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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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Adhesive joints between metal parts made amenable to nondestructive radiographic inspection by incorporating radiopaque fillers that increase x-ray contrasts of joints. Adhesives can be epoxies, urethanes, acrylics, phenolics, or silicones, with appropriate curing agents and with such modifiers as polysulfides, polyamides, or butadiene rubbers.
A pilot experiment was done to determine what factors influence potential performance errors related to vigilance in Orbiter processing activities. The selected activities include post flight inspection for burned gap filler material and pre-rollout inspection for tile processing shim material. It was determined that the primary factors related to performance decrement were the color of the target and the difficulty of the target presentation.
A process for making a combustion chamber for a rocket engine wherein a copper alloy in particle form is injected into a stream of heated carrier gas in plasma form which is then projected onto the inner surface of a hollow metal jacket having the configuration of a rocket engine combustion chamber is described. The particles are in the plasma stream for a sufficient length of time to heat the particles to a temperature such that the particles will flatten and adhere to previously deposited particles but will not spatter or vaporize. After a layer is formed, cooling channels are cut in the layer, then the channels are filled with a temporary filler and another layer of particles is deposited.
Ply-lift and pocketing are two critical anomalies of carbon cloth phenolic composites (CCPC) in rocket nozzle applications. Ply lift occurs at low temperatures when the A/P and in-plane permeabilities of the composite materials are still very low and in-plane porous paths are blocked. Pocketing occurs at elevated temperatures when in-plane permeability is reduced by the A/P compressive stress. The thermostructural response of CCPC in a rapid heating environment involves simultaneous heat, mass, and momentum transfer along with the degradation of phenolic resin in a multiphase system with temperature- and time-dependent material properties as well as dynamic processing conditions. Three temperature regions represent the consequent chemical reactions, material transformations, and property transitions, and provide a quick qualitative method for characterizing the thermostructural behavior of a CCPC. In order to optimize the FM5939 LDCCP (low density carbon cloth phenolic) for the nozzle performance required in the Advanced Solid Rocket Motor (ASRM) program, a fundamental study on LDCCP materials was conducted. The cured composite has a density of 1.0 +/- 0.5 gm/cc which includes 10 to 25 percent void volume. The weight percent of carbon microballoon is low (7-15 percent). However, they account for approximately one third of the volume and historically their percentages have not been controlled very tightly. In addition, the composite properties show no correlation with microballoon weight percent or fiber properties (e.g. fiber density or fiber moisture adsorption capacity). Test results concerning the ply-lift anomaly in the MNASA motor firings were: (1) Steeper ply angle (shorter path lenght) designs minimized/eliminated by lifting, (2) material with higher void volume ply lifted less frequently, (3) materials with high (greater than 9 percent) microballoon content had a higher rate of ply lifting, and (4) LDCCP materials failed at microballoon-resin interfaces. The objectives of this project are: (1) to investigate the effects of carbon microballoon and cabosil fillers as well as fiber heat treatment on plylift-related mechanical properties, (2) to develop a science-based thermostructural process model for the carbon phenolics. The model can be used in the future for the selection of the improved ASRM materials, (3) to develop the micro-failure mechanisms for the ply-lift initiation and propagation processes during the thermoelastic region of phenolic degradation, i.e. postcuring and devolatilization.
Tensile and pure bending tests were conducted on specimens having welded joints made from 2219-T87 aluminum alloy and 2319 filler. Data were collected using photoelastic coatings and strain gages. Stress-strain relationships and contraction ratios were determined at several points in a grid covering the weld material and heat affected zone. Material behavior was nonlinear and nonuniform at all points in the grid and contraction ratios did not conform to those predicted by Chakrabarty's plasticity theory. Yielding in joints made using four new welding procedures was examined. None of the new procedures produced more uniform yielding in the joint.
A composite solid electrolyte film is formed by dissolving a lithium salt such as lithium iodide in a mixture of a first solvent which is a co-solvent for the lithium salt and a binder polymer such as polyethylene oxide and a second solvent which is a solvent for the binder polymer and has poor solubility for the lithium salt. Reinforcing filler such as alumina particles are then added to form a suspension followed by the slow addition of binder polymer. The binder polymer does not agglomerate the alumina particles. The suspension is cast into a uniform film.
