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NASA NTRS1997

ETP-0474: Evaluation of Electroless Nickel Coatings to Achieve Interference Fit in the RSRM Without Fretting

Part of the redesign of the SRMs for the Space Shuttle involved the substitution of three new capture cylinders for three of the previously used cylinders. These new cylinders mate with the old standard case segments in each of the three field joints. The new capture cylinders contain an integral capture latch on the tang end which mates with a case clevis during stackup at KSC. The capture cylinders also contain a groove in the capture latch to provide for a third 0-ring in the joint and are designed to achieve a metal-to- metal interference fit between the capture latch and the mating clevis. An unexpected fretting problem has occurred on the tang capture feature and the inner clevis leg interference fit surfaces on flight hardware since STS-26. Varying degrees of fretting damage have been found on the case segments from different flight motors. Fretting is a wear phenomena that occurs when two tightly fitting metal surfaces are subject to cyclic relative motion of extremely small amplitudes (generally less than 0.010-inch) in the absence of adequate lubrication. It is adhesive ("cold" - welding) in nature and vibration is its essential causative factor. This problem has manifested itself on the flight motors as a series of pits and axial gouges on the inside diameter (ID) surfaces of the inner clevis legs and the outside diameter (OD) surfaces of the tang capture features. The problem occurs in varying degrees of severity in all of the field joints. It is not believed that fretting is a flight safety issue. However, it could become a reusability issue if left unattended. Fretting has been encountered in other industries for many years and measures that will prevent or reduce it have been devised. These include: elimination or reduction of vibration (amplitudes and/or frequencies), elimination of slip, improved lubrication between parts, increased surface separation, increased interference, inducing residual compressive stresses in the surfaces of the mating parts, and employing non-fretting interference shims. Looking at each of these separately; vibration and slip occur in varying degrees and magnitudes in the field joints (as part of the roll-out, launch, flight, splashdown, flotation, and/or tow back) and are difficult to define or eliminate. Improved lubrication is something that was evaluated since it would be the simplest change to incorporate, but little or no improvement was found. Increasing surface separation would defeat the purpose of the interference fit. The effect of increasing the interference fit is unknown. Additional shot peening and/or surface rolling to impart residual compressive stresses in the joints undoubtedly would alter the characteristics and finish of the sealing surfaces of the motor cases. Also, experimental data' indicate that the tangs and clevises already have residual compressive stress fields on their surfaces yet fretting occurs. These stresses probably result from the case machining and the glass beading used to clean these surfaces.

Schaffnit, William O.↗

NASA NTRS1998

Inner Core Rotation from Geomagnetic Westward Drift and a Stationary Spherical Vortex in Earth's Core

The idea that geomagnetic westward drift indicates convective leveling of the planetary momentum gradient within Earth's core is pursued in search of a differentially rotating mean state, upon which various oscillations and secular effects might be superimposed. The desired state conforms to roughly spherical boundary conditions, minimizes dissipative interference with convective cooling in the bulk of the core, yet may aid core cooling by depositing heat in the uppermost core and lower mantle. The variational calculus of stationary dissipation applied to a spherical vortex within the core yields an interesting differential rotation profile, akin to spherical Couette flow bounded by thin Hartmann layers. Four boundary conditions are required. To concentrate shear induced dissipation near the core-mantle boundary, these are taken to be: (i) no-slip at the core-mantle interface; (ii) geomagnetically estimated bulk westward flow at the base of the core-mantle boundary layer; (iii) no-slip at the inner-outer core interface; and, to describe magnetic locking of the inner core to the deep outer core; (iv) hydrodynamically stress-free at the inner-outer core boundary. By boldly assuming the axial core angular momentum anomaly to be zero, the super-rotation of the inner core relative to the mantle is calculated to be at most 1.5 deg./yr.

