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NASA NTRS1994

Evaluation of turbulence models in the PARC code for transonic diffuser flows

Flows through a transonic diffuser were investigated with the PARC code using five turbulence models to determine the effects of turbulence model selection on flow prediction. Three of the turbulence models were algebraic models: Thomas (the standard algebraic turbulence model in PARC), Baldwin-Lomax, and Modified Mixing Length-Thomas (MMLT). The other two models were the low Reynolds number k-epsilon models of Chien and Speziale. Three diffuser flows, referred to as the no-shock, weak-shock, and strong-shock cases, were calculated with each model to conduct the evaluation. Pressure distributions, velocity profiles, locations of shocks, and maximum Mach numbers in the duct were the flow quantities compared. Overall, the Chien k-epsilon model was the most accurate of the five models when considering results obtained for all three cases. However, the MMLT model provided solutions as accurate as the Chien model for the no-shock and the weak-shock cases, at a substantially lower computational cost (measured in CPU time required to obtain converged solutions). The strong shock flow, which included a region of shock-induced flow separation, was only predicted well by the two k-epsilon models.

Georgiadis, N. J.↗
NASA NTRS2005

Developing a Methodology for Eliciting Subjective Probability Estimates During Expert Evaluations of Safety Interventions: Application for Bayesian Belief Networks

The NASA Aviation Safety Program (AvSP) has defined several products that will potentially modify airline and/or ATC operations, enhance aircraft systems, and improve the identification of potential hazardous situations within the National Airspace System (NAS). Consequently, there is a need to develop methods for evaluating the potential safety benefit of each of these intervention products so that resources can be effectively invested to produce the judgments to develop Bayesian Belief Networks (BBN's) that model the potential impact that specific interventions may have. Specifically, the present report summarizes methodologies for improving the elicitation of probability estimates during expert evaluations of AvSP products for use in BBN's. The work involved joint efforts between Professor James Luxhoj from Rutgers University and researchers at the University of Illinois. The Rutgers' project to develop BBN's received funding by NASA entitled "Probabilistic Decision Support for Evaluating Technology Insertion and Assessing Aviation Safety System Risk." The proposed project was funded separately but supported the existing Rutgers' program.

Wiegmann, Douglas A.a↗
NASA NTRS1996

High Reynolds number analysis of flat plate and separated afterbody flow using non-linear turbulence models

The ability of the three-dimensional Navier-Stokes method, PAB3D, to simulate the effect of Reynolds number variation using non-linear explicit algebraic Reynolds stress turbulence modeling was assessed. Subsonic flat plate boundary-layer flow parameters such as normalized velocity distributions, local and average skin friction, and shape factor were compared with DNS calculations and classical theory at various local Reynolds numbers up to 180 million. Additionally, surface pressure coefficient distributions and integrated drag predictions on an axisymmetric nozzle afterbody were compared with experimental data from 10 to 130 million Reynolds number. The high Reynolds data was obtained from the NASA Langley 0.3m Transonic Cryogenic Tunnel. There was generally good agreement of surface static pressure coefficients between the CFD and measurement. The change in pressure coefficient distributions with varying Reynolds number was similar to the experimental data trends, though slightly over-predicting the effect. The computational sensitivity of viscous modeling and turbulence modeling are shown. Integrated afterbody pressure drag was typically slightly lower than the experimental data. The change in afterbody pressure drag with Reynolds number was small both experimentally and computationally, even though the shape of the distribution was somewhat modified with Reynolds number.

Carlson, John R.↗
NASA NTRS2018

Methodologies for Verification and Validation of Space Launch System (SLS) Structural Dynamic Models

