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At least 847 records · Page 47
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Laser-Interference Surface Preparation for Enhanced Coating Adhesion and Adhesive Joining of Multi-Materials (Final Project Report)

This report investigates a laser-interference surface treatment as a non-contact, i.e., without major solid/liquid medium application or abrasion, and non-chemical surface preparation method for aerospace coating systems. It was proposed to use the laser-interference technique to structure surfaces of Al and/or Ti, creating "rough" surfaces with pre-engineered series of ridges and valleys at submicron scale. The science goal of this study was to develop an understanding of the surface microstructure, topology, and physical mechanisms that would improve adhesion and corrosion protection of Al2024-T3. Microstructure analysis indicates that the laser-interference structuring (LIS) was found to reduce the formation of CuMn-rich precipitates in Al 2024-T3 over a 500-800 nm depth from top surface. The X-cut and cross-hatch coating adhesion ratings indicate that the LIS specimens meet the performance requirements in the coating adhesion specifications by having a higher or identical ranking to those specimens prepared with current state-of-the-art chemical conversion or sulfuric acid anodizing. After the ASTM B117 corrosion exposure, it was found that the laser processed specimens exhibited only few blisters. It was found that the corrosion damage was minimized at a laser rastering speed of 4 mm/s, for which only 33% of specimens developed very minor corrosion damage. The ASTM D1654 creepage ratings, used to evaluate corrosion damage along the scribe lines, were found to be at least nine for all coated panels. These results indicate that the laser-interference technique with the additional acetone wiping has the potential to be further developed as a minor chemical surface preparation technique for chromate-containing epoxy primers coatings.

36 MATERIALS SCIENCE↗
NASA NTRS1973

Microwave emission and scattering from vegetated terrain

Models are developed for the apparent temperature and backscattering coefficient of vegetated terrain to illustrate the effects of vegetation on the sensitivity of these parameters to variations of soil moisture. Three types of terrain are simulated for both the passive and the active case: a uniform canopy over a smooth surface, plant rows on a smooth surface, and plant rows on a rough surface. In each case the canopy is defined by its overall dimensions and by its electric permittivity, which is determined from Weiner model for dielectric mixture. Emission and scattering from both the soil and the canopy are considered, but atmospheric effects are neglected. Calculated data indicate that the sensitivity of the apparent temperature and backscattering coefficient to variations of soil moisture, decreases as the amount of vegetation increases. It is shown that the same effect results from increasing signal frequency or angle of incidence.

Sibley, T. G.↗
NASA NTRS1984

The Chemical Nature of the Fiber/resin Interface in Composite Materials

Carbon fiber/epoxy resin composites are considered. The nature of the fiber structure and the interaction that occurs at the interface between fiber and matrix are emphasized. Composite toughness can be improved by increased axial tensile and compressive strengths in the fibers. The structure of carbon fibers indicates that the fiber itself can fail transversely, and different transverse microstructures could provide better transverse strengths. The higher surface roughness of lower modulus and surface-treated carbon fibers provides better mechanical interlocking between the fiber and matrix. The chemical nature of the fiber surface was determined, and adsorption of species on this surface can be used to promote wetting and adhesion. Finally, the magnitude of the interfacial bond strength should be controlled such that a range of composites can be made with properties varying from relatively brittle and high interlaminar shear strength to tougher but lower interlaminar shear strength.

Diefendorf, R. J.↗
NASA NTRS1990

On the modelling of roughness effects

It is thought that the presently available numerical codes could be used for analysis of the laminar-turbulent transition process in boundary layers above rough walls with roughness simulated by proper distribution of surface suction. It is shown that the equivalence between both types of flows, i.e., the flow with surface roughness and the flow with distributed suction, might not exist.

Floryan, Jerzy M.↗
NASA NTRS1993

Turbulent heat transfer from a sparsely vegetated surface - Two-component representation

The conventional calculation of heat fluxes from a vegetated surface involving the coefficient of turbulent heat transfer which increases logarithmically with surface roughness, is inappropriate such highly structured surfaces as desert scrub or open forest. An approach is developed here for computing sensible heat flux from sparsely vegetated surfaces, where the absorption of insolation and the transfer of absorbed heat to the atmosphere are calculated separately for the plants and for the soil. This approach is applied to a desert-scrub surface in the northern Sinai, for which the turbulent transfer coefficient of sensible heat flux from the plants is much larger than that from the soil below, as shown by an analysis of plant, soil, and air temperatures. The plant density is expressed as the sum of products (plant-height) x (plant-diameter) of plants per unit horizontal surface area. The solar heat absorbed by the plants is assumed to be transferred immediately to the airflow. The effective turbulent transfer coefficient k(g-eff) for sensible heat from the desert-scrub/soil surface computed under this assumption increases sharply with increasing solar zenith angle, as the plants absorb a greater fraction of the incoming irradiation. The surface absorptivity (the coalbedo) also increases sharply with increasing solar zenith angle, and thus the sensible heat flux from such complex surfaces is a much broader function of time of day than when computed under constant k(g-eff) and constant albedo assumptions.