Voorhies, Coerte V.↗

NASA NTRS1998

Mechanistic Models of Friction Stir Welding

Friction stir welding is a welding process developed at The Welding Institute (TWI) in England. The method uses very large strain plastic deformation of the material to join two pieces of metal together. The material is deformed using a tool which is forced between the two pieces which rotates causing a bond. Beyond this, very little is actually known although many people working in the field are willing to speculate on the detailed mechanisms involved. Some measurements made using sacrificial thermocouples at the weld joint indicate that the maximum temperature during the weld process is on the order of 370C - well below the melting temperature of the material. However, at this temperature, the material properties are highly temperature dependent, and the yield stress is approximately an order of magnitude less at this temperature than it is at room temperature. As expected, there are many interpretations of the physical mechanisms occurring during the weld process. Although there is very little published concerned with FSW, some of the anecdotal theories will be described. One describes the primary mechanism as frictional heating at the front of the tool caused by slip between the tool and the material. At elevated temperatures, the weld material becomes soft and deforms around the tool but not essentially altered by the tool rotation, similar to an extrusion. As the material meets again at the rear of the tool, the temperatures and pressures are sufficient to cause the material to bond. All other structures seen are secondary and unimportant. Another theory examined last summer at NASA's Marshall Space Flight Center (MSFC) was that there was no slip between the tool and the material resulting in a rotating mass of plastic weld material traveling at a variety of angular velocities - the greatest at the tool surface diminishing to zero at the outer edge of the plastic mass surrounding the tool. This conceptual model was followed by simplified calculations which showed that the balance of moments through the weld plug was not possible under steady state conditions and realistic temperature profiles. This led to some consideration of a quasi-steady oscillating process. Later when force measurements became available some models were modified and new ones were proposed.

Stewart, Michael B.↗

NASA NTRS1998

Report 1: Basic Operation of the Switched Reluctance Motor

Typically salient poles have windings forming coils wrapped around the waists (or pole cores) of each pole. This is true for the stator of the SRM but not for the rotor. The rotor has no windings, no coils, no magnets, no commutator, or slip rings it is only comprised of laminated steel sheets stamped in the shape of the pole design and mounted on a shaft. This allows for ease in manufacturing the rotor as well as reducing the rotor's inertia. There is also no electrical loss associated with the rotor since there are no windings, commutator, or slip rings.

Pillay, Pragasen↗

NASA NTRS1999

Parametric Studies of the Ejector Process within a Turbine-Based Combined-Cycle Propulsion System

Performance characteristics of the ejector process within a turbine-based combined-cycle (TBCC) propulsion system are investigated using the NPARC Navier-Stokes code. The TBCC concept integrates a turbine engine with a ramjet into a single propulsion system that may efficiently operate from takeoff to high Mach number cruise. At the operating point considered, corresponding to a flight Mach number of 2.0, an ejector serves to mix flow from the ramjet duct with flow from the turbine engine. The combined flow then passes through a diffuser where it is mixed with hydrogen fuel and burned. Three sets of fully turbulent Navier-Stokes calculations are compared with predictions from a cycle code developed specifically for the TBCC propulsion system. A baseline ejector system is investigated first. The Navier-Stokes calculations indicate that the flow leaving the ejector is not completely mixed, which may adversely affect the overall system performance. Two additional sets of calculations are presented; one set that investigated a longer ejector region (to enhance mixing) and a second set which also utilized the longer ejector but replaced the no-slip surfaces of the ejector with slip (inviscid) walls in order to resolve discrepancies with the cycle code. The three sets of Navier-Stokes calculations and the TBCC cycle code predictions are compared to determine the validity of each of the modeling approaches.

Georgiadis, Nicholas J.↗

NASA NTRS1999

Effects of Internal and External Hydrogen on Inconel 718

Internal hydrogen embrittlement (IHE) and hydrogen environment embrittlement (HEE) tensile and bend crack growth tests were performed on Inconel 718. For the IHE tests, the specimens were precharged to approximately 90 ppm hydrogen by exposure to 34.5 MPa H2 at 650 C. The HEE tests were performed in 34.5 MPa H2. Parameters evaluated were test temperature, strain rate for smooth and notch specimen geometries. The strain rate effect was very significant at ambient temperature for both IHE and HEE and decreased with increasing temperatures. For IHE, the strain rate effect was neglible at 260'C, and for HEE the strain rate effect was neglible at 400 C. At low temperatures, IHE was more severe than HEE, and at high temperatures HEE was more severe than IHE with a cross over temperature about 350 C. At 350 C, the equilibrium hydrogen concentration in Inconel 718 is about 50% lower than the hydrogen content of the precharged IHE specimens. Dislocation hydrogen sweeping of surface absorbed hydrogen was the likely transport mechanism for increasing the hydrogen concentration in the HEE tests sufficiently to produce the same degree of embrittlement as that of the more highly hydrogen charged IHE specimens. The main IHE fracture characteristic was formation of large, brittle flat facets, which decreased with increasing test temperature. The IHE fracture matrix surrounding the large facets ranged between brittle fine faceted to microvoid ductility depending upon strain rate, specimen geometry as well as temperature. The HEE fractures were characteristically fine featured, transgranular and brittle with a significant portion forming a "saw tooth" crystallographic pattern. Both IHE and HEE fractures were predominantly along the {1 1 1) slip and twin boundaries. With respect to embrittlement mechanism, it was postulated that dislocation hydrogen sweeping and hydrogen enhanced localized plasticity were active in HEE and IHE for concentrating hydrogen along (1 1 1) slip and twin planes. Final brittle failure occurred by hydrogen induced planer decohesion.