Responses to challenges associated with verification and validation (V&V) of Space Launch System (SLS) structural dynamics models are presented in this paper. Four methodologies addressing specific requirements for V&V are discussed. (1) Residual Mode Augmentation (RMA), which has gained acceptance by various principals in the NASA community, defines efficient and accurate FEM modal sensitivity models that are useful in test-analysis correlation and reconciliation and parametric uncertainty studies. (2) Modified Guyan Reduction (MGR) and Harmonic Reduction (HR, introduced in 1976), developed to remedy difficulties encountered with the widely used Classical Guyan Reduction (CGR) method, are presented. MGR and HR are particularly relevant for estimation of "body dominant" target modes of shell-type SLS assemblies that have numerous "body", "breathing" and local component constituents. Realities associated with configuration features and "imperfections" cause "body" and "breathing" mode characteristics to mix resulting in a lack of clarity in the understanding and correlation of FEM- and test-derived modal data. (3) Mode Consolidation (MC) is a newly introduced procedure designed to effectively "de-feature" FEM and experimental modes of detailed structural shell assemblies for unambiguous estimation of "body" dominant target modes. Finally, (4) Experimental Mode Verification (EMV) is a procedure that addresses ambiguities associated with experimental modal analysis of complex structural systems. Specifically, EMV directly separates well-defined modal data from spurious and poorly excited modal data employing newly introduced graphical and coherence metrics.

Coppolino, Robert N.↗
NASA NTRSDate not supplied

Carbothermal Reduction Demonstration (CaRD) Gas Analysis Subsystem Development

The Carbothermal Reduction Demonstration (CaRD) project is currently developing a subscale system to demonstrate the operation and performance of the carbothermal reduction process and quantify the production of molar equivalent oxygen (carbon monoxide (CO) and carbon dioxide (CO2)). Traditionally, gas chromatography (GC) systems are utilized to qualify gases due to their ability to separate the volatile compounds within the gas mixture, followed by quantification of the isolated component of interest. Despite these capabilities, GCs require consumables for their operational mobile phase and consequently are not often considered a flight-forward option. An alternative analytical technique known as mass spectrometry measures the presentence of gas phase molecules based on their mass-to-charge ratio. Residual gas analyzers (RGAs) which utilize mass spectrometry are not traditionally used to quantify analytes, but proper design and calibrations can result in a flight-forward analytical instrument capable of direct quantification of volatile gases of interest. Kennedy Space Center's role for the project is to design a gas analyzer system to detect and quantify the CO and CO2 gas produced during the carbothermal reaction utilizing a commercial version of the Mass Spectrometer Observing Lunar Operations (MSolo) instrument. MSolo is a modified commercial off-the-shelf mass spectrometer which consists of quadrupole mass filter and space rated electronics. MSolo is currently a TRL 6 technology and manifested on the PRIME-1 and VIPER missions. This paper describes leveraging MSolo based instrumentation to develop a gas analysis system for the work outlined in the 2023 International Conference on Environmental Systems (ICES) paper number 313. The design and testing of the brassboard phase of the project will be described along with the current work underway which will cover the design and preliminary test results of the prototype phase.

Ryan Patrick Gott↗
NASA NTRS1997

Development of Improved Surface Integral Methods for Jet Aeroacoustic Predictions

The accurate prediction of aerodynamically generated noise has become an important goal over the past decade. Aeroacoustics must now be an integral part of the aircraft design process. The direct calculation of aerodynamically generated noise with CFD-like algorithms is plausible. However, large computer time and memory requirements often make these predictions impractical. It is therefore necessary to separate the aeroacoustics problem into two parts, one in which aerodynamic sound sources are determined, and another in which the propagating sound is calculated. This idea is applied in acoustic analogy methods. However, in the acoustic analogy, the determination of far-field sound requires the solution of a volume integral. This volume integration again leads to impractical computer requirements. An alternative to the volume integrations can be found in the Kirchhoff method. In this method, Green's theorem for the linear wave equation is used to determine sound propagation based on quantities on a surface surrounding the source region. The change from volume to surface integrals represents a tremendous savings in the computer resources required for an accurate prediction. This work is concerned with the development of enhancements of the Kirchhoff method for use in a wide variety of aeroacoustics problems. This enhanced method, the modified Kirchhoff method, is shown to be a Green's function solution of Lighthill's equation. It is also shown rigorously to be identical to the methods of Ffowcs Williams and Hawkings. This allows for development of versatile computer codes which can easily alternate between the different Kirchhoff and Ffowcs Williams-Hawkings formulations, using the most appropriate method for the problem at hand. The modified Kirchhoff method is developed primarily for use in jet aeroacoustics predictions. Applications of the method are shown for two dimensional and three dimensional jet flows. Additionally, the enhancements are generalized so that they may be used in any aeroacoustics problem.