Otterman, J.↗
DOE OSTI2022

Optical Imaging for Understanding of Thermal Barrier Coated Piston Engine Performance

Thermal barrier coatings (TBC) applied to pistons have been a recently renewed research topic in the field of internal combustion engines. Single cylinder testing of a conventional C15™ Tier 4 final pro-duction steel piston and a TBC coated piston showed that the Yttrium stabilized Zirconia (YSZ) TBC did not significantly alter engine performance, with the TBC piston having slower combustion rates and higher criteria emissions. For deeper understanding, research continued by studying 3D-piston sections optically in a constant pressure vessel using photodiodes, four high-speed cameras (natural luminosity, CH*, and OH*), and visualization of the flame from two orthogonal directions. Particle Im-aging Velocimetry (PIV) algorithms were adapted to perform Combustion Imaging Velocimetry (CIV) to aid in quantification of the observed visual combustion flow field differences. The optical work showed that the TBC piston flame development is slower, spatially different, with lower mixing energy for the TBC variant. Geometric profiles of engine pistons and optical vessel 3D-piston sections were measured using a Coordinate Measurement Machine (CMM), and surface roughness was measured with a stylus surface profilometer. CMM results showed that the TBC piston bowl had reasonable macroscopic accuracy, but the rim had a larger radius with less reentrancy. A discussion of the results and analyses in relation to future TBC effort and direction concludes the work.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1985

Surface texture characterization by angular distributions of scattered light

Work at the National Bureau of Standards to develop an on-line optical measurement device and attendant algorithms for automated optical scattering measurements of machined metal surfaces are described. The surfaces could be milled, ground or lapped, and the system is intended to categorize the resulting surface characteristics. The optical device consists of a He-Ne laser which is shone on a surface. The scattered light is captured by a semicircular array of 87 detector elements rotated over the scanned area. The light signals are processed through a digital voltmeter and then an A/D converter. The signals are then stored for later comparisons with optical scattering data obtained by optical instruments used with stylus instruments for characterizing surface topographies. A theoretical model has been defined which relates light scattering and the characteristics of the surface roughness. Initial experimental results with a sinusoidal surface have indicated that although the system can follow the trend of the roughness, the roughness amplitude is as yet uncertainly defined and the computations require excessive time.

Gilsinn, D. E.↗
NASA NTRS2007

Sun Glint and Sea Surface Salinity Remote Sensing

The Aquarius/SAC-D mission will employ three L-band (1.41 GHz) radiometers dedicated to remote sensing of Sea Surface Salinity. The mission will be in a dawn/dusk sun-synchronous orbit with the beam oriented toward the night time side of the orbit in order to limit interference from the Sun. The effect of surface roughness on solar radiation reflected from the surface will be examined. It will be shown that including the small scale roughness (waves) can have a major impact. Also, it will be shown that when the small scale waves are included it is possible to have significant radiation reflected into the main beam during seasonal extremes when a portion of the main beam is on the illuminated side of day-night terminator.

Dinnat, Emmanuel P.↗
NASA NTRS1983

Coherent scattering of a spherical wave from an irregular surface

The scattering of a spherical wave from a rough surface using the Kirchhoff approximation is considered. An expression representing the measured coherent scattering coefficient is derived. It is shown that the sphericity of the wavefront and the antenna pattern can become an important factor in the interpretation of ground-based measurements. The condition under which the coherent scattering-coefficient expression reduces to that corresponding to a plane wave incidence is given. The condition under which the result reduces to the standard image solution is also derived. In general, the consideration of antenna pattern and sphericity is unimportant unless the surface-height standard deviation is small, i.e., unless the coherent scattering component is significant. An application of the derived coherent backscattering coefficient together with the existing incoherent scattering coefficient to interpret measurements from concrete and asphalt surfaces is shown.

