneously at the level of coordination polyhedral with an apparent dependence on bond strength.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Localized corrosion of high performance metal alloys in an acid/salt environment

Various vacuum jacketed cryogenic supply lines at the Space Shuttle launch site at Kennedy Space Center use convoluted flexible expansion joints. The atmosphere at the launch site has a very high salt content, and during a launch, fuel combustion products include hydrochloric acid. This extremely corrosive environment has caused pitting corrosion failure in the thin walled 304L stainless steel flex hoses. A search was done to find a more corrosion resistant replacement material. The study focussed on 19 metal alloys. Tests which were performed include electrochemical corrosion testing, accelerated corrosion testing in a salt fog chamber, and long term exposure at a beach corrosion testing site. Based on the results of these tests, several nickel based alloys were found to have very high resistance to this corrosive environment. Also, there was excellent agreement between the electrochemical tests and the actual beach exposure tests. This suggests that electrochemical testing may be useful for narrowing the field of potential candidate alloys before subjecting samples to long term beach exposure.

Macdowell, L. G.↗
NASA NTRS1992

Thermal conductance of two interface materials and their applications in space systems

The temperature control of spacecraft and instrument systems and subsystems requires heat transfer interface materials that possess good thermal and structural characteristics, among other properties, to respond to the vacuum environment of space. These materials must be easy to apply to, and remove from, the surfaces where they are applied, and must be able to withstand power dissipation extremes, and be used for different clamping configurations and pressures. Silicone based greases, used in the past, tend to migrate and to contaminate nearby surfaces. Bare metal to metal contact offers low thermal conductance and difficulties in estimating the actual heat transfer. Several polymeric materials containing different thermal conductive compounds and structural reinforcements were prepared to overcome grease and metal problems. Two polymeric materials were evaluated: Cho-Therm 1671 elastomer; and the CV-2946, a conductive RTV silicone. Tests were done to learn more about these products. Results indicate that the tightly bolted, torqued fixtures did not buckle or distort, and provided optimum thermal conductance. Fixtures simulating actual spacecraft configuration suffered bowing and separating.

Scialdone, J. J.↗
NASA NTRS1999

Control Design Strategies to Enhance Long-Term Aircraft Structural Integrity

Over the operational lifetime of both military and civil aircraft, structural components are exposed to hundreds of thousands of low-stress repetitive load cycles and less frequent but higher-stress transient loads originating from maneuvering flight and atmospheric gusts. Micro-material imperfections in the structure, such as cracks and debonded laminates, expand and grow in this environment, reducing the structural integrity and shortening the life of the airframe. Extreme costs associated with refurbishment of critical load-bearing structural components in a large fleet, or altogether reinventoring the fleet with newer models, indicate alternative solutions for life extension of the airframe structure are highly desirable. Increased levels of operational safety and reliability are also important factors influencing the desirability of such solutions. One area having significant potential for impacting crack growth/fatigue damage reduction and structural life extension is flight control. To modify the airframe response dynamics arising from command inputs and gust disturbances, feedback loops are routinely applied to vehicles. A dexterous flight control system architecture senses key vehicle motions and generates critical forces/moments at multiple points distributed throughout the airframe to elicit the desired motion characteristics. In principle, these same control loops can be utilized to influence the level of exposure to harmful loads during flight on structural components. Project objectives are to investigate and/or assess the leverage control has on reducing fatigue damage and enhancing long-term structural integrity, without degrading attitude control and trajectory guidance performance levels. In particular, efforts have focused on the effects inner loop control parameters and architectures have on fatigue damage rate. To complete this research, an actively controlled flexible aircraft model and a new state space modeling procedure for crack growth have been utilized. Analysis of the analytical state space model for crack growth revealed the critical mathematical factors, and hence the physical mechanism they represent, that influenced high rates of airframe crack growth. The crack model was then exercised with simple load inputs to uncover and expose key crack growth behavior. To characterize crack growth behavior, both "short-term" laboratory specimen test type inputs and "long-term" operational flight type inputs were considered. Harmonic loading with a single overload revealed typical exponential crack growth behavior until the overload application, after which time the crack growth was retarded for a period of time depending on the overload strength. An optimum overload strength was identified which leads to maximum retardation of crack growth. Harmonic loading with a repeated overload of varying strength and frequency again revealed an optimum overload trait for maximizing growth retardation. The optimum overload strength ratio lies near the range of 2 to 3 with dependency on frequency. Experimental data was found to correlate well with the analytical predictions.