Pilon, Anthony R.↗
NASA NTRS2008

Active Management of Flap-Edge Trailing Vortices

The vortex hazard produced by large airliners and increasingly larger airliners entering service, combined with projected rapid increases in the demand for air transportation, is expected to act as a major impediment to increased air traffic capacity. Significant reduction in the vortex hazard is possible, however, by employing active vortex alleviation techniques that reduce the wake severity by dynamically modifying its vortex characteristics, providing that the techniques do not degrade performance or compromise safety and ride quality. With this as background, a series of experiments were performed, initially at NASA Langley Research Center and subsequently at the Berlin University of Technology in collaboration with the German Aerospace Center. The investigations demonstrated the basic mechanism for managing trailing vortices using retrofitted devices that are decoupled from conventional control surfaces. The basic premise for managing vortices advanced here is rooted in the erstwhile forgotten hypothesis of Albert Betz, as extended and verified ingeniously by Coleman duPont Donaldson and his collaborators. Using these devices, vortices may be perturbed at arbitrarily long wavelengths down to wavelengths less than a typical airliner wingspan and the oscillatory loads on the wings, and hence the vehicle, are small. Significant flexibility in the specific device has been demonstrated using local passive and active separation control as well as local circulation control via Gurney flaps. The method is now in a position to be tested in a wind tunnel with a longer test section on a scaled airliner configuration. Alternatively, the method can be tested directly in a towing tank, on a model aircraft, a light aircraft or a full-scale airliner. The authors believed that this method will have significant appeal from an industry perspective due to its retrofit potential with little to no impact on cruise (devices tucked away in the cove or retracted); low operating power requirements; small lift oscillations when deployed in a time-dependent manner; and significant flexibility with respect to the specific devices selected.

Greenblatt, David↗
NASA NTRS2021

A Semi-Empirical Scheme for Bathymetric Mapping in Shallow Water by ICESat-2 and Sentinel-2: A Case Study in the South China Sea

To derive shallow water bathymetry for coastal areas, a common approach is to deploy a scanning airborne bathymetric light detection and ranging (LiDAR) system or a shipborne echosounder for ground surveys. However, recent advancements in satellite remote sensing, including the Ice, Cloud and land Elevation Satellite-2 (ICESat-2) offer new tools for generating satellite derived bathymetry (SDB). The key payload onboard ICESat-2 is the Advanced Topographic Laser Altimeter System (ATLAS), a micro-pulse, photon-counting LiDAR system, simultaneously emitting six separate 532 nm beams at 10 kHz pulse rate. However, despite its high resolution, the major limitation for bathymetry is that ICESat-2 only provides along-track height profiles, leaving observation gaps between the parallel ground tracks. Merging ICESat-2 observations with optical multispectral imagery, as demonstrated herein, provides an effective solution for deriving a full scene of water depth in light of the spectral attenuation behavior. This study aims to combine ICESat-2 and Sentinel-2 optical data to derive shallow water bathymetry (depth <20 m) at six islands and reefs in the South China Sea. ICESat-2 ATL03 point clouds of georeferenced photons are first filtered to determine the seafloor elevation along the ground track. Results indicate a root-mean-square error (RMSE) of 0.26–0.61 m as compared with independent observations from an airborne LiDAR campaign. Next, three semi-empirical functions, namely the Modified Linear/Polynomial/Exponential Ratio Models with its kernel formed by the log ratio between Sentinel-2′s green and blue bands, are used to fit the spectral data with ICESat-2 height profiles. After water depth mapping using the trained model, independent ICESat-2 point clouds are used to validate the Sentinel-2 derived bathymetry. The RMSE values of the three models using the weighted average of multiple images for these six islands are within 0.50–0.90 m in 0–15 m deep. We also demonstrate that a synthesis of satellite laser altimetry and optical remote sensing can produce SDB results that potentially meet the requirement of category C in Zones of Confidence (ZOC) of the Electronic Navigational Chart (ENC) in 0–8 m deep. It is foreseen that ICESat-2 will be a helpful tool for mapping coastal and shallow waters around the world especially where bathymetric data are unavailable.

