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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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Method maintains cleanliness of joint-sealing surfaces under dust-laden conditions. This is accomplished by keeping seal and sealing surface covered with sliding plastic rings, which slide out of the way when a joint is seated.
Two phases have been completed, of a program whose ultimate objective is the development of an alkali metal resistant, thermal shock resistant, leak-tight, and neutron radiation resistant ceramic-to-metal seal capable of operation at 1200 C for three to five years. The first phase involved the screening of platinum-base, vanadium-base and vanadium-niobium base brazes for the joining of Cb-1Zr or T-111 alloys to high purity alumina. The second phase involved studies of the performance of sealed capsule samples during 5000-hour aging tests at 800, 1000, and 1200 C in high vacuum. Sealed capsules which were made using pure vanadium braze, and were brazed at 1850 C for one minute, survived 64 thermal cycles to 1200 C at the heating/cooling rate of 100 C/minute. Vanadium braze samples survived 5000-hour aging tests at 800, 1000, and 1200 C. One thermally cycled sample survived a subsequent 5000-hour aging period at 1000 C, but another, at 1200 C, did not survive. It was concluded that a pure vanadium braze used to bond high purity alumina to Cb-1Zr alloy is the best of the systems studied, but that additional studies must be performed to establish its service temperature limitations for the desired three to five years' service.
The load factor is investigated for subsonic and choked flow conditions, laminar and turbulent flows, and various seal entrance conditions. Both parallel sealing surfaces and surfaces with small linear deformation were investigated. The load factor for subsonic flow depends strongly on pressure ratio; under choked flow conditions, however the load factor is found to depend more strongly on film thickness and flow entrance conditions rather than pressure ratio. The importance of generating hydrodynamic forces to keep the seal balanced under severe and multipoint operation is also discussed.
Comparative tests of modified and unmodified carbon ring seals showed that addition of helical grooves to conventional segmented carbon ring seals reduced leakage significantly. Modified seal was insensitive to shaft runout and to flooding by lubricant.
Space shuttle orbiter elevon effectiveness was measured with the 6 inch elevon/elevon and elevon/fuselage gaps and various configurations of wing/elevon upper hingeline gap sealing flapper doors. The elevon configuration parametric variations consisted of sealing the lower hingeline to prevent flow-through and testing a long chord flapper door, a short chord flapper door, no flapper door (elevon/wing gap upper hingeline completely open), and a completely sealed elevon at elevon deflections from +20 deg to -40 deg. Preliminary data analysis indicates loss of elevon effectiveness at deflections more negative than -20 deg, and little or no effect of flapper door configuration on elevon effectiveness. Flow visualization photographs taken at alpha = 15 deg for two flapper door configurations substantiated the force data results. Aerodynamic force and moment data were measured in the body axis by a 2.5 inch task type internal strain gage balance. The model was sting supported through the base region with a nominal angle of attack range of -10 deg less than or equal to alpha less than or equal to 24 deg at a model angle of sideslip of Beta equal to 0 deg.
The work to correct several design deficiencies present in the bearings used in the orbital extravehicular spacesuit is reported. These deficiencies included: difficult stitch-on interface between fabric and outer race; a tendency for the clamping threads to seize; and, most importantly, the failure of the sealing surfaces (Teflon seat, Delrin seal) to maintain integrity with cycling. The first problem was corrected by raising the stitch-on holes so as to be more accessible. The seizing was eliminated by changing to a coarser thread, from 32/inch to 24/inch. The solution to the sealing problem required a materials evaluation, candidate material selection, and adhesive evaluation (for bonding the seat material to the outer race) and bench-cycling of candidate seal/seat combinations. The final configuration, successfully bench-cycled and delivered to NASA, is shown.
A number of 20 Ah and 3 Ah negative limited nickel-cadmium cells were fabricated and assembled in hermetically sealed stainless steel containers. The cells exhibit a large voltage rise signal, in excess of 250 mA, at the end of each charge period. They also exhibit lower self discharge rates than conventional sealed nickel-cadmium cells and do not require overcharge. The cells are capable of operating at charge and discharge rates up to 5C and can deliver at least 1000 cycles on a 30 minute regime at 25% DOD. A small amount of gassing occurs, but is not deemed critical or detrimental in view of the facts that, (1) operating pressures are in the range of 7 to 20 psig and (2) the cells are operated in the flooded condition so therefore contain little internal void volume. The cells were found to exhibit somewhat higher capacity loss rates during cycling than conventional sealed nickel-cadmium batteries.
Textbook covers fundamentals of fluid sealing. Included are seal performance parameters and seal operating regimes.