Newman, Brett A.↗
DOE OSTI2023

Molecular dynamics study of grain boundary and radiation effects on tritium population and diffusion in zirconium

Tritium population thermodynamics and transport kinetics critically define the tritium storage performance of zirconium tritides that can be used for a variety of nuclear applications including tritium-producing burnable absorber rods. Both thermodynamic and kinetic properties can be sensitive to grain sizes of materials and can be significantly altered by irradiated defects during operation under the reactor environments. A thorough experimental characterization of how these properties evolve under different reactor conditions and different initial grain structures is extremely challenging. Here molecular dynamics simulations are used to investigate tritium population and diffusion in zirconium with and without different planar symmetric and asymmetric tilt grain boundaries and irradiated defects. Here, we found that in addition to trapping tritium, the most significant effect of planar grain boundaries is to increase tritium diffusivity on the boundary plane. Furthermore, fine grain structures are found to mitigate the change of tritium diffusivity due to irradiated point defects as these point defects are likely to migrate to and sink at grain boundaries.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Evaluating Material Design Principles for Calcium-Ion Mobility in Intercalation Cathodes

Multivalent-ion batteries offer an alternative to Li-based technologies, with the potential for greater sustainability, improved safety, and higher energy density, primarily due to their rechargeable system featuring a passivating metal anode. Although a system based on the Ca 2+ /Ca couple is particularly attractive given the low electrochemical plating potential of Ca 2+ , the remaining challenge for a viable rechargeable Ca battery is to identify Ca cathodes with fast ion transport. In this work, a high-throughput computational pipeline is adapted to (1) discover novel Ca cathodes in a largely unexplored space of empty intercalation hosts and (2) develop material design rules for Ca-ion mobility. One candidate from the screening, W 2 O 3 (PO 4 ) 2 , is confirmed to have a low Nudged Elastic Band (NEB) barrier of 168 meV within a one-dimensional (1D) ion percolation topology. This candidate is subsequently synthesized and electrochemically tested, achieving reversible Ca cycling with a capacity of 25 mA h/g. To further accelerate the screening for promising Ca intercalation electrodes, machine learning (ML) Random Forest (RF) and Extreme Gradient Boosting (XGB) classification models are created with local environment descriptors based on a large, structurally and chemically diverse dataset of minimum energy pathways, spanning over 5,000 density functional theory (DFT) site energy calculations. Accuracies of 92% are achieved, material design metrics are quantified, ML force-fields are leveraged in an accelerated iteration of the screening, and a total of 27 novel Ca cathode materials are highlighted for further investigation.

25 ENERGY STORAGE↗
DOE OSTI2024

Experimental investigation of thermal conductivity of high entropy ceramics

In this talk, we will present the experimental investigation of thermal conductivity of high entropy carbides (HEC) and borides (HEB) with different compositions. Thermal conductivity determines the capability of a material to transport thermal energy and is considered as one critical physical property, specially in the energy industry. Due to the presences of disordered cation sublattice, it is expected that thermal conductivity of high entropy ceramics is lower than the counterparts with simpler compositions, but the experimental studies are relatively few. Using laser-based spatial-domain and frequency-domain thermoreflectance technique, we measured thermal conductivity of HECs and HEBs in a temperature range from 77K to 773K. Furthermore, by focusing the laser using an objective lens, we were able to perform the thermal property mapping on samples with the spatial resolution of micrometer. Such measurements could reveal important microstructure information in a rapid and efficient way without using scanning electron microscopy. The high spatial resolution also enables thermal conductivity measurements on ion-irradiated HECs with the damage layer of merely 1.1µm. These measurements can provide valuable information to predict the performances of HECs and HEBs with different compositions and from different manufacturing processes, and in the extreme environments such as nuclear reactors.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Theoretical Prediction of Thermal Expansion Anisotropy for Y 2 Si 2 O 7 Environmental Barrier Coatings Using a Deep Neural Network Potential and Comparison to Experiment

Environmental barrier coatings (EBCs) are an enabling technology for silicon carbide (SiC)-based ceramic matrix composites (CMCs) in extreme environments such as gas turbine engines. However, the development of new coating systems is hindered by the large design space and difficulty in predicting the properties for these materials. Density Functional Theory (DFT) has successfully been used to model and predict some thermodynamic and thermo-mechanical properties of high-temperature ceramics for EBCs, although these calculations are challenging due to their high computational costs. In this work, we use machine learning to train a deep neural network potential (DNP) for Y 2 Si 2 O 7 , which is then applied to calculate the thermodynamic and thermo-mechanical properties at near-DFT accuracy much faster and using less computational resources than DFT. We use this DNP to predict the phonon-based thermodynamic properties of Y 2 Si 2 O 7 with good agreement to DFT and experiments. We also utilize the DNP to calculate the anisotropic, lattice direction-dependent coefficients of thermal expansion (CTEs) for Y 2 Si 2 O 7 . Molecular dynamics trajectories using the DNP correctly demonstrate the accurate prediction of the anisotropy of the CTE in good agreement with the diffraction experiments. In the future, this DNP could be applied to accelerate additional property calculations for Y 2 Si 2 O 7 compared to DFT or experiments.