Coastal Bathymetry↗
NASA NTRS1990

Grid generation and flow computation about a Martian entry vehicle

A number of vehicles are currently being proposed for a manned mission to Mars. One of these vehicles has a modified blunt-nosed cone configuration. Experimental results were obtained for this vehicle in 1968. They show lift-over-drag ratios comparable to those needed for Mars entry. Computations are performed to verify the earlier results and to further describe the flight characteristics of this vehicle. An analytical method is used to define the surface of this vehicle. A single-block volume grid is generated around the vehicle using the algebraic Two-Boundary Grid Generation algorithm (TBGG) and transfinite interpolation. Euler solutions are then obtained from a Langley Aerodynamic Upward Relaxation Algorithm (LAURA) at Mach 6.0 and angles of attack of 0, 6, and 12 deg. The lift coefficient determined from the LAURA code agree very well with the experimental results. The drag and pitching moment coefficients, however, are underestimated by the code since viscous effects are not considered. Contour plots of the flowfield show no evidence of separation for angles of attack up to 12 deg.

Stewart, J. E.↗
NASA NTRSDate not supplied

Models for Facilitating Government-Funded Activities in the Post-ISS LEO Ecosystem

The International Space Station National Lab (ISSNL) was established through Congressional authority in 2005 and has been managed by a nonprofit called the Center for the Advancement of Science in Space (CASIS) since 2011 to support research, development, education, and commercial activities in low-Earth orbit (LEO). NASA leadership is considering next steps for microgravity and orbital activities in LEO in preparation for the retirement of the International Space Station (ISS) and transition to Commercial LEO Destinations (CLDs) in the 2030 timeframe. Specifically, our study team within the NASA Office of Technology, Policy, and Strategy addressed the question: What are potential models for an ISS National Lab facilitating government-funded or subsidized activities on a commercial LEO platform after the transition of the ISS to one or more private platforms? To inform the trade space of potential models, we conducted over 40 discussions with stakeholders internal and external to NASA and reviewed over 35 documents related to LEO legislation, commercialization, models, and activities. Following the extensive literature review and discussions with diverse stakeholders, we defined and evaluated six models, in addition to the current ISSNL model. We assessed each model across three possible future scenarios (dynamic, steady, and limited growth of the commercial LEO market and activities) and across five stakeholder-driven model evaluation criteria (ability to meet NASA’s needs, adaptability, opportunity for collaboration, market sustainability, and equity and accessibility). The six models in the future trade space were: • Government Research Broker: Customizable research efforts on transport vehicles and CLDs • Innovation Campus: Modern terrestrial campus with workforce focus • Anchor Tenant: Long-term, substantial agreement for leasing space on a single CLD • Fee for Service: Free market approach with NASA-sponsored grants and service/data buys • Matchmaker: Neutral third-party connecting users to platforms • Institute Network: Network of separate but related efforts to enable commercial scaling The Government Research Broker model performed best across the scenarios, followed by Innovation Campus, Anchor Tenant, and Fee for Service. While Matchmaker and Institute Network exhibited positive aspects, the two models performed most favorably in future scenarios with well-established communities and markets. The six models presented in this study are representative of the potential trade space and are illustrative examples. NASA leadership can adjust models as desired to align to their priorities more closely by using combinations of the unique model features provided in our analysis. The optimal model is likely a combination of features from multiple models. Building upon this work to best position NASA and the diverse stakeholders of LEO activities for success post-ISS, further work will explore the near-term impact of preparing for the transition of the ISS to CLDs by identifying opportunities for modifying the current ISSNL-CASIS partnership. ACKNOWLEDGEMENTS We thank the many reviewers and discussants, internal and external to NASA, that contributed to the work.

Erica Rodgers↗
NASA NTRS1984

GCM sensitivity to 1982 - 1983 equatorial Pacific sea surface temperature anomalies

The response of the GLAS climate model to the much larger 1982-83 sea surface temperatures (SST) anomalies is discussed. Two separate 75 day experiments (control and anomaly simulation pairs) were started from observed initial conditions on 16 Dec. 1982 and initial conditions on 16 Dec. 1979 taken from a 2 year model control run after one year of simulation, respectively. The January control and anomaly SST fields used in both experiments are given. Notable is the greatly extended region of very warm (approximately equal to 29 C) SST water in the anomaly simulation. The January SST anomaly field is representative of the other months of the experiments, all of which had a much larger region of very warm SST in the anomaly simulation than in the previously noted general circulation model studies. The model used is an improved version of the GLAS B-grid GCM used by Shukla and Wallace (1983). The most important physical change in the model is the inclusion of the surface flux parameterization of Deardorff (1972) as modified by Randall (1976). An important improvement in the model simulations is the removal of the climate drift towards unrealistically high temperatures in the tropics, which was moted by Shukla and Wallace (1983).

