COMPATIBILITY OF MATERIALS WITH HIGH TEMPERATURE POTASSIUM.
Compatibility of materials with high temperature potassium
POTASSIUM↗
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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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Polymer Matrix Composite Material Oxygen Compatibility
Carbon fiber/polymer matrix composite materials look promising as a material to construct liquid oxygen (LOX) tanks. Based on mechanical impact tests the risk will be greater than aluminum, however, the risk can probably be managed to an acceptable level. Proper tank design and operation can minimize risk. A risk assessment (hazard analysis) will be used to determine the overall acceptability for using polymer matrix composite materials.
Owens, Tom↗
A survey of compatibility of materials with high pressure oxygen service
The available information on the compatibility of materials with oxygen as applied to the production, transport, and applications experience of high pressure liquid and gaseous oxygen is compiled. High pressure is defined as about 2000 to 3000 psia. Since high pressure projections sometimes can be made from lower pressure data, some low pressure data are also included. Low pressure data are included if they are considered helpful to a better understanding of the behavior at high pressures.
Hust, J. G.↗
Mishaps with Oxygen in NASA Operations
Data from a substantial number of oxygen mishaps obtained from NASA and contractor records are presented. Information from several Air Force records, concerning oxygen accidents involving aircraft operations, are also included. Descriptions of the mishaps and their causes, for both liquid and gaseous oxygen in ground test facilities and space vehicle systems, are given. A number of safety regulations aimed at reducing the accident probability is discussed. The problems related to material compatibility and materials testing are considered, and the limited information on factors affecting the ignition of materials in oxygen is presented. In addition, details are given of several of the accident/incidents listed in order to define the combination of conditions causing the mishap. In addition to propellant system mishaps, accident/incidents which occurred in space and ground system structures were included, as well as those in electrical systems, ground support facilities, ordnance, and related operations.
Ordin, Paul M.↗
Assessment of Silver Based Disinfection Technology for CEV and Future US Spacecraft
Silver biocide offers a potential advantage over iodine, the current state-of-the-art in US spacecraft disinfection technology, in that silver can be safely consumed by the crew. As such, silver may reduce the overall complexity and mass of future spacecraft potable water systems, particularly those used to support long duration missions. A primary technology gap identified for the use of silver biocide is one of material compatibility. Wetted materials of construction are required to be selected such that silver ion concentrations can be maintained at biocidally effective levels. Preliminary data on silver biocide depletion rates in heritage spacecraft potable water system wetted-materials of construction has been gathered as part of a multi-phase test project aimed at the characterization of silver based biocide technology through: development of preferred materials lists, investigation of silver biocide forms and delivery methods, down-selection of silver biocide technologies, and integrated testing. A 10% - 20% loss in silver ion concentration per day was observed for acid passivated Nitronic 40 tubing with surface area to volume (S/V) ratios of approximately 4.59 cm-1. The Nitronic 40 tubes were tested both with and without biocide pretreatment. Silver biocide depletion was also observed at approximately 0.1% per day for the first 35 days of exposure to acid passivated Inconel 718 coupon, S/V of approximately 0.14 cm-1. Surface analysis by scanning election microscopy (SEM) suggested deposition of silver metal on both test materials. SEM analysis also provided evidence of potential variability in the passivation process for tube configuration of the Nitronic 40 test apparatus. These preliminary results are presented and discussed herein, along with the current project status.
Callahan, Michael R.↗
Advanced techniques for determining long term compatibility of materials with propellants
The search for advanced measurement techniques for determining long term compatibility of materials with propellants was conducted in several parts. A comprehensive survey of the existing measurement and testing technology for determining material-propellant interactions was performed. Selections were made from those existing techniques which were determined could meet or be made to meet the requirements. Areas of refinement or changes were recommended for improvement of others. Investigations were also performed to determine the feasibility and advantages of developing and using new techniques to achieve significant improvements over existing ones. The most interesting demonstration was that of the new technique, the volatile metal chelate analysis. Rivaling the neutron activation analysis in terms of sensitivity and specificity, the volatile metal chelate technique was fully demonstrated.