36 MATERIALS SCIENCE↗
NASA NTRS1987

Enhanced thermal emittance of space radiators by ion-discharge chamber texturing

The discharge chamber of a 30-cm argon ion source was successfully used to texture potential space radiator materials for the purpose of obtaining values of thermal emittance greater than 0.85 at 700 and 900 K. Some samples were also treated in acid prior to texturing. To evaluate the durability of the textured materials to atomic oxygen, samples were exposed to an RF air plasma environment. The spectral emittance between 2.0 anf 15.0 microns was measured before and after the textured materials were exposed to the plasma asher. The results indicate that copper with extremely high values of emittance after texturing (0.978 and 0.983) at 700 and 900 K, respectively,did not change its values of emittance after ashing, whereas the emittance of stainless steel fell below 0.85 after ashing. These data, along with scanning electron photomicrographs, and the results of texturing and ashing titanium and Nb(1)Zr are presented .

Mirtich, Michael J.↗
NASA NTRS1987

Space suit extravehicular hazards protection development

Presented is an overview of the development of the integral thermal/micrometeoroid garment (ITMG) used for protection of a space-suited crewmember from hazards of various extravehicular environments. These hazard conditions can range from thermal extremes, meteoroid and debris particles, and radiation conditions in near-earth orbits and free space to sand and dust environments encountered on lunar or planetary surfaces. Representative ITMG materials cross-section layups are identified and described for various space-suit configurations ranging from the Gemini Program to planned protective requirements and considerations for anticipated Space Station EV operations.

Kosmo, Joseph J.↗
NASA NTRS1987

Space suit extravehicular hazards protection development

Presented is an overview of the development of the integral thermal/micrometeoroid garment (ITMG) used for protection of a space-suited crewmember from hazards of various extravehicular environments. These hazard conditions can range from thermal extremes, meteoroid and debris particles, and radiation conditions in near-earth orbits and free space to sand and dust environments encountered on lunar and planetary surfaces. Representative ITMG materials cross-section layups are identified and described for various space suit configurations ranging from the Gemini program to planned protective requirements and considerations for anticipated Space Station EV operations.

Kosmo, Joseph J.↗
NASA NTRS2002

The Design of a Remotely Operated Shutter (ROS) for Thermal Vacuum Testing

Space-flight hardware is required to meet specific outgassing criteria under vacuum conditions in order to reduce the risk of contaminating sensitive optics and spacecraft components. Under certain circumstances, it is desirable to measure the contamination levels that are being released from all surfaces of the test payload. This certification is often accomplished with a Total Outgassing Measurement (TOM) box. The TOM box has one 103.2 square centimeter (16 square inch) opening and one 4.84 square centimeter (0.75 square inches) opening. The larger opening allows contaminants to easily escape the box during the hardware bakeout phase. The smaller opening provides a limited conductance path for outgassed contaminants during the certification phase. A Thermoelectric Quartz Crystal Microbalance (TQCM) monitors the contamination levels inside the box to provide the total outgassing measurement. During transition from the bakeout phase to the certification phase, the TOM box is reconfigured to close the larger opening. For previous certifications, the vacuum chamber was returned to ambient conditions and the larger conductance port was closed manually. The ROS system eliminates the need to enter the chamber by remotely closing the large TOM box opening. Substantial schedule and cost savings are achieved through the use of this system. The ROS system consists of three main components; a shutter, a motion actuator, and an actuator controller. Each of these components was selected or designed to operate in an extreme-temperature and vacuum environment while providing a high level of reliability. Different types of motion actuators were considered for driving the shutter. Design parameters for the actuator included material properties, force capability, reliability, and cost.

Hale, Kathleen L.↗
NASA NTRS2003

Thermal Contributions to the Degradation of Ground-Laboratory- and Space-Irradiated Teflon Investigated

The Hubble Space Telescope (HST) is covered with two primary types of thermal control materials, radiators and multilayer insulation blankets, which passively control temperatures during orbit. Both of these thermal control materials utilize back-surface metalized Teflon FEP (DuPont, fluorinated ethylene propylene) as the exterior (spacefacing) layer because of its excellent optical properties (low solar absorptance and high thermal emittance). The aluminized-FEP (Al-FEP) outermost layer of the multilayer insulation blankets on the HST has become embrittled while in space, resulting in severe on-orbit cracking (see the photographs). During the second servicing mission, an extremely embrittled piece of Al-FEP was retrieved that had curled, exposing the backsurface aluminum to space (see the photograph on the right). Because the aluminum surface has a lower thermal emittance than the FEP, this curled piece reached 200 C during orbit, 150 C higher than the nominal temperature extreme. To better understand the effect of temperature on the rate of degradation, and on the mechanism of degradation, of this insulation material in the low-Earth-orbit environment, researchers at the NASA Glenn Research Center conducted experiments to determine the effect of heating on the degradation of FEP that has been irradiated in a ground laboratory facility or in space on the HST. For this study, Teflon FEP retrieved from the HST during the third servicing mission after 9.7 years of space exposure was provided to Glenn by the NASA Goddard Space Flight Center.

deGroh, Kim K.↗