Lightweight ceramic ablators (LCA's) were recently developed at Ames to investigate the use of low density fibrous substrates and organic resins as high temperature, high strength ablative heat shields. Unlike the traditional ablators, LCA's use porous ceramic/carbon fiber matrices as substrates for structural support, and polymeric resins as fillers. Several substrates and resins were selected for the initial studies, and the best performing candidates were further characterized. Three arcjet tests were conducted to determine the LCA's thermal performance and ablation characteristics in a high enthalpy, hypersonic flow environment. Mass loss and recession measurements were obtained for each sample at post test, and the recession rates were determined from high speed motion films. Surface temperatures were also obtained from optical pyrometers.
There are no well-developed technologies for recycling composite materials other than grinding to produce fillers. New approaches are needed to reclaim these valuable resources. Chemical or tertiary recycling, conversion of polymers into low molecular weight hydrocarbons for reuse as chemicals or fuels, is emerging as the most practical means for obtaining value from waste plastics and composites. Adherent Technologies is exploring a low-temperature catalytic process for recycling plastics and composites. Laboratory results show that all types of plastics, thermosets as well as thermoplastics, can be converted in high yields to valuable hydrocarbon products. This novel catalytic process runs at 200 C, conversion times are rapid, the process is closed and, thus, nonpolluting, and no highly toxic gas or liquid products have been observed so no negative environmental impact will result from its implementation. Tests on reclamation of composite materials show that epoxy, imide, and engineering thermoplastic matrices can be converted to low molecular weight hydrocarbons leaving behind the reinforcing fibers for reuse as composite reinforcements in secondary, lower-performance applications. Chemical recycling is also a means to dispose of sensitive or classified organic materials without incineration and provides a means to eliminate or reduce mixed hazardous wastes containing organic materials.
Localized corrosion in 2219-T87 aluminum (Al) alloy, 2195 aluminum-lithium (Al-Li) alloy, and welded 2195 Al-Li alloy (4043 filler) have been investigated using the relatively new scanning reference electrode technique (SRET). Anodic sites are more frequent and of greater strength in the 2195 Al-Li alloy than in the 2219-T87 Al alloy, indicating a greater tendency toward pitting for the latter. However, the overall corrosion rates are about the same for these two alloys, as determined using the polarization resistance technique. In the welded 2195 Al-Li alloy, the weld bean is entirely cathodic, with rather strongly anodic heat affected zones (HAZ) bordering both sides, indicating a high probability of corrosion in the HAZ parallel to the weld bead.
This report covers the results of investigations directed toward studying the effects of novel aromatic diamine structures on epoxy adhesive properties and includes work done under a modification to the original contract. Three aromatic diamines based on diphenylsulfone and benzophenone were studied as epoxy adhesive curing agents. Previously found differences in adhesive strengths for meta vs para orientation were not found in these series. The use of aluminum and alumina as fillers in a m,m'-methylene dianiline-cured epoxy adhesive was not found to be beneficial to adhesive strength. Alumina filled adhesives had much lower strength than unfilled adhesives. The unfilled m,m'-methylene dianiline-based epoxy adhesive had excellent resistance to moisture relative to a p,p'-methylene dianiline-based adhesive and maintained good strengths up to 250 F. A glass fiber composite based on a m,m'-methylene dianiline-cured epoxy appeared to be equivalent to the p,p'-methylene dianiline-cured epoxy as judged by short beam shear tests.
This report describes the results of arc-jet testing at Ames Research Center on behalf of Jet Propulsion Laboratory (JPL) for the development of the Mars-Pathfinder heat shield. The current test series evaluated the performance of the ablating SLA-561V heat shield material under shear conditions. In addition, the effectiveness of several methods of repairing damage to the heat shield were evaluated. A total of 26 tests were performed in March 1994 in the 2 in. X 9 in. arc-heated turbulent Duct Facility, including runs to calibrate the facility to obtain the desired shear stress conditions. A total of eleven models were tested. Three different conditions of shear and heating were used. The non-ablating surface shear stresses and the corresponding, approximate, non-ablating surface heating rates were as follows: Condition 1, 170 N/m(exp 2) and 22 W/cm(exp 2); Condition 2, 240 N/m(exp 2) and 40 W/cm(exp 2); Condition 3, 390 N/m(exp 2) and 51 W/cm(exp 2). The peak shear stress encountered in flight is represented approximately by Condition 1; however, the heating rate was much less than the peak flight value. The peak heating rate that was available in the facility (at Condition 3) was about 30 percent less than the maximum value encountered during flight. Seven standard ablation models were tested, of which three models were instrumented with thermocouples to obtain in-depth temperature profiles and temperature contours. An additional four models contained a variety of repair plugs, gaps, and seams. These models were used to evaluated different repair materials and techniques, and the effect of gaps and construction seams. Mass loss and surface recession measurements were made on all models. The models were visually inspected and photographed before and after each test. The SLA-561 V performed well; even at test Condition 3, the char remained intact. Most of the resins used for repairs and gap fillers performed poorly. However, repair plugs made of SLA-561V performed well. Approximately 70 percent of the thermocouples yielded good data.
