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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.
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Knife-edge sealing technique forms reliable, vacuum-tight bonds between materials having very different thermal-expansion characteristics. Seal is thin and flexible and absorb shear, hoop, and bonding stresses at joint so that seal remains vacuum tight.
Several experimental concepts representing potential high pressure turbine seal material systems were subjected to cyclic thermal shock exposures similar to those that might be encountered under severe engine start-up and shut-down sequences. All of the experimental concepts consisted of plasma-sprayed yttria stabilized ZrO2 on the high temperature side of the blade tip seal shroud. Between the ZrO2 and a cooled, dense metal backing, various intermediate layer concepts intended to mitigate thermal stresses were incorporated. Performance was judged on the basis of the number of thermal shock cycles required to cause loss of seal material through spallation. The most effective approach was to include a low modulus, sintered metal pad between the ZrO2 and the metallic backing. It was also found that reducing the density of the ZrO2 layer significantly improved the performance of specimens with plasma-sprayed metal/ceramic composite intermediate layers.
Residual gas analysis techniques were employed to measure the moisture in sealed hybrid packages as a function of substrate attach material, vacuum bake time and sequence, and sealing procedure. It is shown that when room atmospheric exposure is eliminated following the vacuum bakeout moisture levels of less than 1000 ppm may be achieved for modest bake times and solder substrate attach techniques. Suitable moisture levels were achieved for epoxy attached substrates only when seam sealing procedures were employed.
A systematic study was performed to evaluate the suitability of adhesives for sealing hybrid packages. Selected adhesives were screened on the basis of their ability to seal gold-plated Kovar butterfly-type packages that retain their seal integrity after individual exposures to increasingly severe temperature-humidity environments. Tests were also run using thermal shock, temperature cycling, mechanical shock and temperature aging. The four best adhesives were determined and further tested in a 60 C/98% RH environment and continuously monitored in regard to moisture content. Results are given, however, none of the tested adhesives passed all the tests.
A system for sealing vacuum baked hybrids in a dry inert atmosphere using an overlapping spot resistance weld is described. A unique electrode configuration and fixturing that permits sealing of large and irregularly shaped gold plated Kovar packages to the hermeticity requirements of MIL-STD-883 was discussed. Metallurgical considerations and comparisons to laser sealing were made. Problems encountered during the development and optimization of the process were highlighted. Solutions to plating, fixturing, warpage, weld splatter and cracked bead problems are presented.
Two strength level variations of sintered NiCrAl (about 40 percent dense), candidate high pressure turbine seal materials, were subject to rub tolerance testing against AM 355 steel blade tips. The high strength material (17 N/sq mm tensile strength) showed frictional and radial loads that were 20 to 50 percent higher than those measured for the low strength material (15.5 N/ sq mm tensile strength). Measured wear to the AM 355 blade tips was not significantly different for the two sintered NiCrAl seal materials. Wear of the sintered NiCrAl was characterized by material removal to a depth greater than the depth to which blade tips were driven into the seal, indicating self-erosion effects.
The development of a static seal configuration to meet the lightweight low-leakage requirements of the Space Shuttle Main Engine (pressure carrying capability of up to 75.84 MPa) is discussed. The design features, fabrication methods, lab testing, and performance of seal are examined. Flange and bolt details of the joint assembly are considered with attention to an ultrasonic technique for measuring preload in the bolts. Methods used for leak testing in the laboratory and in the field are described; the practicality of the procedures is considered. Attention is directed to hydrogen-environment embrittlement and its influence on seal and joint design.
Curing technique for producing variable viscosity seal has hard sealing surface supported by softer rubber. Valve seal is clamped between two jaws for curing with hotter jaw at temperature of approximately 350 F and lower at room temperature. Result is durable tight valve-seat.
Composite seal remains flexible between -423 and +500 F. Due to wide temperature capability seal outperforms conventional elastometic seals used in industrial freezers, environmental chambers, refrigerated trucks and railcars, and aircraft doors.