Walter, R. J.↗

NASA NTRS2000

A Study of Single Crystal Fatigue Failure Criteria

This paper presents the results of a study whose objective was to study the applicability of different failure equations in modeling low cycle fatigue (LCF) test data for single crystal test specimens. A total of four failure criteria were considered in this study. One of the failure equations was developed by Pratt & Whitney and is based on normal and shear strains on the primary crystallographic slip planes of the single crystal material. Other failure equations considered are based on isotropic criteria. Because these failure equations were originally developed for isotropic materials such as structural steel, they were modified to be applicable to the single crystal slip systems of the LCF specimen material. By observing how closely the various equations were able to reduce the scatter in the LCF test data, the applicability of those equations in modeling the LCF test data was assessed. It is desired to subsequently use the failure equation with the highest correlation in the development of a new single crystal failure criterion for the Alternative Turbopump Development (ATD) for the space shuttle main engine (SSME) High Pressure Fuel Turbopump (HPFTP).

Sayyah, Tarek↗

NASA NTRS1999

Inner Core Rotation from Geomagnetic Westward Drift and a Stationary Spherical Vortex in Earth's Core

The idea that geomagnetic westward drift indicates convective leveling of the planetary momentum gradient within Earth's core is pursued in search of a differentially rotating mean state, upon which various oscillations and secular effects might be superimposed. The desired state conforms to roughly spherical boundary conditions, minimizes dissipative interference with convective cooling in the bulk of the core, yet may aide core cooling by depositing heat in the uppermost core and lower mantle. The variational calculus of stationary dissipation applied to a spherical vortex within the core yields an interesting differential rotation profile akin to spherical Couette flow bounded by thin Hartmann layers. Four boundary conditions are required. To concentrate shear induced dissipation near the core-mantle boundary, these are taken to be: (i) no-slip at the core-mantle interface; (ii) geomagnetically estimated bulk westward flow at the base of the core-mantle boundary layer; (iii) no-slip at the inner-outer core interface; and, to describe magnetic locking of the inner core to the deep outer core, (iv) hydrodynamically stress-free at the inner-outer core boundary. By boldly assuming the axial core angular momentum anomaly to be zero, the super-rotation of the inner core is calculated to be at most 1.5 degrees per year.

Voorhies, C. V.↗

NASA NTRS2000

The Plastic Flow Field in the Vicinity of the Pin-Tool During Friction Stir Welding

The plastic flow field in the vicinity of the pin-tool during Friction Stir Welding (FSW) needs to be understood if a theoretical understanding of the process is to be attained. The structure of welds does not exhibit the flow field itself, but consists in a residue of displacements left by the plastic flow field. The residue requires analysis to extract from it the instantaneous flow field around the pin-tool. A simplified merry-go-round model makes sense of some tracer experiments reported in the literature. A quantitative comparison is made of the displacements of copper wire markers with displacements computed from a hypothetical plastic flow field. The hypothetical plastic flow field consists in a circular rotation field about a translating pin tool with angular velocity varying with radius from the pin centerline. A sharply localized rotational field comprising slip on a surface around the tool agreed better with observations than a distributed slip field occupying a substantial volume around the tool. Both the tracer and the wire displacements support the "rotating plug" model, originally invoked or thermal reasons, of the FSW process.