The suitability of using transient liquid phase (TLP) bonding to fabricate honeycomb core sandwich panels with Ti-14Al-21Nb (wt%) titanium aluminide (T3Al) face sheets for high-temperature hypersonic vehicle applications was evaluated. Three titanium alloy honeycomb cores and one Ti3Al alloy honeycomb core were investigated. Edgewise compression (EWC) and flatwise tension (FWT) tests on honeycomb core sandwich specimens and tensile tests of the face sheet material were conducted at temperatures ranging from room temperature to 1500 F. EWC tests indicated that the honeycomb cores and diffusion bonded joints were able to stabilize the face sheets up to and beyond the face sheet compressive yield strength for all temperatures investigated. The specimens with the T3Al honeycomb core produced the highest FWT strengths at temperatures above 1000 F. Tensile tests indicated that TLP processing conditions resulted in decreases in ductility of the Ti-14Al-21Nb face sheets. Microstructural examination showed that the side of the face sheets to which the filler metals had been applied was transformed from equiaxed alpha2 grains to coarse plates of alpha2 with intergranular Beta. Fractographic examination of the tensile specimens showed that this transformed region was dominated by brittle fracture.
Small pyrex glass spheres, representative of stoney meteoroids, were fired into 2024-T3 aluminum alclad multiple-sheet structures at velocities to 11,000 feet per second to evaluate the effectiveness of multisheet hull construction as a means of increasing the resistance of a spacecraft to meteoroid penetrations. The results of these tests indicate that increasing the number of sheets in a structure while keeping the total sheet thickness constant and increasing the spacing between sheets both tend to increase the penetration resistance of a structure of constant weight per unit area. In addition, filling the space between the sheets with a light filler material was found to substantially increase structure penetration resistance with a small increase in weight. An evaluation of the meteoroid hazard to space vehicles is presented in the form of an illustrative-example for two specific lunar mission vehicles, a single-sheet, monocoque hull vehicle and a glass-wool filled, double-sheet hull vehicle. The evaluation is presented in terms of the "best" and the "worst" conditions that might be expected as determined from astronomical and satellite measurements, high-speed impact data, and hypothesized meteoroid structures and compositions. It was observed that the vehicle flight time without penetration can be increased significantly by use of multiple-sheet rather than single-sheet hull construction with no increase in hull weight. Nevertheless, it is evident that a meteoroid hazard exists, even for the vehicle with the selected multiple-sheet hull.
Presentation discusses Micro Plasma Transfer Arc (MPTA) welding. It was introduced in 1960, and has been used for blade refurbishment for jet engines since 1980. It is compared with Gas Tungsten Arc Welding. MPTA welding reduces the heat input to perform the weld. It uses controlled filler material, and it is easy to use.
A heritage wine-rack thermal/mechanical design for the nickel-hydrogen batteries was the baseline at the Landsat-7 Preliminary Design Review. An integrated thermal and power analysis of the batteries performed by the author in 1994 revealed that the maximum cell-to-cell gradient was 6.6 C. The author proposed modifying the heritage wine-rack design by enhancing heat conduction from cells to cells, and from cells to battery frame. At the 1995 Intersociety Energy Conversion Engineering Conference (IECEC), the author presented a paper on methods of modifying the wine-rack design. It showed that the modified wine-rack option, which uses a metallic filler, could reduce the maximum cell-to-cell temperature gradient to 1.30 C, and could also reduce the maximum cell temperature by as much as 80 C. That design concept was adopted by the Landsat7 Project Office, and a design change was made at the Critical Design Review. Results of the spacecraft thermal vacuum and thermal balance tests, and temperature data in flight show that the temperatures of the battery cells are very uniform. The maximum cell-to-cell gradient is 1.50 C. They validate the modified wine-rack thermal design.