Green, R. L.↗
Compatibility Studies of Hydrogen Peroxide and a New Hypergolic Fuel Blend
Several preliminary materials compatibility studies have been conducted to determine the practicality of a new hypergolic fuel system. Hypergolic fuel ignites spontaneously as the oxidizer decomposes and releases energy in the presence of the fuel. The bipropellant system tested consists of high-test hydrogen peroxide (HTP) and a liquid fuel blend consisting of a hydrocarbon fuel, an ignition enhancer and a transition metal catalyst. In order for further testing of the new fuel blend to take place, some basic materials compatibility and HTP decomposition studies must be accomplished. The thermal decomposition rate of HTP was tested using gas evolution and isothermal microcalorimetry (IMC). Materials were analyzed for compatibility with hydrogen peroxide including a study of the affect welding has on stainless steel elemental composition and its relation to HTP decomposition. Compatibility studies of valve materials in the fuel blend were performed to determine the corrosion resistance of the materials.
Baldridge, Jennifer↗
A survey of compatibility of materials with high pressure oxygen service.
The literature on high pressure oxygen compatibility has been surveyed in order to present the existing state of knowledge. Searches have been conducted of NASA and NBS data retrieval systems. In addition, many individuals, active in the field, were contacted in order to retrieve useful unpublished information. Compatibility data, such as mechanical impact, pneumatic impact, ignition temperature, and flash-and-fire point, were compiled for pressures above 200 bar. Lower pressure data were included if they were useful for extrapolation to pressures above 200 bar. These data, too numerous to be given here, are available from the authors. Brief descriptions of the trends of these data are given. Recommendations for additional high pressure studies are included.
Hust, J. G.↗
Survey of materials for hydrazine propulsion systems in multicycle extended life applications
An assessment is presented of materials compatibility data for hydrazine monopropellant propulsion systems applicable to the Space Shuttle vehicle missions. Materials were evaluated for application over a 10-yr/100-mission operational lifetime with minimum refurbishment. A general materials compatibility rating for a broad range of materials and several propellants based primarily on static liquid propellant immersion testing and an in-depth evaluation of hydrazine decomposition as a function of purity, temperature, material, surface conditions, etc., are presented. The most promising polymeric material candidates for propellant diaphragms and seals appear to have little effect on increasing hydrazine decomposition rates, but the materials themselves do undergo changes in physical properties which can affect their 10-yr performance in multicycle applications. The available data on these physical properties of elastomeric materials as affected by exposure to hydrazine or related environments are presented.
Coulbert, C. D.↗
Testing of Candidate Polymeric Materials for Compatibility with Pure Alternate Pretreat as Part of the Universal Waste Management System (UWMS)
The Universal Waste Management System (UWMS) is an improved Waste Collection System for astronauts living and working in low Earth orbit spacecraft. Polymeric materials used in water recovery on International Space Station are regularly exposed to phosphoric acid-treated 'pretreated' urine. Polymeric materials used in UWMS are not only exposed to pretreated urine, but also to concentrated phosphoric acid with oxidizer before dilution known as 'pure pretreat.' Samples of five different polymeric materials immersed in pure pretreat for 1 year were tested for liquid compatibility by measuring changes in storage modulus with a dynamic mechanical analyzer.
Wingard, C. D.↗
Brushing Your Spacecrafts Teeth: A Review of Biological Reduction Processes for Planetary Protection Missions
Much like keeping your teeth clean, where you brush away biofilms that your dentist calls "plaque," there are various methods to clean spaceflight hardware of biological contamination, known as biological reduction processes. Different approaches clean your hardware's "teeth" in different ways and with different levels of effectiveness. We know that brushing at home with a simple toothbrush is convenient and has a different level of impact vs. getting your teeth cleaned at the dentist. In the same way, there are some approaches to biological reduction that may require simple tools or more complex implementation approaches (think about sonicating or just soaking your dentures, vs. brushing them). There are also some that are more effective for different degrees of cleanliness and still some that have materials compatibility concerns. In this article, we review known and NASA-certified approaches for biological reduction, pointing out materials compatibility concerns and areas where additional research is needed.