Bernstein, E. L.↗

NASA NTRS2000

One Century of Tectonic Deformation Along the Sumatran Fault from Triangulation and GPS Surveys

An analysis combining historical triangulation and recent Global Positioning System (GPS) survey measurements in West and North Sumatra, Indonesia, reveals a detailed slip history along the central part of the Sumatran Fault. The arc-parallel components of the combined velocity field are consistent with slip rates inferred from GPS data, ranging from 23 to 24 mm/yr. Between 1.0 S and 1.3 N the Sumatran Fault appears to be characterized by deep locking depths, on the order of 20 km, and the occurrence of large (M (sub w) approximately 7) earthquakes. The long-term (1883-1993) strains show simple right-lateral shear, with rates similar to GPS-measured, 1989-1993 strain rates. Coseismic deformation due to the 1892 Tapanuli and 1926 Padang Panjang earthquakes, estimated from triangulation measurements taken before and after the events, indicate that the main shocks were significantly larger than previously reported. The 1892 earthquake had a likely magnitude of M (sub w) approximately equal to 7.6, while the 1926 events appear to be comparable in size to the subsequent (M approximately 7) 1943 events, and an order of magnitude higher than previously reported.

Prawirodirdjo, L.↗

NASA NTRS2000

A Unified Wall Boundary Treatment for Viscous and Inviscid Flows in the CE/SE Method

In the setting of the conservation element-solution element (CE/SE) method, a new and unified wall boundary treatment for the Navier-Stokes and Euler Equations is proposed. In essence, the shear stress exerted on the fluid by a wall is modeled as a source term as a part of local spacetime flux conservation in the vicinity of a wall boundary. When the fluid is inviscid, the source term vanishes and the boundary condition reduces to the usual 'slip' condition. On the other hand, when the fluid is viscous, the source-term effect is consistent with the traditional no-slip condition. Numerical results show that the new treatment is robust, efficient, and accurate for viscous and inviscid flows.

Chang, Sin-Chung↗

NASA NTRS1999

The Micromechanics of the Moving Contact Line

A transient moving contact line is investigated experimentally. The dynamic interface shape between 20 and 800 microns from the contact line is compared with theory. A novel experiment is devised, in which the contact line is set into motion by electrically altering the solid-liquid surface tension gamma(sub SL). The contact line motion simulates that of spontaneous wetting along a vertical plate with a maximum capillary number Ca approx. = 4 x 10(exp -2). The images of the dynamic meniscus are analyzed as a funtion of Ca. For comparison, the steady-state hydrodynamic equation based on the creeping flow model in a wedge geometry and the three-region uniform perturbation expansion of Cox (1986) is adopted. The interface shape is well depicted by the uniform solutions for Ca <= 10(exp -3). However, for Ca > 10(exp -3), the uniform solution over-predicts the viscous bending. This over-prediction can be accounted for by modifying the slip coefficient within the intermediate solution. With this correction, the measured interface shape is seen to match the theoretical prediction for all capillary numbers. The amount of slip needed to fit the measurements does not scale with the capillary number.

Lichter, Seth↗

NASA NTRS1999

Particle Segregation in Collisional Shearing Flows

The size segregation of flowing or shaken grains is a commonly observed phenomenon in industrial processes and in nature. In systems that do not involve much agitation of the grains, several mechanisms that involve gravity have been identified as leading to such segregation. In highly agitated flows, there is a mechanism independent of gravity that is available to drive separation of different grains. This is associated with spatial gradients in the energy of their velocity fluctuations. Because collisions between grains inevitably dissipate energy, collisional granular shear flows are usually of limited extent in the direction transverse to the flow. One consequence of this is that shear flows are strongly influenced by their boundaries. Because grains, on average, slip relative to boundaries, a bumpy or frictional boundary can convert slip energy into fluctuation energy. However, because each collision between a grain and the boundary dissipates fluctuation energy, there is a competition between production and dissipation. In principle, it is possible to design the geometry of the boundary - for example, the size and spacing of the bumps - so that the boundary either produces or dissipates fluctuation energy. This permits the control of the component of the spatial gradient of the fluctuation energy that is normal to the boundary. The gradients in fluctuation energy established by such boundaries may be exploited to drive the separation by size or other properties in a binary mixture of spherical grains. Microgravity makes the visual observations possible by permitting us to employ moderate rates of shear. On earth, the effects of gravity can be minimized by shearing so rapidly that the particle pressure overwhelms gravity. However, in this event, separation takes place too rapidly for visual observation, buoyancy and/or condensation associated with the centripetal acceleration must be accounted for, and the particles can be severely damaged. Because, in the absence of gravity, the only available time scale is proportional to the speed of the moving boundary, this speed can be made arbitrarily slow to permit observations and to avoid particle damage, without altering the phenomenon under study. The primary goal of this research is to carry out a physical experiment in which particle segregation is induced and maintained in a collisional flow of a binary mixture of two different types of spheres.