Blood volume and body composition for diving and nondiving harbor seals were measured at six-week intervals during a 10-month period of captitivity. Whole body hematocrit, red cell volume per kg of lean body mass, and total circulating hemoglobin per kg lean body mass were significantly higher in the diving group, but relatively large blood volumes expressed in terms of body weight (11-12%) were found in both groups. A pair of harbor seals exposed to high altitude for about three months registered significant increases in red cell volume, blood hemoglobin levels, and blood volume expressed in terms of body weight; results of alveolar gas analyses indicate that hyperventilation also occurred. These typical mammalian responses to hypoxia suggest that the harbor seal's large blood volume and high hemoglobin content are an expression of phylogenetic control, and that in spite of its adaptability to apnea during its diving life, the animal cannot be considered preacclimatized to high altitude.
The Space Shuttle carries more than 500,000 kg of liquid oxygen (LO2) and 100,000 kg of liquid hydrogen (LH2) propellant. Seals for this main propellant system therefore must provide extremely high reliability under prolonged service at cryogenic temperatures. The chief threat to consistently reliable operation is not the cryogenic service itself, but the 325 K temperature variation encountered during each individual mission. Moreover, this reliability must be sustained during the entire 100-mission/ten-year projected life of the Space Shuttle. It was feared that conventional liquid oxygen seal materials (filled Teflon and Kel-F) could cold flow or compression set to such an extent during the high-temperature phases of the 100 successive missions that failures could result. Thus, in addition to LO2 compatibility and cryogenic serviceability, this program was directed toward seals that were not thermoplastic and had good compression set resistance
Knife-edge sealing technique forms reliable, vacuum-tight bonds between materials having very different thermal-expansion characteristics. Seal is thin and flexible and absorb shear, hoop, and bonding stresses at joint so that seal remains vacuum tight.
Several experimental concepts representing potential high pressure turbine seal material systems were subjected to cyclic thermal shock exposures similar to those that might be encountered under severe engine start-up and shut-down sequences. All of the experimental concepts consisted of plasma-sprayed yttria stabilized ZrO2 on the high temperature side of the blade tip seal shroud. Between the ZrO2 and a cooled, dense metal backing, various intermediate layer concepts intended to mitigate thermal stresses were incorporated. Performance was judged on the basis of the number of thermal shock cycles required to cause loss of seal material through spallation. The most effective approach was to include a low modulus, sintered metal pad between the ZrO2 and the metallic backing. It was also found that reducing the density of the ZrO2 layer significantly improved the performance of specimens with plasma-sprayed metal/ceramic composite intermediate layers.
Residual gas analysis techniques were employed to measure the moisture in sealed hybrid packages as a function of substrate attach material, vacuum bake time and sequence, and sealing procedure. It is shown that when room atmospheric exposure is eliminated following the vacuum bakeout moisture levels of less than 1000 ppm may be achieved for modest bake times and solder substrate attach techniques. Suitable moisture levels were achieved for epoxy attached substrates only when seam sealing procedures were employed.
A systematic study was performed to evaluate the suitability of adhesives for sealing hybrid packages. Selected adhesives were screened on the basis of their ability to seal gold-plated Kovar butterfly-type packages that retain their seal integrity after individual exposures to increasingly severe temperature-humidity environments. Tests were also run using thermal shock, temperature cycling, mechanical shock and temperature aging. The four best adhesives were determined and further tested in a 60 C/98% RH environment and continuously monitored in regard to moisture content. Results are given, however, none of the tested adhesives passed all the tests.
A system for sealing vacuum baked hybrids in a dry inert atmosphere using an overlapping spot resistance weld is described. A unique electrode configuration and fixturing that permits sealing of large and irregularly shaped gold plated Kovar packages to the hermeticity requirements of MIL-STD-883 was discussed. Metallurgical considerations and comparisons to laser sealing were made. Problems encountered during the development and optimization of the process were highlighted. Solutions to plating, fixturing, warpage, weld splatter and cracked bead problems are presented.
Two strength level variations of sintered NiCrAl (about 40 percent dense), candidate high pressure turbine seal materials, were subject to rub tolerance testing against AM 355 steel blade tips. The high strength material (17 N/sq mm tensile strength) showed frictional and radial loads that were 20 to 50 percent higher than those measured for the low strength material (15.5 N/ sq mm tensile strength). Measured wear to the AM 355 blade tips was not significantly different for the two sintered NiCrAl seal materials. Wear of the sintered NiCrAl was characterized by material removal to a depth greater than the depth to which blade tips were driven into the seal, indicating self-erosion effects.
The development of a static seal configuration to meet the lightweight low-leakage requirements of the Space Shuttle Main Engine (pressure carrying capability of up to 75.84 MPa) is discussed. The design features, fabrication methods, lab testing, and performance of seal are examined. Flange and bolt details of the joint assembly are considered with attention to an ultrasonic technique for measuring preload in the bolts. Methods used for leak testing in the laboratory and in the field are described; the practicality of the procedures is considered. Attention is directed to hydrogen-environment embrittlement and its influence on seal and joint design.