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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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Carbon cloth is starting material for promising new catalytic electrodes. Carbon-cloth electrodes are more efficient than sintered-carbon configuration previously used. Are also chemically stable and require less catalyst--an important economic advantage when catalyst is metal such as platinum.
Materials studies as well as general and specific device development were carried out in the InGaAsP system. A comparison was made of three standard methods of evaluating substrate quality by means of dislocation studies. A cause of reduced yield of good wafers, the pullover of melt from one bin to the next, has been analyzed. Difficulties with reproducible zinc acceptor doping have been traced to segregation of zinc in the In/Zn alloy used for the doping source. Using EBIC measurments, the pn junction was shown to drift in location depending on factors not always under control. An analysis of contact structures by SIMS showed that the depth to which the sintered Au/Zn contact penetrates into the structure is typically 0.13 microns, or well within the cap layer and out of the p-type cladding and thus not deleterious to laser prformance. The problem of single-mode laser development was investigated and it was shown to be related to the growth habit over four different possible substrate configurations. The fabrication of constricted double heterojunctions, mesa stripe buried heterostructures, and buried heterostructures was discussed, and measurements were presented on the device properties of single-mode buried heterostructure lasers. Results include single spectral line emission at 3 mW and a threshold current of 60 mA.
Silicon powders with three levels of impurities, principally Fe, were sintered in He or H2. Non-densifying mechanisms of material transport were dominant in all cases. High purity Si showed coarsening in He while particle growth was suppressed in H2. Lower purity powder coarsened in both He and H2. The same three Si powders and Si /111/ single crystal wafers were nitrided in both N2 and N2/H2 atmospheres. Hydrogen increased the degree of nitridation of all three powders and the alpha/beta ratio of the lower purity powder. Some Si3N4 whiskers and open channels through the surface nitride layer were observed in the presence of Fe, correlating with the nitridation-enhancing effects of Fe. Thermodynamic calculations showed that when SiO2 is present on the Si, addition of H2 to the nitriding atmosphere decreases the amount of SiO2 and increases the partial pressure of Si-containing vapor species, that is, Si and SiO. Large amounts of NH3 and SiH4 were also predicted to form.
Improvement in the high-pressure turbopumps, both fuel and oxidizer, in the Space Shuttle main engine were considered. The operation of these pumps is limited by temperature restrictions of the metallic components used in these pumps. Ceramic materials that retain strength at high temperatures and appear to be promising candidates for use as turbine blades and impellers are discussed. These high strength materials are sensitive to many related processing parameters such as impurities, sintering aids, reaction aids, particle size, processing temperature, and post thermal treatment. The specific objectives of the study were to: (1) identify and define the processing parameters that affect the properties of Si3N4 ceramic materials, (2) design and assembly equipment required for processing high strength ceramics, (3) design and assemble test apparatus for evaluating the high temperature properties of Si3N4, and (4) conduct a research program of manufacturing and evaluating Si3N4 materials as applicable to rocket engine applications.
The thermal shock resistance of Si2N2O refractory material was studied. The thermal expansion coeff. is 3.55x10 to the -6th power at 20 to 800 C and 2.86x10 to the -6th power m/m/deg at 20 to 200 C. The breaking loads are high at high stress. Young's modulus E and the shear modulus G decrease linearly with increasing porosity. For dense material E sub o approx. = 216,500 N/mm2 and G approx = 90,600 N/mm2. The Vickers hardness of the dense material is comparable to that of sapphire. The results on thermal shock show that R, the breaking load, stays constant for T T sub c, the first cracks appear and R decreases sharply for T=T sub c. As the severity of the thermal shock is increased at T T sub c, a small no. of new, large-size cracks appears. The shock's cumulative effect is negligible, and repeated shocks do not change the cracks. The low values of the thermal expansion coefficient and Young's modulus and the high tension breaking load are considered. Sintered Si2N2O with 5% MgO shows excellent cracking resistance under thermal shock.
Vibration tests on high permeability magnetic shields used in the SAO-NRL Advanced Development Model (ADM) hydrogen maser were made. Magnetic shielding factors were measured before and after vibration. Preliminary results indicate considerable (25%) degradation. Test results on the NRL designed vacuum pumping station for the ADM hydrogen maser are also discussed. This system employs sintered zirconium carbon getter pumps to pump hydrogen plus small ion pumps to pump the inert gases. In situ activation tests and pumping characteristics indicate that the system can meet design specifications.
A conceptual design was made for a solar thermal receiver capable of operation in the 1095 to 1650 C (2000 to 3000 F) temperature range. This receiver is designed for use with a two-axis paraboloidal concentrator in the 25 to 150 kW sub t power range, and is intended for industrial process heat, Brayton engines, or chemical/fuels reactions. Three concepts were analyzed parametrically. One was selected for conceptual design. Its key feature is a helical coiled tube of sintered silicon nitride which serves as the heat exchanger between the incident solar radiation and the working fluid. A mechanical design of this concept was prepared, and both thermal and stress analysis performed. The analysis showed good performance, low potential cost in mass production, and adaptability to both Brayton cycle engines and chemical/fuels production.
Skin friction and profiles of mean velocity, axial and normal turbulence intensity, and Reynolds stress in the untripped boundary layer were measured directly on a large diameter, axisymmetric body with: (1) a smooth, solid surface; (2) a sandpaper-roughened, solid surface; (3) a sintered metal, porous surface; (4) a smooth, perforated titanium surface; (5) a rough solid surface made of fine, diffusion bonded screening, and (6) a rough, porous surface of the same screening. Results obtained for each of these surfaces are discussed. It is shown that a rough, porous wall simply does not influence the boundary layer in the same way as a rough solid wall. Therefore, turbulent transport models for boundary layers over porous surfaces either with or without injection or suction, must include both surface roughness and porosity effects.