Fennessy, M. J.↗
NASA NTRS2007

Analysis Method for Non-Nominal First Acquisition

First this paper describes a method how the trajectory of the launcher can be modelled for the contingency analysis without having much information about the launch vehicle itself. From a dense sequence of state vectors a velocity profile is derived which is sufficiently accurate to enable the Flight Dynamics Team to integrate parts of the launcher trajectory on its own and to simulate contingency cases by modifying the velocity profile. Then the paper focuses on the thorough visibility analysis which has to follow the contingency case or burn performance simulations. In the ideal case it is possible to identify a ground station which is able to acquire the satellite independent from the burn performance. The correlations between the burn performance and the pointing at subsequent ground stations are derived with the aim of establishing simple guidelines which can be applied quickly and which significantly improve the chance of acquisition at subsequent ground stations. In the paper the method is applied to the Soyuz/Fregat launch with the MetOp satellite. Overall the paper shows that the launcher trajectory modelling with the simulation of contingency cases in connection with a ground station visibility analysis leads to a proper selection of ground stations and acquisition methods. In the MetOp case this ensured successful contact of all ground stations during the first hour after separation without having to rely on any early orbit determination result or state vector update.

Sieg, Detlef↗
NASA NTRSDate not supplied

AERACEPT (Aerosol Rapid Analysis Combined Entry Probe/sonde Technology): Enabling Technology for Missions to the Venus Clouds

AERACEPT (AErosol Rapid Analysis Combined Entry Probe/sonde Technology) is an early-stage technology allowing a single aeroshell body to act as both an entry vehicle and aerosol-sampling passive descent sonde. AERACEPT does not require heat shield separation, deployable parachutes, or descent control, thus reducing the mass, volume, and complexity of planetary aerosol sampling. AERACEPT is particularly well suited for a Venus mission, where the particles of greatest interest are within the subsonic descent regime. AERACEPT uses the aeroshell’s own velocity to drive aerosol capture and separation through a series of embedded inlets. It takes advantage of recently developed thermal protection materials (3D-CC and HEEET) in combination with heritage aerosol sampling technologies from both planetary and airborne science (high-speed inlets and particle separation). The trade space for a given descent trajectory includes the particle capture efficiency for a given size, the bias introduced in the sampled particle size and concentration distributions, and the thermal alteration experienced by the particles during their brief exposure to the internal flow environment. AERACEPT is included in the Nephele mission concept study for a small spacecraft targeting the Venus middle and lower cloud layers. Nephele complements larger missions targeting Venus atmospheric gas analysis, such as DAVINCI and Venera-D, by specifically targeting cloud and haze particles. Because of the short lifetime of the probe in the lower atmosphere, Nephele requires a fast cadence of analysis of the captured particles, and includes the VOLTR dual optical spectrometer (SERS/LIBS) as part of its notional payload. Preliminary modeling based on the Nephele trajectory at 63 km to 39 km indicates AERACEPT can limit sample heating to 30-60 K above ambient. A modified particle tracking model has been implemented to estimate capture efficiency of particles larger than 0.1 µm and total sample volume as part of an inlet and interal flow path geometry trade study. Further modeling and empirical testing is underway to improve these estimates.

AERACEPT↗
NASA NTRS1993

Cross-tail current - Resonant orbits

A technique to generate self-consistent 1D current sheets is described. Groups of monoenergetic protons were followed in a modified Harris magnetic field. This sample current sheet is characterized by resonant quasi-adiabatic orbits. The magnetic moment of a quasi-adiabatic ion which is injected from outside a current sheet changes substantially during the orbit but returns to almost its initial value by the time the ion leaves. Several ion and electron groups were combined to produce a plasma sheet in which the charged particles carry the currents needed to generate the magnetic field in which the orbits were traced. An electric field also is required to maintain charge neutrality. Three distinct orbit types, one involving untrapped ions and two composed of trapped ions, were identified. Limitations associated with the use of a 1D model also were investigated; it can provide a good physical picture of an important component of the cross-tail current, but cannot adequately describe any region of the magnetotail in which the principal current sheet is separated from the plasma sheet boundary layer by a nearly isotropic outer position of the central plasma sheet.

