Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “durable”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,045 records · Page 58
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Advances in Composites Technology

A significant level of research is currently focused on the development of tough resins and high strain fibers in an effort to gain improved damage tolerance. Moderate success has been achieved with the development of new resins such as PEEK and additional improvements look promising with new thermoplastic resins. Development of innovative material forms such as 2-D and 3-D woven fabrics and braided structural subelements is also expected to improve damage tolerance and durability of composite hardware. The new thrust in composites is to develop low cost manufacturing and design concepts to lower the cost of composite hardware. Processes being examined include automated material placement, filament winding, pultrusion, and thermoforming. The factory of the future will likely incorporate extensive automation in all aspects of manufacturing composite components.

Tenney, D. R.↗
NASA NTRS1984

Electric utility acid fuel cell stack technology advancement

The principal effort under this program was directed at the fuel cell stack technology required to accomplish the initial feasibility demonstrations of increased cell stack operating pressures and temperatures, increased cell active area, incorporation of the ribbed substrate cell configuration at the bove conditions, and the introduction of higher performance electrocatalysts. The program results were successful with the primary accomplishments being: (1) fabrication of 10 sq ft ribbed substrate, cell components including higher performing electrocatalysts; (2) assembly of a 10 sq ft, 30-cell short stack; and (3) initial test of this stack at 120 psia and 405 F. These accomplishments demonstrate the feasibility of fabricating and handling large area cells using materials and processes that are oriented to low cost manufacture. An additional accomplishment under the program was the testing of two 3.7 sq ft short stacks at 12 psia/405 F to 5400 and 4500 hours respectively. These tests demonstrate the durability of the components and the cell stack configuration to a nominal 5000 hours at the higher pressure and temperature condition planned for the next electric utility power plant.

Congdon, J. V.↗
NASA NTRS1984

An investigation of enhanced capability thermal barrier coating systems for diesel engine components

Material systems and processes for the development of effective and durable thermal barriers for heavy duty diesel engines were investigated. Seven coating systems were evaluated for thermal conductivity, erosion resistance, corrosion/oxidation resistance, and thermal shock resistance. An advanced coating system based on plasma sprayed particle yttria stabilized zirconia (PS/HYSZ) was judged superior in these tests. The measured thermal conductivity of the selected coating was 0.893 W/m C at 371 C. The PS/HYSZ coating system was applied to the piston crown, fire deck and valves of a single cylinder low heat rejection diesel engine. The coated engine components were tested for 24 hr at power levels from 0.83 MPa to 1.17 MPa brake mean effective pressure. The component coatings survived the engine tests with a minimum of distress. The measured fire deck temperatures decreased 86 C (155 F) on the intake side and 42 C (75 F) on the exhaust side with the coating applied.

Holtzman, R. L.↗
NASA NTRS1984

Thermal barrier coating system

A high temperature oxidation resistant, thermal barrier coating system is disclosed for a nickel cobalt, or iron base alloy substrate. An inner metal bond coating contacts the substrate, and a thermal barrier coating covers the bond coating. NiCrAlR, FeCrAlR, and CoCrAlR alloys are satisfactory as bond coating compositions where R=Y or Yb. These alloys contain, by weight, 24.9-36.7% chromium, 5.4-18.5% aluminum, and 0.05 to 1.55% yttrium or 0.05 to 0.53% ytterbium. The coatings containing ytterbium are preferred over those containing yttrium. An outer thermal barrier coating of partial stabilized zirconium oxide (zirconia) which is between 6% and 8%, by weight, of yttrium oxide (yttria) covers the bond coating. Partial stabilization provides a material with superior durability. Partially stabilized zirconia consists of mixtures of cubic, tetragonal, and monoclinic phases.

Stecura, S.↗
NASA NTRS1984

Advanced thin film thermocouples

The fabrication, materials characterization, and performance of thin film platinum rhodium thermocouples on gas turbine alloys was investigated. The materials chosen for the study were the turbine blade alloy systems MAR M200+Hf with NiCoCrAlY and FeCrAlY coatings, and vane alloy systems MAR M509 with FeCrAlY. Research was focussed on making improvements in the problem areas of coating substrate stability, adhesion, and insulation reliability and durability. Diffusion profiles between the substrate and coating with and without barrier coatings of Al2O3 are reported. The relationships between fabrication parameters of thermal oxidation and sputtering of the insulator and its characterization and performance are described. The best thin film thermocouples were fabricated with the NiCoCrAlY coatings which were thermally oxidized and sputter coated with Al2O3.

Kreider, K. G.↗
NASA NTRS1985

Cyclic structural analyses of anisotropic turbine blades for reusable space propulsion systems

Turbine blades for reusable space propulsion systems are subject to severe thermomechanical loading cycles that result in large inelastic strains and very short lives. These components require the use of anisotropic high-temperature alloys to meet the safety and durability requirements of such systems. To assess the effects on blade life of material anisotropy, cyclic structural analyses are being performed for the first stage high-pressure fuel turbopump blade of the space shuttle main engine. The blade alloy is directionally solidified MAR-M 246 alloy. The analyses are based on a typical test stand engine cycle. Stress-strain histories at the airfoil critical location are computed using the MARC nonlinear finite-element computer code. The MARC solutions are compared to cyclic response predictions from a simplified structural analysis procedure developed at the NASA Lewis Research Center.

