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All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Common problems and pitfalls in gear design

There are several pitfalls and problems associated with the successful design of a new gear transmission. A new design will require the knowledge and experience of several technical areas of engineering. Most of the pitfalls and problems associated with a new design are related to an inadequate evaluation of several areas, such as, the lubrication and cooling requirements, complete static and dynamic load analysis, evaluation of materials and heat treatment and the latest manufacturing technology. Some of the common problems of the gear design process are discussed with recommendations made for avoiding these conditions.

Townsend, Dennis P.↗
NASA NTRS1987

Composition optimization of self-lubricating chromium-carbide-based composite coatings for use to 760 C

This paper describes new compositions of self-lubricating coatings that contain chromium carbide. A bonded chromium carbide was used as the base stock because of the known excellent wear resistance and the chemical stability of chromium carbide. Additives were silver and barium fluoride/calcium fluoride eutectic. The coating constituents were treated as a ternary system consisting of: (1) the bonded carbide base material, (2) silver, and (3) the eutectic. A study to determine the optimum amounts of each constituent was performed. The various compositions were prepared by powder blending. The blended powders were then plasma sprayed onto superalloy substrates and diamond ground to the desired coating thickness. Friction and wear studies were performed at temperatures from 25 to 760 C in helium and hydrogen. A variety of counterface materials were evaluated with the objective of discovering a satisfactory metal/coating sliding combination for potential applications such as piston ring/cylinder liner couples for Stirling engines.

Dellacorte, Chris↗
NASA NTRS1987

Evaluation of polyimide films as adhesives

A commercially available LARC-TPI film and an experimentally prepared film of LARC-TPI with 5 mol pct of 4,4-prime-oxydianiline (ODA), designated as LARC-TPI/ODA, were evaluated as thermoplastic adhesive films for bonding Ti-6Al-4V. Lap shear strength was used to evaluate the materials as adhesives. They were characterized after fracture by determining the glass transition temperature, T(g). The mode of failure is also reported. Thermal exposure at 240 C for 500 and 1000 h and a 72-h water-boil were conducted on lap shear specimens prepared with the two adhesive films. Lap shear tests were conducted at room temperature, 177 C, 204 C, and 232 C before and after exposures.

Progar, Donald J.↗
NASA NTRS1988

Evaluation of alternative phase change materials for energy storage in solar dynamic applications

The performance of fluoride salt and metallic thermal energy storage materials are compared in terms of basic performance as applied to solar dynamic power generation. Specific performance considerations include uniformity of cycle inlet temperature, peak cavity temperature, TES utilization, and system weights. Also investigated were means of enhancing the thermal conductivity of the salts and its effect on the system performance.

Crane, R. A.↗
NASA NTRS1989

Plasma torch testing for thermostructural evaluation of rocket motor nozzle materials

This paper presents data from the thermostructural testing of tape-wrapped carbon phenolic. This work has been performed with the use of a plasma torch and loading device in an effort to study the anomalous erosion characteristicfs of that seen in the Space Shuttle Solid Rocket Motor Nozzle STS-8A. Testing is conducted in an effort to determine conditions or parameters involved in this mode of failure.

Prince, Andrew S.↗
NASA NTRS1990

Friction And Wear Of Silicon Ceramics

Report presents results of experimental study of friction and wear in unlubricated sliding of silicon-based ceramics on Inconel(R) 718 nickel-based alloy. Both monolithic and fiber-reinforced ceramics tested at temperatures from 25 to 800 degrees C. Evaluates ceramic materials for potential use as cylinder liners, piston caps, and other engine parts subjected to sliding or rubbing.

Deadmore, Daniel L.↗
NASA NTRS1990

A constitutive model for the inelastic multiaxial response of Rene 80 at 871 C and 982 C

This paper contains an extension of the uniaxial state variable constitutive model of Ramaswamy et al. (1988) to the case of multiaxial loading. The correlation between uniaxial and multiaxial loading conditions is achieved through the assumptions of material isotropy and conservation of inelastic volume. The multiaxial extension is based only on the material parameters evaluated from uniaxial loading. The research is accompanied by a multiaxial experimental program to evaluate the response of Rene 80 at 871 C and 982 C. Experiments in the program include torsion, proportional axial and torsion, and nonproportional loading. It was shown experimentally that there is no extra hardening from the multiaxial loading than results from uniaxial loading. Further, it is shown that the multiaxial model is successful in predicting the experimental results using only the parameters determined from the uniaxial experiments.