Pugel, D. E. (Betsy)↗
Brushing Your Spacecrafts Teeth: A Review of Biological Reduction Processes for Planetary Protection Missions
Much like keeping your teeth clean, where you brush away biofilms that your dentist calls plaque, there are various methods to clean spaceflight hardware of biological contamination, known as biological reduction processes. Different approaches clean your hardwares teeth in different ways and with different levels of effectiveness. We know that brushing at home with a simple toothbrush is convenient and has a different level of impact vs. getting your teeth cleaned at the dentist. In the same way, there are some approaches to biological reduction that may require simple tools or more complex implementation approaches (think about sonicating or just soaking your dentures, vs. brushing them). There are also some that are more effective for different degrees of cleanliness and still some that have materials compatibility concerns. In this article, we review known and NASA-certified approaches for biological reduction, pointing out materials compatibility concerns and areas where additional research is needed.
Pugel, D.E. (Betsy)↗
Evaluation of AMSOIL® -ANT PGW Coolant Formula Change and Super Space AMSOIL Development
AMSOIL ® Propylene Glycol Water (PGW), is the baselined internal thermal control fluid for multiple manned spacecraft including Gateway (HALO, IHAB, and ALM modules) and Orion. The use of AMSOIL-ANT PGW was originally validated through extensive NASA/Collins materials-compatibility testing (circa 2008–2015). However, in late 2019, AMSOIL implemented an unannounced change in its PG inhibitor package. Because of this reformulation, concerns around materials compatibility arose. Therefore, NASA initiated corrosion rate and coolant stability testing in 2024. Results showed that the reformulated AMSOIL PG produced substantially elevated corrosion rates in aluminum alloys (about two times when compared to the original AMSOIL PG formula) accompanied by visible surface degradation. Coolant stability testing indicated accelerated propylene-glycol breakdown as well, with glycolate levels about nine times higher than the original formulation. Based on these findings, NASA Materials & Processes and Thermal Control Systems groups have baselined the use of the original PGW chemistry for all spacecraft use. In response, AMSOIL produced a reformulated variant, “Super Space AMSOIL” (ANT-SSA), compliant with MPCV 70156.This paper documents the reformulation testing completed, details on the formulation change, and the development of Super Space AMSOIL.
Woody Beringer↗
Evaluation of AMSOIL ® -ANT PGW Coolant Formula Change and Super Space AMSOIL ® Development
AMSOIL ® Propylene Glycol Water (PGW), is the baselined internal thermal control fluid for multiple manned spacecraft including Gateway (HALO, IHAB, and ALM modules) and Orion. The use of AMSOIL-ANT PGW was originally validated through extensive NASA/Collins materials-compatibility testing (circa 2008–2015). However, in late 2019, AMSOIL implemented an unannounced change in its PG inhibitor package. Because of this reformulation, concerns around materials compatibility arose. Therefore, NASA initiated corrosion rate and coolant stability testing in 2024. Results showed that the reformulated AMSOIL PG produced substantially elevated corrosion rates in aluminum alloys (about two times when compared to the original AMSOIL PG formula) accompanied by visible surface degradation. Coolant stability testing indicated accelerated propylene-glycol breakdown as well, with glycolate levels about nine times higher than the original formulation. Based on these findings, NASA Materials & Processes and Thermal Control Systems groups have baselined the use of the original PGW chemistry for all spacecraft use. In response, AMSOIL produced a reformulated variant, “Super Space AMSOIL” (ANT-SSA), compliant with MPCV 70156.This paper documents the reformulation testing completed, details on the formulation change, and the development of Super Space AMSOIL.