Kaufmann, Richard L.↗
NASA NTRS1990

Experimental and theoretical aerodynamic characteristics of a high-lift semispan wing model

Experimental and theoretical aerodynamic characteristics were compared for a high-lift, semispan wing configuration that incorporated a slightly modified version of the NASA Advanced Laminar Flow Control airfoil section. The experimental investigation was conducted in the Langley 14- by 22-Foot Subsonic Tunnel at chord Reynolds numbers of 2.36 and 3.33 million. A two-dimensional airfoil code and a three-dimensional panel code were used to obtain aerodynamic predictions. Two-dimensional data were corrected for three-dimensional effects. Comparisons between predicted and measured values were made for the cruise configuration and for various high-lift configurations. Both codes predicted lift and pitching moment coefficients that agreed well with experiment for the cruise configuration. These parameters were overpredicted for all high-lift configurations. Drag coefficient was underpredicted for all cases. Corrected two-dimensional pressure distributions typically agreed well with experiment, while the panel code overpredicted the leading-edge suction peak on the wing. One important feature missing from both of these codes was a capability for separated flow analysis. The major cause of disparity between the measured data and predictions presented herein was attributed to separated flow conditions.

Applin, Zachary T.↗
NASA NTRS1993

Modeling of the coupled magnetospheric and neutral wind dynamos

The solar wind interaction with the earth's magnetosphere generates electric fields and currents that flow from the magnetosphere to the ionosphere at high latitudes. Consequently, the neutral atmosphere is subject to the dissipation and conversion of this electrical energy to thermal and mechanical energy through Joule heating and Lorentz forcing. As a result of the mechanical energy stored within the neutral wind (caused in part by Lorentz--and pressure gradient--forces set up by the magnetospheric flux of electrical energy), electric currents and fields can be generated in the ionosphere through the neutral wind dynamo mechanism. At high latitudes this source of electrical energy has been largely ignored in past studies, owing to the assumed dominance of the solar wind/magnetospheric dynamo as an electrical energy source to the ionosphere. However, other researchers have demonstrated that the available electrical energy provided by the neutral wind is significant at high latitudes, particularly in the midnight sector of the polar cap and in the region of the magnetospheric convection reversal. As a result, the conclusions of a number of broad ranging high-latitude investigations may be modified if the neutral-wind contribution to high-latitude electrodynamics is properly accounted for. These include the following: studies assessing solar wind-magnetospheric coupling by comparing the cross polar cap potential with solar wind parameters; research based on the alignment of particle precipitation with convection or field aligned current boundaries; and synoptic investigations attributing seasonal variations in the observed electric field and current patterns to external sources. These research topics have been initiated by satellite and ground-based observations and have been attributed to magnetospheric causes. However, the contribution of the neutral wind to the high-latitude electric field and current systems and their seasonal and local time dependence has yet to be quantitatively evaluated. In this program, we are evaluating the coupled magnetospheric and neutral wind dynamos at high latitudes under various conditions. In addition to examining the impact of seasonal variations, we are investigating the consequences of the separate dynamos having pure current-source or voltage-source behaviors.

Thayer, Jeff P.↗
NASA NTRS2002

Techniques Optimized for Reducing Instabilities in Advanced Nickel-Base Superalloys for Turbine Blades