Progress in the Progress ceramic materials is reported. Experiments and models for sintering and microstructure evolution are described. Models and data for understanding the kinetics of grain boundary motion and of pore coarsening and new materials for fuel cells and batteries; are developed. New experimental techniques using lasers for forming fine, monosized powders and for forming stable and metastable structures from liquids, and solar materials research are also developed. Colloidal science and ceramics processing are explored; and research programs on the presintering science necessary for controlled green microstructures are outlined.
Electrochemical experiments performed at sintered and bulk electrodes show that beta nickel hydroxide contains an electrochemically inactive proportion of cadmium hydroxide of up to 10%. The electrochemically ineffective cadmium hydroxide is homogeneously dissolved in beta nickel hydroxide.
Platinum sintering on phosphoric acid fuel cell cathodes is discussed. The cathode of the phosphoric acid fuel cell uses a high surface area platinum catalyst dispersed on a conductive carbon support to minimize both cathode polarization and fabrication costs. During operation, however, the active surface area of these electrodes decreases, which in turn leads to decreased cell performance. This loss of active surface area is a major factor in the degradation of fuel cell performance over time.
The physical metallurgy of near-solidus integranular cracking in Inconel 718 welds was investigated. The data, although inconclusive, suggest at least two mechanisms which might explain intergranular cracking (microfissuring) in the heat-affected zone of several high temperature alloys. One theory is based on the separation of intergranular liquid while the other involves mechanical failure of solid ligaments surrounded by intergranular liquid. Both mechanisms concentrate strain in the grain boundaries resulting in low strain (1%) intergranular brittleness. The mechanisms reported might also pertain to the physical metallurgy of casting, powder metallurgy sintering and hot isostatic pressing.
Analysis was made of the heat transfer and pressure drop through turbine vanes made of a sintered, porous metal coated with a thin layer of ceramic and convection cooled by spanwise flow of cooling air. The analysis was made to determine the feasibility of using this concept for cooling very small turbines, primarily for short duration applications such as in missile engines. The analysis was made for gas conditions of approximately 10 and 40 atm and 1644 K and with turbine vanes made of felt-type porous metals with relative densities from 0.2 and 0.6 and ceramic coating thicknesses of 0.076 to 0.254 mm.
The turbulent boundary layer over three porous walls with different surface geometries was studied in order to investigate the individual influences of porosity and small roughness, as well as their combined effects, on turbulent boundary layer behavior. The tests were conducted in a 2 m x 2 m tunnel on a large axisymmetric model at speeds corresponding to Re(L) = 5,000,000-6,000,000. The development of the turbulent boundary layer was compared for that of sintered metal, bonded screening, and perforated sheet and then to that for the flow over a solid smooth wall and a solid, sand-roughened wall. The comparisons reveal that the effect of porosity is to shift the logarithmic region of the wall law down by a certain amount from the solid wall results and to increase the skin friction values by about 30-40%. The downward shift of the logarithmic region of the wall law and the increase of the skin friction value by the combined effects of small roughness and porosity are found to be roughly the sum of their individual effects.
The room-temperature strength distributions of a sintered and a hot-pressed SiC were examined as-machined, after oxidation at 1370 C, and after oxidation under load at 1370 C. The strengths were observed to be dependent on both the duration of oxidation and the magnitude of the applied load. Processes resulting in both strengthening and weakening behavior were observed to occur, at times simultaneously within the same strength distribution. This dynamic situation indicates that the strength-controlling flaw populations are highly transient in nature.
The physical and magnetic properties of Mn-Al-C, Fe-Cr-Co, and RE-TM (rare earth-transition metal intermetallics) in polymer and soft metal bonded or sintered form are considered for ac circuit machine usage. The manufacturing processes for the magnetic materials are reviewed, and the mechanical and electrical properties of the magnetic materials are compared, with consideration given to the reference Alnico magnet. The Mn-Al-C magnets have the same magnetic properties and costs as Alnico units, operate well at low temperatures, but have poor high temperature performance. Fe-Cr-Co magnets also have comparable cost to Alnico magnets, and operate at high or low temperature, but are brittle, expensive, and contain Co. RE-Co magnets possess a high energy density, operate well in a wide temperature range, and are expensive. Recommendation for exploring the rare-earth alternatives are offered.
Screenable thick film solar cell electrodes are made using the all-metal electrode system, which eliminates the commonly used glass frit and substitutes an oxide scavenger such as silver fluoride. The low temperature firing copper metal systems give good results on solar cells obtaining cell efficiencies of 13% AM1, and adhering sintered structures are demonstrated with nickel systems. The potential effect of copper upon cell performance at elevated temperatures over long periods of time is determined, and it is found that the formation of a copper-silicon eutectic at 550 C produces needle-like structures with broad bases on the silicon, extending into and occasionally through the metallization layer.
The use of nickel plus solder is shown to be feasible for contact metallization for silicon solar cells by offering a relatively inexpensive method of making electrical contact with the cell surfaces. Nickel is plated on silicon solar cells using an electroless chemical deposition method to give contacts with good adhesion, and in some cases where adhesion is poor initially, sintering under relatively mild conditions will dramatically improve the quality of the bond without harming the p-n junction of the cell. The cells can survive terrestrial environment stresses, which is demonstrated by a 1000 hour test at 85 C and 85% relative humidity under constant forward bias of 0.45 volt.