David Brockett↗
Heat Transfer and Thermal Stability Research for Advanced Hydrocarbon Fuel Technologies
In recent years there has been increased interest in the development of a new generation of high performance boost rocket engines. These efforts, which will represent a substantial advancement in boost engine technology over that developed for the Space Shuttle Main Engines in the early 1970s, are being pursued both at NASA and the United States Air Force. NASA, under its Space Launch Initiative s Next Generation Launch Technology Program, is investigating the feasibility of developing a highly reliable, long-life, liquid oxygen/kerosene (RP-1) rocket engine for launch vehicles. One of the top technical risks to any engine program employing hydrocarbon fuels is the potential for fuel thermal stability and material compatibility problems to occur under the high-pressure, high-temperature conditions required for regenerative fuel cooling of the engine combustion chamber and nozzle. Decreased heat transfer due to carbon deposits forming on wetted fuel components, corrosion of materials common in engine construction (copper based alloys), and corrosion induced pressure drop increases have all been observed in laboratory tests simulating rocket engine cooling channels. To mitigate these risks, the knowledge of how these fuels behave in high temperature environments must be obtained. Currently, due to the complexity of the physical and chemical process occurring, the only way to accomplish this is empirically. Heated tube testing is a well-established method of experimentally determining the thermal stability and heat transfer characteristics of hydrocarbon fuels. The popularity of this method stems from the low cost incurred in testing when compared to hot fire engine tests, the ability to have greater control over experimental conditions, and the accessibility of the test section, facilitating easy instrumentation. These benefits make heated tube testing the best alternative to hot fire engine testing for thermal stability and heat transfer research. This investigation used the Heated Tube Facility at the NASA Glenn Research Center to perform a thermal stability and heat transfer characterization of RP-1 in an environment simulating that of a high chamber pressure, regenerative cooled rocket engine. The first step in the research was to investigate the carbon deposition process of previous heated tube experiments by performing scanning electron microscopic analysis in conjunction with energy dispersive spectroscopy on the tube sections. This analysis gave insight into the carbon deposition process and the effect that test conditions played in the formation of deleterious coke. Furthermore, several different formations were observed and noted. One other crucial finding of this investigation was that in sulfur containing hydrocarbon fuels, the interaction of the sulfur components with copper based wall materials presented a significant corrosion problem. This problem in many cases was more life limiting than those posed by the carbon deposition process. The results of this microscopic analysis was detailed and presented at the December 2003 JANNAF Air-Breathing Propulsion Meeting as a Materials Compatibility and Thermal Stability Analysis of common Hydrocarbon Fuels (reference 1).
DeWitt, Kenneth↗
An Overview of Long Duration Sodium Heat Pipe Tests
High temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, and Stirling cycle heat sources; with the resurgence of space nuclear power, additional applications include reactor heat removal elements and radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly long-term materials compatibility is being evaluated through the use of high temperature life test heat pipes. Thermacore International, Inc., has carried out several sodium heat pipe life tests to establish long term operating reliability. Four sodium heat pipes have recently demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A 3l6L stainless steel heat pipe with a sintered porous nickel wick structure and an integral brazed cartridge heater has successfully operated at 650 to 700 C for over 115,000 hours without signs of failure. A second 3l6L stainless steel heat pipe with a specially-designed Inconel 60 I rupture disk and a sintered nickel powder wick has demonstrated over 83,000 hours at 600 to 650 C with similar success. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 41 ,000 hours at nearly 700 0c. A hybrid (i.e. gas-fired and solar) heat pipe with a Haynes 230 envelope and a sintered porous nickel wick structure was operated for about 20,000 hours at nearly 700 C without signs of degradation. These life test results collectively have demonstrated the potential for high temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability, Detailed design specifications, operating hi story, and test results are described for each of these sodium heat pipes. Lessons learned and future life test plans are also discussed.
Rosenfeld, John H.↗
Post-Test Analysis of a 10-Year Sodium Heat Pipe Life Test
High-temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, Stirling cycle heat sources; and with the resurgence of space nuclear power both as reactor heat removal elements and as radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly, long-term materials compatibility is being evaluated through the use of high-temperature life test heat pipes. Thermacore, Inc., has carried out a sodium heat pipe 10-year life test to establish long-term operating reliability. Sodium heat pipes have demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 87,000 hr (10 years) at nearly 700 C. These life test results have demonstrated the potential for high-temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability. Detailed design specifications, operating history, and post-test analysis of the heat pipe and sodium working fluid are described. Lessons learned and future life test plans are also discussed.
Rosenfeld, John H.↗
Ten Year Operating Test Results and Post-Test Analysis of a 1/10 Segment Stirling Sodium Heat Pipe, Phase III
High-temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, Stirling cycle heat sources; and with the resurgence of space nuclear power both as reactor heat removal elements and as radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly, long-term materials compatibility is being evaluated through the use of high-temperature life test heat pipes. Thermacore, Inc., has carried out a sodium heat pipe 10-year life test to establish long-term operating reliability. Sodium heat pipes have demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 87,000 hr (10 yr) at nearly 700 C. These life test results have demonstrated the potential for high-temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability. Detailed design specifications, operating history, and post-test analysis of the heat pipe and sodium working fluid are described.
Rosenfeld, John, H↗