Manderscheid, J. M.↗
NASA NTRS1985

Rocket thrust chamber thermal barrier coatings

Subscale rocket thrust chamber tests were conducted to evaluate the effectiveness and durability of thin yttria stabilized zirconium oxide coatings applied to the thrust chamber hot-gas side wall. The fabrication consisted of arc plasma spraying the ceramic coating and bond coat onto a mandrell and then electrodepositing the copper thrust chamber wall around the coating. Chambers were fabricated with coatings .008, and .005 and .003 inches thick. The chambers were thermally cycled at a chamber pressure of 600 psia using oxygen-hydrogen as propellants and liquid hydrogen as the coolant. The thicker coatings tended to delaminate, early in the cyclic testing, down to a uniform sublayer which remained well adhered during the remaining cycles. Two chambers with .003 inch coatings were subjected to 1500 thermal cycles with no coating loss in the throat region, which represents a tenfold increase in life over identical chambers having no coatings. An analysis is presented which shows that the heat lost to the coolant due to the coating, in a rocket thrust chamber design having a coating only in the throat region, can be recovered by adding only one inch to the combustion chamber length.

Quentmeyer, R. J.↗
NASA NTRS1985

Vacuum plasma coatings for turbine blades

Turbine blades, vacuum plasma spray coated with NiCrAlY, CoCrAlY or NiCrAlY/Cr2O3, were evaluated and rated superior to standard space shuttle main engine (SSME) coated blades. Ratings were based primarily on 25 thermal cycles in the MSFC Burner Rig Tester, cycling between 1700 F (gaseous H2) and -423 F (liquid H2). These tests showed no spalling on blades with improved vacuum plasma coatings, while standard blades spalled. Thermal barrier coatings of ZrO2, while superior to standard coatings, lacked the overall performance desired. Fatigue and tensile specimens, machined from MAR-M-246(Hf) test bars identical to the blades were vacuum plasma spray coated, diffusion bond treated, and tested to qualify the vacuum plasma spray process for flight hardware testing and application. While NiCrAlY/Cr2O3 offers significant improvement over standard coatings in durability and thermal protection, studies continue with an objective to develop coatings offering even greater improvements.

Holmes, R. R.↗
NASA NTRS1985

Material technology

Advanced high pressure O2/H2 propulsion systems as exemplified by the Space Shuttle Main Engine (SSME) create challenging operating environments for materials. Many components operate in either hydrogen or hydrogen-steam environments which may significantly degrade the performance of common alloys. The objective of the materials technology projects is to develop and evaluate candidate materials for application in advanced high pressure O2/H2 propulsion systems. These new and improved materials are to improve the durability or performance of the SSME or derivative engine. The program includes projects on the following topics: (1) Hydrogen Resistant Alloys; (2) High Pressure O2 Ignition and Burning; (3) Improved Turbine Blades; (4) Improved Turbine Disk Material; (5) Impact Reactivity in High Pressure O2; and Fiber Reinforced Superalloys.

Dreshfield, R. L.↗
NASA NTRS1985

Bearings working group

The service life of the Space Shuttle Main Engine (SSME) turbomachinery bearings was a predominant factor in engine durability and maintenance problems. Recent data has indicated that bearing life is about one order of magnitude lower than the goal of seven and one-half hours particularly those in the High Pressure Oxidizer Turbopump (HPOTP). Bearing technology, primarily cryogenic turbomachinery bearing technology, is expanded by exploring the life and performance effects of design changes; design concept changes; materials changes; manufacturing technique changes; and lubrication system changes. Each variation is assessed against the current bearing design in full scale cryogenic tests.

Source record↗
NASA NTRS1985

Analytical study of flow phenomena in SSME turnaround duct geometries

The SSME fuel turbopump hot gas manifold was identified as a source of loss and flow distortion which significantly affects the performance and durability of both the drive turbine and the LOX injector area of the main combustion chamber. Two current SSME geometries were studied, the full power level (FPL) and the first manned orbital flight (FMOF) configuration. The effects of turnaround duct geometry on flow losses and distortions, by varying wall curvature and flow area variation in the 180 deg turnaround region were examined. The effects of the duct inlet flow phenomena such as the radial distortion of the inlet flow and inlet swirl level on turnaround duct performance were also investigated. It is shown that of the two current geometries, the FMOF configuration had lower pressure losses and generated less flow distortion, but had a small flow separation bubble at the 180 deg turnaround exit. It is found that by optimizing wall curvature and flow diffusion in the turnaround, improved duct performance can be achieved.

Mclallin, K. L.↗
NASA NTRS1985

Overview of Aerothermodynamic Loads Definition Study

The Aerothermodynamic Loads Definition were studied to develop methods to more accurately predict the operating environment in the space shuttle main engine (SSME) components. Development of steady and time-dependent, three-dimensional viscous computer codes and experimental verification and engine diagnostic testing are considered. The steady, nonsteady, and transient operating loads are defined to accurately predict powerhead life. Improvements in the structural durability of the SSME turbine drive systems depends on the knowledge of the aerothermodynamic behavior of the flow through the preburner, turbine, turnaround duct, gas manifold, and injector post regions.