Jenkins, J. T.↗

NASA NTRS1994

Analysis of F/A-18 Tail Buffet Data Acquired in the 80- by 120-Foot Wind Tunnel

Tail buffet studies were conducted on a full-scale, production, F/A-18 fighter aircraft in the 80- by 120-Foot Wind Tunnel of the National Full-Scale Aerodynamic Complex at NASA Ames Research Center at Moffett Field, California. Tail buffet data were acquired over an angle-of-attack range of +20 deg to +40 deg, a side-slip range of -16 deg to + 16 deg, and at wind speeds up to 100 knots. The maximum speed corresponds to a Reynolds number of l2.3 x l0(exp 6) based on mean aerodynamic chord and a Mach number of 0. 15. The port, vertical tail fin was instrumented with ninety-six surface-pressure transducers, arranged in six by eight arrays, on each side of the fin. ne aircraft was also equipped with a removable Leading-Edge Extension (LEX) fence whose purpose is to reduce tail-buffet loads. Current analysis methods for the unsteady aerodynamic pressures and loads are described. Only results for the zero side-slip condition are to be presented, both with and without the LEX fence. Results of the time-averaged, power-spectral analysis are presented for the tail fin bending moments which are derived from the integrated pressure field. Local wave velocities on the tail surfaces are calculated from pressure correlations. It was found that the LEX fence significantly reduces the magnitude of the root-mean-square pressures and bending moments. Scaling and repeatability issues are addressed by comparing the present full scale results for pressures at the 60%-span and 45%-chord location with previous full-scale F/A-18 tail-buffet test in the 80- by 120- Foot Wind Tunnel, and with several small-scale tests. The comparisons show that the tail buffet frequency scales very well with tail chord and free-stream velocity, and that there is good agreement with the previous full-scale test. Root-mean-square pressures and power spectra do not scale as well as the frequency results. Addition of a LEX fence caused tail-buffet loads to be reduced at all model scales.

James, Kevin D.↗

NASA NTRS1993

Full-Scale Wind Tunnel Studies of F/A-18 Tail Buffet

Tail buffet studies were conducted on a full-scale, production, F/A-18, fighter aircraft in the 80- by 120-Foot Wind Tunnel of the National Full-Scale Aerodynamic Complex at NASA Ames Research Center in Moffett Field, California. The F/A-18 was tested over an angle-of-attack range of 18deg to 50deg, a side-slip range of -15deg to 15deg, and at wind speeds of up to 100 knots. The maximum speed corresponds to a Reynolds number of 12.3 x 10(exp 6) based on mean aerodynamic chord and a Mach number of 0.15. The port, vertical tail fin was instrumented with thirty-two surface pressure transducers, arranged in four by four arrays on both sides on the fin. The aircraft was also equipped with a removable Leading Edge eXtension (LEX) fence that is used on F/A-18 aircraft to reduce tail buffet loads. Time-averaged, power-spectral analysis results are presented for the tail fin bending moment derived from the integrated pressure field. The results are only for the zero side-slip condition, both with and without the LEX fence. The LEX fence significantly reduces the magnitude of the root-mean-square pressures and bending moments. Scaling issues are addressed by comparing full-scale results for pressures at the 60%-span and 45%-chord location with published results of small-scale, F/A-18 tail-buffet tests. The comparison shows that the tail buffet frequency scales very well with length and velocity. Root-mean-square pressures and power spectra do not scale as well. The LEX fence is shown to reduce tail buffet loads at all model scales.