Stouffer, D. C.↗
NASA NTRS1990

Physical interpretation and application of principles of ultrasonic nondestructive evaluation of high-performance materials

An ultrasonic measurement system employed in the experimental interrogation of the anisotropic properties (through the measurement of the elastic stiffness constants) of the uniaxial graphite-epoxy composites is presented. The continuing effort for the development of improved visualization techniques for physical parameters is discussed. The background is set for the understanding and visualization of the relationship between the phase and energy/group velocity for propagation in high-performance anisotropic materials by investigating the general requirements imposed by the classical wave equation. The consequences are considered when the physical parameters of the anisotropic material are inserted into the classical wave equation by a linear elastic model. The relationship is described between the phase velocity and the energy/group velocity three dimensional surfaces through graphical techniques.

Miller, James G.↗
NASA NTRS1991

High-pressure promoted combustion chamber

In the preferred embodiment of the promoted combusiton chamber disclosed herein, a thick-walled tubular body that is capable of withstanding extreme pressures is arranged with removable upper and lower end closures to provide access to the chamber for dependently supporting a test sample of a material being evaluated in the chamber. To facilitate the real-time analysis of a test sample, several pressure-tight viewing ports capable of withstanding the simulated environmental conditions are arranged in the walls of the tubular body for observing the test sample during the course of the test. A replaceable heat-resistant tubular member and replaceable flame-resistant internal liners are arranged to be fitted inside of the chamber for protecting the interior wall surfaces of the combustion chamber during the evaluation tests. Inlet and outlet ports are provided for admitting high-pressure gases into the chamber as needed for performing dynamic analyses of the test sample during the course of an evaluation test.

Rucker, Michelle A.↗
NASA NTRS1992

Monitoring Polymer Curing Via Electromagnetic Impedance

New nondestructive in-situ electromagnetic-impedance measurement technique senses cure-processing properties of high-temperature, high-performance thermostat and thermoplastic resins. Continuous frequency-dependent measurement and analysis performed during curing cycle. Monitors and measures molecular properties of polymeric resin in liquid and solid states. Applications include nondestructive means for evaluation of materials, determination of "window" boundaries of curing cycles of thermoplastics and thermoset resins, and for online, closed-loop control of curing cycles.

Freeman, William T.↗
NASA NTRS1992

Thermal conductance of two interface materials and their applications in space systems

The temperature control of spacecraft and instrument systems and subsystems requires heat transfer interface materials that possess good thermal and structural characteristics, among other properties, to respond to the vacuum environment of space. These materials must be easy to apply to, and remove from, the surfaces where they are applied, and must be able to withstand power dissipation extremes, and be used for different clamping configurations and pressures. Silicone based greases, used in the past, tend to migrate and to contaminate nearby surfaces. Bare metal to metal contact offers low thermal conductance and difficulties in estimating the actual heat transfer. Several polymeric materials containing different thermal conductive compounds and structural reinforcements were prepared to overcome grease and metal problems. Two polymeric materials were evaluated: Cho-Therm 1671 elastomer; and the CV-2946, a conductive RTV silicone. Tests were done to learn more about these products. Results indicate that the tightly bolted, torqued fixtures did not buckle or distort, and provided optimum thermal conductance. Fixtures simulating actual spacecraft configuration suffered bowing and separating.

Scialdone, J. J.↗
NASA NTRS1992

Invacuo tribological evaluation of coarse-pitch gears for use on the Space Station alpha joint

Existing invacuo or ambient test data of slow-speed (less than 30 meters/minute pitch line velocity), coarse-pitch gears could not be found suitable for use in evaluating gear materials and surface treatments for the gear-driven bearing race of the Solar Alpha Rotary Joint (SARJ) for Space Station Freedom (SSF). Gear testing was conducted by AEC-Able Engineering Company, Inc. to obtain design data for this critical SSF component. Some bull gear/pinion/lubrication combinations endured over 600,000 cycles (100 SSF years) without measurable wear, while other combinations experienced surface treatment degradation after only 40,000 cycles (seven SSF years). No catastrophic failures, such as seizing or tooth breakage, occurred during any test, all of which were run at least 201,000 cycles (34.5 SSF years). Specific results such as debris characteristics, mechanical efficiencies, effectiveness and degradation of lubrication, and wear data for the various gear combinations tested are described.

Allen, Scotty R.↗
NASA NTRS1992

The evaluation of GOES black paint materials

The purpose of this paper is to study the contamination effect of black paint materials on the GOES instrument performance. The GOES spacecraft materials were originally selected for their low outgassing properties. Samples of the materials were tested according to the ASTM E-595 test method to fulfill the total mass loss and collected volatile condensable materials criteria for traditional spacecraft material selection. Due to the instrument design, the cavity will experience high temperatures during operation greater than the specified temperature in the ASTM test. As a result of this high cavity temperature, normally stable paint materials on the painted surface may severely outgas even though they have passed the ASTM test. Further enhancement of the contaminant remaining on the mirror by UV irradiation is also a great consideration. This concern prompted an investigation into the outgassing characteristics of the black paints at the predicted operating temperatures.