Povinelli, L. A.↗
NASA NTRS1985

SSME Fuel Preburner Two-dimensional Analysis

The durability of the SSME turbine is strongly affected by the temperature profile leaving the preburner. A reacting flow computer model to predict the turbine inlet temperature profile was used. Calculations were made by using a reacting flow code, to assess the sensitivity of the turbine inlet temperature profile to variations in the flow entering the SSME preburner.

Thomas J. Vanoverbeke↗
NASA NTRS1985

Simulation of Multistage Turbine Flows

The numerical simulation of turbine flows serves to enhance the understanding of the flow phenomena within multistage turbomachinery components. The direct benefit of this activity is improved modeling capability, which can be used to improve component efficiency and durability. A hierarchy of equations was formulated to assess the difficulty in analyzing the flow field within multistage turbomachinery components. The Navier-Stokes equations provides the most complete description. The simplest description is given by a set of equations that govern the quasi-one-dimensional flow. The number of unknowns to be solved for increases monotonically above the number of equations. The development of the additional set of equations needed to mathematically close the system of equations forms the closure problem associated with that level of description. For the Navier-Stokes equation there is no closure problem. For the quasi-one-dimensional equation set random flow fluctuations, unsteady fluctuations, nonaxisymmetric flow variations, and hub-to-shroud variations on the quasi-one-dimensional flow must be accounted for.

Celestina, M. L.↗
NASA NTRS1985

Probabilistic Structural Analysis Theory Development

The objective of the Probabilistic Structural Analysis Methods (PSAM) project is to develop analysis techniques and computer programs for predicting the probabilistic response of critical structural components for current and future space propulsion systems. This technology will play a central role in establishing system performance and durability. The first year's technical activity is concentrating on probabilistic finite element formulation strategy and code development. Work is also in progress to survey critical materials and space shuttle mian engine components. The probabilistic finite element computer program NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) is being developed. The final probabilistic code will have, in the general case, the capability of performing nonlinear dynamic of stochastic structures. It is the goal of the approximate methods effort to increase problem solving efficiency relative to finite element methods by using energy methods to generate trial solutions which satisfy the structural boundary conditions. These approximate methods will be less computer intensive relative to the finite element approach.

Burnside, O. H.↗
NASA NTRS1985

Cyclic Structural Analyses of SSME Turbine Blades

The problems of calculating the structural response of high-temperature space propulsion components such as turbine blades for the fuel turbopump are addressed. The first high-pressure-stage fuel turbine blade (HPFTB) in the liquid-hydrogen turbopump of the space shuttle main engine (SSME) was selected for this study. In the past these blades have cracked in the blade shank region and at the airfoil leading edge adjacent to the platform. To achieve the necessary durability, these blades are currently being cast by using directional solidification. Single-crystal alloys are also being investigated for future SSME applications. The study evaluated the utility of advanced structural analysis methods in assessing the low-cycle fatigue lives of these anisotropic components. The turbine blade airfoil of the high-pressure stage of the SSME fuel turbopump was analyzed because it has a history of rapid crack initiation.

Kaufman, A.↗
NASA NTRS1985

Thin-film Sensors for Space Propulsion Technology

SSME components such as the turbine blades of the high pressure fuel turbopump are subjected to rapid and extreme thermal transients that contribute to blade cracking and subsequent failure. The objective was to develop thin film sensors for SSME components. The technology established for aircraft gas turbine engines was adopted to the materials and environment encountered in the SSME. Specific goals are to expand the existing thin film sensor technology, to continue developing improved sensor processing techniques, and to test the durability of aircraft gas turbine engine technology in the SSME environment. A thin film sensor laboratory is being installed in a refurbished clean room, and new sputtering and photoresist exposure equipment is being acquired. Existing thin film thermocouple technology in an SSME environment are being tested. Various coatings and their insulating films are being investigated for use in sensor development.

Kim, W. S.↗
NASA NTRS1985

Optical Strain Measurement System Development

Investigations of physical phenomena affecting the durability of SSME components require measurement systems operational in hostile environments. The need for such instrumentation caused the definition and operation of an optical strain measurement system. This optical strain measurement system based on the speckle shift method is being developed. This is a noncontact, automatic method of measuring surface strain in one dimension that corrects for error due to rigid body motion. It provides a gauge length of 1 to 2 mm and allows the region of interest on the test specimen to be mapped point by point. The output is a graphics map of the points inspected on the specimen; data points is stored in quasi-real time. This is the first phase of a multiphase effort in optical strain measurement. The speckle pattern created by the test specimen is interpreted as high order interference fringes resulting from a random diffraction grating, being the natural surface roughness of the specimen. Strain induced on the specimen causes a change in spacing of the surface roughness, which in turn shifts the position of the interference pattern (speckles).

Lant, C. T.↗