Meyn, Larry A.↗

NASA NTRS2001

Comparison Between Oil-mist and Oil-jet Lubrication of High-speed, Small-bore, Angular-contact Ball Bearings

Parametric tests were conducted with an optimized 35-mm-bore-angular-contact ball bearing on a high-speed, high-temperature bearing tester. Results from both air-oil mist lubrication and oil-jet lubrication systems used to lubricate the bearing were compared to speeds of 2.5 x 10(exp 6) DN. The maximum obtainable speed with air-oil mist lubrication is 2.5 x 10(exp 6) DN. Lower bearing temperatures and higher power losses are obtained with oil-jet lubrication than with air-oil mist lubrication. Bearing power loss is a direct function of oil flow to the bearing and independent of oil delivery system. For a given oil-flow rate, bearing temperature and power loss increase with increases in speed. Bearing life is an inverse function of temperature, the difference in temperature between the individual bearing ring components, and the resultant elastohydrodynamic (EHD) film thicknesses. Bearing life is independent of the oil delivery system except as it affects temperature. Cage slip increased with increases in speed. Cage slip as high as 7 percent was measured and was generally higher with air-oil mist lubrication than with oil-jet lubrication.

Pinel, Stanley I.↗

NASA NTRS2001

Comparison Between Oil-Mist and Oil-Jet Lubrication of High-Speed, Small-Bore, Angular-Contact Ball Bearings

Parametric tests were conducted with an optimized 35-mm-bore-angular-contact ball bearing on a high-speed, high-temperature bearing tester. Results from both air-oil mist lubrication and oil-jet lubrication systems used to lubricate the bearing were compared to speeds of 2.5x10(exp 6) DN. The maximum obtainable speed with air-oil mist lubrication is 2.5x10(exp 6) DN. Lower bearing temperatures and higher power losses are obtained with oil-jet lubrication than with air-oil mist lubrication. Bearing power loss is a direct function of oil flow to the bearing and independent of oil delivery system. For a given oil-flow rate, bearing temperature and power loss increase with increases in speed. Bearing life is an inverse function of temperature, the difference in temperature between the individual bearing ring components, and the resultant elastohydrodynamic (EHD) film thicknesses. Bearing life is independent of the oil delivery system except as it affects temperature. Cage slip increased with increases in speed. Cage slip as high as 7% was measured and was generally higher with air-oil mist lubrication than with oil-jet lubrication.

Pinel, Stanley I.↗

NASA NTRS1997

Molecular Dynamics Simulation of a Multi-Walled Carbon Nanotube Based Gear

We used molecular dynamics to investigate the properties of a multi-walled carbon nanotube based gear. Previous work computationally suggested that molecular gears fashioned from (14,0) single-walled carbon nanotubes operate well at 50-100 gigahertz. The gears were formed from nanotubes with teeth added via a benzyne reaction known to occur with C60. A modified, parallelized version of Brenner's potential was used to model interatomic forces within each molecule. A Leonard-Jones 6-12 potential was used for forces between molecules. The gear in this study was based on the smallest multi-walled nanotube supported by some experimental evidence. Each gear was a (52,0) nanotube surrounding a (37,10) nanotube with approximate 20.4 and 16,8 A radii respectively. These sizes were chosen to be consistent with inter-tube spacing observed by and were slightly larger than graphite inter-layer spacings. The benzyne teeth were attached via 2+4 cycloaddition to exterior of the (52,0) tube. 2+4 bonds were used rather than the 2+2 bonds observed by Hoke since 2+4 bonds are preferred by naphthalene and quantum calculations by Jaffe suggest that 2+4 bonds are preferred on carbon nanotubes of sufficient diameter. One gear was 'powered' by forcing the atoms near the end of the outside buckytube to rotate to simulate a motor. A second gear was allowed to rotate by keeping the atoms near the end of its outside buckytube on a cylinder. The ends of both gears were constrained to stay in an approximately constant position relative to each other, simulating a casing, to insure that the gear teeth meshed. The stiff meshing aromatic gear teeth transferred angular momentum from the powered gear to the driven gear. The simulation was performed in a vacuum and with a software thermostat. Preliminary results suggest that the powered gear had trouble turning the driven gear without slip. The larger radius and greater mass of these gears relative to the (14,0) gears previously studied requires a smaller rotation rate and multiple rows of teeth to avoid excessive force on the gear teeth resulting, in slip and failure of the driven gear to turn. We hope that studies such as these will eventually lead to synthesis of components that can be assembled into atomically precise fullerene machines. These machines, in turn, may someday be used in machine-phase fullerene materials with remarkable properties.

Han, Jie↗