Chen, Philip T.↗
NASA NTRS1992

Momentum distribution in debris cloud during hypervelocity impact

The long term operation of the Space Station Freedom requires a scheme to protect it from high velocity impacts by both man-made particles and micrometeor fragments. One such scheme is the use of metal plates to serve as shields against such orbital debris. These 'bumper' plates, as they are referred to, serve to break up any incident particle and redistribute its momentum over a larger area. It is therefore necessary to determine the momentum distribution within the debris cloud produced by such collisions in order to evaluate a materials effectiveness at accomplishing this task. This paper details the design and development of an innovative device which has made this possible. Momentum profiles were obtained for a series of test conditions. Total momentum values in the debris cloud were then calculated from these profiles. These results indicated that a momentum amplification exists with a multiplication factor of between 2 and 3. Thus the role of the bumper to serve as a means for momentum redistribution and not reduction was verified.

Lemaster, P.↗
NASA NTRS1992

Improved ablative materials for the ASRM nozzle

Rayon precursor carbon-cloth phenolic was developed more than 30 years ago and is used in most nozzles today including the Poseidon, Trident, Peacekeeper, Small ICBM, Space Shuttle, and numerous tactical and space systems. Specifications and manufacturing controls were placed on these materials and, once qualified, a no-change policy was instituted. The current material is acceptable; however, prepreg variability does not always accommodate the requirements of automation. The advanced solid rocket motor requires material with less variability for automated manufacturing. An advanced solid rocket motor materials team, composed of NASA, Thiokol, Aerojet, SRI, and Lockheed specialists, along with materials suppliers ICI Fiberite/Polycarbon, BP Chemicals/Hitco, and Amoco, embarked on a program to improve the current materials. The program consisted of heat treatment studies and standard and low-density material improvements evaluation. Improvements evaluated included fiber/fabric heat treatments, weave variations, resin application methods, process controls, and monitors.

Canfield, A.↗
NASA NTRS1992

New materials drive high-performance aircraft

This report shows how advanced composite materials and new processing methods are enabling lighter, lower cost aircraft structures. High-temperature polymers research will focus on systems capable of 50,000 to 100,000 hours of operation in the 212-400 F temperature range. Prospective materials being evaluated include high-temperature epoxies, toughened bismaleimides, cyanates, thermoplastics, polyimides and other polymers.

Ruhmann, Douglas C.↗
NASA NTRS1993

Thermal certification tests of Orbiter Thermal Protection System tiles coated with KSC coating slurries

Thermal tests of Orbiter thermal protection system (TPS) tiles, which were coated with borosilicate glass slurries fabricated at Kennedy Space Center (KSC), were performed in the Radiant Heat Test Facility and the Atmospheric Reentry Materials & Structures Evaluation Facility at Johnson Space Center to verify tile coating integrity after exposure to multiple entry simulation cycles in both radiant and convective heating environments. Eight high temperature reusable surface insulation (HRSI) tiles and six low temperature reusable surface insulation (LRSI) tiles were subjected to 25 cycles of radiant heat at peaked surface temperatures of 2300 F and 1200 F, respectively. For the LRSI tiles, an additional cycle at peaked surface temperature of 2100 F was performed. There was no coating crack on any of the HRSI specimens. However, there were eight small coating cracks (less than 2 inches long) on two of the six LRSI tiles on the 26th cycle. There was practically no change on the surface reflectivity, physical dimensions, or weight of any of the test specimens. There was no observable thermal-chemical degradation of the coating either. For the convective heat test, eight HRSI tiles were tested for five cycles at a surface temperature of 2300 F. There was no thermal-induced coating crack on any of the test specimens, almost no change on the surface reflectivity, and no observable thermal-chemical degradation with an exception of minor slumping of the coating under painted TPS identification numbers. The tests demonstrated that KSC's TPS slurries and coating processes meet the Orbiter's thermal specification requirements.

Milhoan, James D.↗
NASA NTRS1991

An Isotope-Powered Thermal Storage unit for space applications

An Isotope-Powered Thermal Storage Unit (ITSU), that would store and utilize heat energy in a 'pulsed' fashion in space operations, is described. Properties of various radioisotopes are considered in conjunction with characteristics of thermal energy storage materials, to evaluate possible implementation of such a device. The utility of the unit is discussed in light of various space applications, including rocket propulsion, power generation, and spacecraft thermal management.

Lisano, Michael E.↗