Fung, A. K.↗
NASA NTRS2018

Effect of Distributed Patch of Smooth Roughness Elements on Transition in a High-Speed Boundary Layer

Surface roughness is known to have a substantial impact on the aerothermodynamic loading of hypersonic vehicles, particularly via its influence on the laminar-turbulent transition process within the boundary layer. Numerical simulations are performed to investigate the effects of a distributed region of densely packed, smooth-shaped roughness elements on the laminar boundary layer over a 7-degree half-angle, circular cone for flow conditions corresponding to a selected trajectory point from the ascent phase of the HIFiRE-1 flight experiment. For peak-to-valley roughness heights of 50 percent or less in comparison with the thickness of the unperturbed boundary layer, the computations converge to a stationary flow, suggesting that the flow is globally stable. Analysis of convective instabilities in the wake of the roughness patch indicates two dominant families of unstable disturbances, namely, a high frequency mode that corresponds to Mack mode waves modified by the wake and a lower frequency mode that corresponds to shear layer instabilities associated with the streaks in the roughness wake. Even though the peak growth rate of the later mode is more than 35 percent greater than the peak growth rates of the Mack modes, the latter modes achieve higher amplification ratios, and hence, are likely to dominate the onset of transition, which is estimated to occur slightly later than that in the unperturbed, i.e., smooth surface boundary layer. Additional computations are performed to investigate the effects of various roughness patch configurations on a Mach 3.5 flat plate boundary layer, to help guide an upcoming experiment in the Mach 3.5 Supersonic Low Disturbance Tunnel at NASA Langley Research Center. In this case, the cumulative reinforcement of basic state distortion over the length of the roughness patch is predicted to yield a significantly earlier transition than that over a smooth plate or a plate with a shorter length roughness patch.

Meelan Choudhari↗
DOE OSTI2022

Controlling melt flow by nanoparticles to eliminate surface wave induced surface fluctuation

The high surface roughness is one of the major challenges encountered in laser metal additive manufacturing (AM) processes, which is closely related to the melt flow behavior. However, how to control the melt flow in laser metal AM processes to improve surface finish is unknown. Here we reveal the effects of nanoparticles on melt flow behavior at every location of melt pool during laser metal AM process for the first time using Al6061 + TiC nanoparticles system and achieve significant improvement of surface finish by using TiC nanoparticles to control the melt flow and damp the surface wave. Based on the in-situ x-ray imaging observation, the surface wave is fully damped after adding TiC nanoparticles, compared with only 56% damping without nanoparticles during LPBF of Al6061. Our in-depth in-situ x-ray imaging analysis and viscosity measurement enable us to identify that nanoparticle-induced increase of viscosity causes the fully damping of the surface wave by (1) increasing the internal fluid friction for more efficient wave amplitude reduction, (2) controlling the melt flow to increase the surface wave number, (3) controlling the melt flow to increase the wave damping time. Furthermore, we also quantified the relative contributions of increasing fluid friction, increasing wave number, and increasing damping time to wave damping, which account for 61%, 25%, and 14%, respectively. Furthermore, our research provides the mechanisms and potential method to address the surface finish challenge in laser metal AM processes.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Quantitatively accounting for the effects of surface topography on the oxidation kinetics of additive manufactured Hastelloy X processed by electron beam melting

In this work, the effects of surface roughness on the high-temperature corrosion of nickel-based superalloy X produced through electron-beam melting (EBM) additive manufacturing were studied. Surface area of samples in the rough, as-fabricated condition was measured using a 2D cross-section image analysis technique and a 3D image analysis technique. To verify the accuracy of surface area measurements, oxidation testing of samples in the as-fabricated and polished conditions was performed; polished sample oxidation curves were then compared to the as-fabricated sample oxidation curves before and after being adjusted using obtained surface area measurements. It was found that the 2D technique accurately measured surface area and accounted for the overlapping features present on EBM sample surfaces, whereas the 3D technique did not. Further, it was also observed that oxidation kinetics were moderately faster on the alloy X samples in the as-fabricated condition than for the polished condition.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Mechanical Characterization of Fe-Co-2V (Hiperco): Fatigue/Monotonic Testing Hardness Testing and Fractography

Fe-Co-2V is a popular metallic alloy used in electromagnetic applications. However, there is a lack of mechanical fatigue characterization of this alloy in the literature. In this work, Fe-Co-2V specimens with rectangular cross-sections were carefully prepared in accordance with standards. They were measured for surface roughness and then subjected to quasi-static monotonic testing, as well as fatigue testing at both 0.5 Hz and 1 Hz frequencies. Both Rockwell hardness and Vickers micro- hardness testing were performed. Additionally, scanning electron microscopy imaging of the fractured surfaces was done. The quasi-static testing revealed a flat yield region characteristic of Laders bands. Here, the fatigue results did not show significant differences or sensitivity to change in frequency, although the fatigue life was higher on average for the 0.5 Hz. However, the fatigue results differed from published work at 0.33 Hz. The fractography revealed purely brittle fracture, with clear chevron marks and fracture initiation always starting at the surface. Lastly, it was identified that the C, D, and F Rockwell hardness scales were appropriate for testing this material and that the grain size necessitated the use of the upper end of indentation force for Vickers micro-hardness testing.

36 MATERIALS SCIENCE↗