Although the levels of volatile organic compound (VOC) emissions from industrial roof coatings and paint operations have been reduced in recent years, the roof coating partnership was an effort to further reduce VOC emission levels and to also demonstrate the use of reclaimed automobile tire rubber as a filler material in roof coating systems. Different materials and coatings were evaluated and tested before the final selection was used to coat the roofs of two small buildings at NASA's MSFC (Marshall Space Flight Center) during fiscal year 1997. The primary objective of the Bridge repair partnership was to strategically leverage public and private sector funds for the purpose of developing a bridge repair process that was cheaper, better, and faster than conventional methods. It was also, imperative that this process be environmentally friendly and capable of performing under extreme conditions for a period of not less than 2 years.
A partnership was formed between the National Aeronautics and Space Administration (NASA), the Environmental Protection Agency (EPA), and United Technologies USBI Company to develop, demonstrate, and evaluate a technology that uses a solventless spray process for depositing a lightweight, highly filled roof coating on low-sloped commercial roofs. Although the levels of volatile organic compound (VOC) emissions from industrial roof coating's and paint operations have been reduced in recent years, this partnership,was an effort to further reduce VOC emission levels and to also demonstrate the use of reclaimed automobile tire rubber as a filler material in roof coating systems. Different materials and coatings were evaluated and tested before the final selection used to coat the roofs of two small buildings at NASA's Marshall Space Flight Center during fiscal year 1997. The project successfully leveraged the investment of EPA, NASA and private sector resources to demonstrate a pre-commercial roofing coating process. This process utilizes the Convergent Spray Technologies process, which was initially developed by USBI to apply highly-filled, thermal protection coatings to the Space Shuttle Solid Rocket Boosters. A second partnership between the NASA, Federal Highway Administration, Alabama Department of Transportation and USBI Company was formed to develop and demonstrate the Convergent Spray Technology as a method of applying a skid resistant coating to interstate roads and concrete bridge decking's. Again, different materials and coatings were evaluated and tested before the final selection of ground flint and resin. Two field demonstrations were performed during fiscal year 1997 for the purpose of evaluating the coating system under actual highway conditions. These coatings were applied on Interstate 65 near Huntsville Alabama, and in the Mobile Bankhead tunnel. The system performed this task without the use of harmful solvents, and accomplished the process in a single application. This project successfully leveraged the investment of NASA, Federal Highway Administration, the Alabama Department of Transportation, and private sector funding.
As part of the ISO-IRAS Faint Galaxy Survey ISO Satellite observations of over 600 IRAS sources have been obtained with the ISOCAM instrument. Because our survey strategy involved relatively short integrations, great care was required in developing analysis software including cosmic-ray and transient removal and calibration. These observations have now been through final pipeline processing at IPAC and ground-based follow-up is ongoing. The observations are for sources from two samples: a " Filler' sample selected to be at z greater than 0.1 and a fainter sample which selected for the highest redshift galaxies in the IRAS survey, with redshifts 0.2 less than z less than 1.0. I now have obtained ground-based follow-up spectrophotometry at Lick and Palomar observatories for 100 LFIRGs with 0.1 less than z less than 0.7. Our observations have confirmed that these systems are comparable to nearby LFIRGs such as Arp 220, with L (sub -)(fir) greater than 10(exp 11) L(sub -) sun and typically HII/Liner optical excitation. About 10% of the galaxies show true AGN (Sy2) excitation. Based on our work on a nearby complete sample of LFIRGS, we believe that the majority of these systems are luminous Starbursts, thus this project is tracing the luminous end of the galaxy star-forming luminosity function - the (infrared) star-formation history of the Universe to z approx. 1, a topic of some considerable recent interest. A by-product of these ISOCAM observations is approximately 1 square degree of deep 2 microns pointings outside the IRAS error boxes, allowing us an independent estimate of the mid-infrared log N - log S relation. Ground-based observations of this sample are continuing.