Computer calculation for determining compressible flow across radial face seals were compared with measured results obtained in a seal simulator rig at pressure ratios to 0.9 (ambient pressure/sealed pressure). In general, the measured and calculated leakages across the seal dam agreed within 3 percent. The resultant loss coefficient, dependent upon the pressure ratio, ranged from 0.47 to 0.68. The calculated pressures were within 2.5 N/cu um of the measured values.
A retractable environmental seal for use in sealing the opening of the exit cone for a rocket nozzle is described. A diaphragm-like cover having a central region adapted to be seated in sealing relation with the periphery of the opening is discussed. Radially extended failure zones for facilitating a pressure-induced rupture of the cover, and a plurality of angularly spaced tension springs connected with the peripheral portion of the cover are characterized.
The first year of a two year experimental and analytical program is reported. The program is directed at the elastohydrodynamic behavior of sliding elastomeric rod seals for the Stirling engine. During the year, experimental and analytical tools were developed for evaluating seal leakage, seal friction, and the fluid film thickness at the seal/cylinder interface.
Several different tests are described which simulated the actual configuration of a cryogenic wind tunnel operating at pressures up to 5 atmospheres (507 kPa) and temperatures from -320 F (78K) to 120 F (322K) in order to determine compatible bolting, adequate sealing, and effective insulating materials. The evaluation of flange attachments (continuous threaded studs) considered bolting based on compatible flanges, attachment materials, and prescribed bolt elongations. Various types of seals and seal configurations were studied to determine suitability and reusability under the imposed pressure and temperature loadings. The temperature profile was established for several materials used for structural supports.
Improvements in fluid film sealing resulting from a proposed research program could lead to an annual energy saving, on a national basis, equivalent to about 37 million bbl of oil or 0.3% of the total U.S. energy consumption. Further, the application of known sealing technology can result in an annual saving of an additional 10 million bbl of oil. The energy saving would be accomplished by reduction in process heat energy loss, reduction of frictional energy generated, and minimization of energy required to operate ancillary equipment associated with the seal system. In addition to energy saving, cost effectiveness is further enhanced by reduction in maintenance and in minimization of equipment for collecting leakage and for meeting environmental pollution standards.
A standard Hastelloy-X honeycomb material and a pack aluminide coated honeycomb material were evaluated as to their performance as labyrinth seal materials for aircraft gas turbine engines. Consideration from published literature was given to the fluid sealing characteristics of two honeycomb materials in labyrinth seal applications, and their rub characteristics, erosion resistance, and oxidation resistance were evaluated. The increased temperature potential of the coated honeycomb material compared to the uncoated standard could be achieved without compromising the honeycomb material's rub tolerance, although there was some penalty in terms of reduced erosion resistance.
A circumferential shaft seal is described which comprises two sealing rings held to a rotating shaft by means of a surrounding elastomeric band. The rings are segmented and are of a rigid sealing material such as carbon or a polyimide and graphite fiber composite.
The hydraulic forces caused by annular pressure seals were investigated. The measured inlet and exit loss coefficients of the flow through the seals were much smaller than the conventional values. The results indicate that the damping coefficient and the inertia coefficient of the fluid film in the seal are not affected much by the rotational speed or the eccentricity of the rotor, though the stiffness coefficient seemed to be influenced by the eccentricity.
An apparatus is described for providing thermal and pressure sealing in an elongated space of varying width between adjacent surface of two members. The apparatus is mounted for at least limited lateral movement between the members and may comprise: an elongated support attached to one of the adjacent surfaces; a second elongated support member attached to the other of the adjacent surfaces, and an elongated seal member sandwiched between the first and second support members. In its non-deformed state, the elongated seal member may be substantially cylindrical but capable of deformation to accommodate limited lateral movement between the adjacent surfaces and varying widths of the space.