The High-Speed Research (HSR) Airfoil Alloy program developed fourth-generation single-crystal superalloys with up to an 85 F increase in creep rupture capability over current production airfoil alloys. Recent results have been generated at the NASA Glenn Research Center on these fourth-generation alloys, but in coated form, for subsonic turbine blade applications under NASA's Ultra-Efficient Engine Technology (UEET) Program. One goal for UEET is to optimize the airfoil alloy/thermal barrier coating system for 3100 F turbine inlet temperatures. The state-of-the art turbine blade airfoil system consists of a superalloy single crystal that provides the basic mechanical performance of the airfoil. A thermal barrier coating is used to reduce the temperature of the base superalloy, and a bondcoat is deposited between the base material and the thermal barrier coating. The bondcoat improves the oxidation and corrosion resistance of the base superalloy and improves the spallation resistance of the thermal barrier coating. A commercial platinum aluminide bondcoat was applied to the HSR-developed alloys, and a diffusion zone developed as a result of interaction between the bondcoat and the superalloy. Optimized strength is obtained for superalloys when the refractory element content is high and the limits of microstructural stability are approached or exceeded slightly. For fourthgeneration alloys, instability leads to the formation of topologically close packed (TCP) phases, which form internally in the superalloy, and a secondary reaction zone (SRZ), which forms under the diffusion zone. There was a concern that excessive quantities of either TCP or SRZ might decrease the mechanical properties of the superalloy, with SRZ thought to be particularly detrimental and its formation unpredictable. Thus, an SRZreduction effort was initiated in the NASA UEET Program so that methods developed during the HSR project could be optimized further to reduce or eliminate the SRZ. An SRZ is a three-phase constituent composed of TCP and stringers of gamma phase in a matrix of gamma prime. An incoherent grain boundary separates the SRZ from the gammagamma prime microstructure of the superalloy. The SRZ is believed to form as a result of local chemistry changes in the superalloy due to the application of the diffusion aluminide bondcoat. Locally high surface stresses also appear to promote the formation of the SRZ. Thus, techniques that change the local alloy chemistry or reduce surface stresses have been examined for their effectiveness in reducing SRZ. These SRZ-reduction steps are performed on the test specimen or the turbine blade before the bondcoat is applied. Stressrelief heat treatments developed at NASA Glenn have been demonstrated to reduce significantly the amount of SRZ that develops during subsequent high-temperature exposures. Stress-relief heat treatments reduce surface stresses by recrystallizing a thin surface layer of the superalloy. However, in alloys with very high propensities to form SRZ, stress relief heat treatments alone do not eliminate SRZ entirely. Thus, techniques that modify the local chemistry under the bondcoat have been emphasized and optimized successfully at Glenn. One such technique is carburization, which changes the local chemistry by forming submicron carbides near the surface of the superalloy. Detailed characterizations have demonstrated that the depth and uniform distribution of these carbides are enhanced when a stress relief treatment and an appropriate surface preparation are employed in advance of the carburization treatment. Even in alloys that have the propensity to develop a continuous SRZ layer beneath the diffusion zone, the SRZ has been completely eliminated or reduced to low, manageable levels when this combination of techniques is utilized. Now that the techniques to mitigate SRZ have been established at Glenn, TCP phase formation is being emphasized in ongoing work under the UEET Program. The limitsf stability of the fourth-generation alloys with respect to TCP phase formation are currently being defined along with high-temperature creep rupture properties. In addition, a regression model is being developed at Glenn for the prediction of the presence of TCP phase in the microstructure and SRZ under the diffusion zone. The model is based on a design-of-experiments methodology with emphasis on the potential synergistic effects of alloying elements.

MacKay, Rebecca A.↗
NASA NTRS1992

Validation test of advanced technology for IPV nickel-hydrogen flight cells: Update

Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts with the intention of improving cycle life and performance. One advancement was to use 26 percent potassium hydroxide (KOH) electrolyte to improve cycle life. Another advancement was to modify the state-of-the-art cell design to eliminate identified failure modes. The modified design is referred to as the advanced design. A breakthrough in the low-earth-orbit (LEO) cycle life of IPV nickel-hydrogen cells has been previously reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 LEO cycles compared to 3,500 cycles for cells containing 31 percent KOH. The boiler plate test results are in the process of being validated using flight hardware and real time LEO testing at the Naval Weapons Support Center (NWSC), Crane, Indiana under a NASA Lewis Contract. An advanced 125 Ah IPV nickel-hydrogen cell was designed. The primary function of the advanced cell is to store and deliver energy for long-term, LEO spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent KOH electrolyte; (2) use of a patented catalyzed wall wick; (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management; and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion due to charge/discharge cycling. The significant improvements resulting from these innovations are: extended cycle life; enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion. The advanced cell design is in the process of being validated using real time LEO cycle life testing of NWSC, Crane, Indiana. An update of validation test results confirming this technology is presented.

Smithrick, John J.↗