Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “SURFACE FINISH”

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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1974

Effect of surface topography on structural growth of thick sputtered films

Primarily thick sputtered S-Monel, silver, and 304 stainless steel coatings were deposited on mica, glass, and metal substrates with various surface finishes to investigate the structural growth of the coating by scanning electron microscopy. Compositional changes within the coating were analyzed by X-ray dispersion microscopy. Defects in the surface finish act as preferential nucleation sites and form isolated and complex nodules and various surface overgrowths in the coating. These nodules do not disappear after full annealing. Further, they have undesirable effects on mechanial properties; cracks are initiated at the nodules when the coating is stressed by mechanical forces. These effects are illustrated by micrographs. Nodular growth within a coating can be minimized or eliminated by reducing the surface roughness.

Spalvins, T.↗
NASA NTRS2007

Materials Database Development for Ballistic Impact Modeling

A set of experimental data is being generated under the Fundamental Aeronautics Program Supersonics project to help create and validate accurate computational impact models of jet engine impact events. The data generated will include material property data generated at a range of different strain rates, from 1x10(exp -4)/sec to 5x10(exp 4)/sec, over a range of temperatures. In addition, carefully instrumented ballistic impact tests will be conducted on flat plates and curved structures to provide material and structural response information to help validate the computational models. The material property data and the ballistic impact data will be generated using materials from the same lot, as far as possible. It was found in preliminary testing that the surface finish of test specimens has an effect on measured high strain rate tension response of AL2024. Both the maximum stress and maximum elongation are greater on specimens with a smoother finish. This report gives an overview of the testing that is being conducted and presents results of preliminary testing of the surface finish study.

Pereira, J. Michael↗
DOE OSTI2019

Roughness Reduction of Additively Manufactured Steel by Electropolishing

Improving surface finishing is the critical step in the application of an additively manufactured (AM) component in high fatigue and corrosion-sensitive fields. This paper provides insights into surface properties of electropolished AM component made up of 316 stainless steel with > 6% carbon. We performed surface analysis with profilometer, scanning electron microscope, and AFM to investigate the electropolished and unpolished AM components. The first major discovery of the present work is that our optical profilometry study provided an estimate of the amount of material to be removed to achieve a shiny and smooth surface on 316 stainless steel AM part. One needs to remove more than 200 μm thick layer from the surface to make a mirror-smooth surface. Such estimation can enable researchers to incorporate requisite tolerance during the design stage itself. The second important finding of our work is that ultrasmooth microstructure on the AM surface appeared when preferential material removal occurred along the boundary of the hexagonal microscopic features. Additionally, our optical profilometry studies provided an analysis of several roughness parameters on the electropolished surface. Electropolishing was effective in reducing the surface roughness below ~ 0.1 μm RMS over microscopic regions. Observation of sub-μm RMS roughness was consistently observed with the optical profilometer, SEM, and AFM. SEM study revealed a significant change in the microstructure of the electropolished samples in a medium and highly smooth state. Here, we also conducted a water contact angle study and spectroscopic reflectance study on electropolished and unpolished AM component surfaces. Our study revealed that electropolishing is a highly promising route for improving the surface finishing of AM components.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Improvement in surface fatigue life of hardened gears by high-intensity shot peening

Two groups of carburized, hardened, and ground spur gears that were manufactured from the same heat vacuum induction melted vacuum arc melted (VIM VAR) AISI 9310 steel were endurance tested for surface fatigue. Both groups were manufactured with a standard ground 16 rms surface finish. One group was subjected to a shot peening (SP) intensity of 7 to 9A, and the second group was subjected to a SP intensity of 15 to 17A. All gears were honed after SP to a surface finish of 16 rms. The gear pitch diameter was 8.89 cm. Test conditions were a maximum Hertz stress of 1.71 GPa, a gear temperature of 350 K, and a speed of 10000 rpm. The lubricant used for the tests was a synthetic paraffinic oil with an additive package. The following results were obtained: The 10 pct. surface fatigue (pitting) life of the high intensity (15 to 17A) SPed gears was 2.15 times that of the medium intensity (7 to 9A) SPed gears, the same as that calculated from measured residual stress at a depth of 127 microns. The measured residual stress for the high intensity SPed gears was 57 pct. higher than that for the medium intensity SPed gears at a depth of 127 microns and 540 pct. higher at a depth of 51 microns.

Townsend, Dennis P.↗
NASA NTRS1986

Thermal conductance of pressed brass contacts at liquid helium temperatures

An apparatus has been designed and fabricated which will measure the thermal conductance of pressed contacts at liquid helium temperatures as a function of applied force, with surface finish as a parameter. The apparatus is automated and was used to measure thermal conductance at temperatures from 1.5 to 6.5 K at applied forces up to 700 N for brass sample pairs having surface finishes from 0.1 to 1.6 micron rms. The experimental data were found to fit a simple power law where the thermal conductance is given by k = alpha T exp n, where k is the thermal conductance, T is the absolute temperature, and alpha and n are empirically determined constants.

Salerno, L. J.↗
NASA NTRS1990

NOVA 201 ultrasonic thickness gage (NOVA Gage)

The measurement integrity of the NOVA 201 digital ultrasonic thickness gage (NOVA gage) was demonstrated by comparing the NOVA gage measurements to the thickness gage measurements, and determining the bias and uncertainty of the NOVA gage when measuring redesigned solid rocket motor (RSRM) hardware per engineering test plans (ETP). The NOVA gage was tested by three different operators on steel and aluminum RSRM hardware for wall thickness. The results show that the measurement bias is not consistent. The uncertainty of the bias is caused by the heterogeneous material properties of the RSRM components that influence the time of flight of ultrasonic waves. The measurement uncertainty inherent to the design and operation of the NOVA gage is less in comparison to the uncertainty of the bias. The total measurement uncertainty cannot be substantially reduced by taking more than one measurement. There is no correlation between bias and the surface finish range of this test unless 3-in-One oil is used as a couplant, in which case there appears to be a slight trend. There is no correlation between uncertainty and the surface finish range. The measurement uncertainty of the NOVA gage can be reduced using 3-in-One oil as a couplant.

Garecht, Diane↗
NASA NTRS1993

Fuel injector design for high temperature aircraft engine

The objective of the Innovative High Temperature Aircraft Engine Fuel Nozzle Program was to design and evaluate a nozzle capable of operating at a combustor inlet air temperature of 1600 F (1144 K) and a fuel temperature of 350 F (450 K). The nozzle was designed to meet the same performance requirements and fit within the size envelope of a current production dual orifice fuel nozzle. The design approach was to use improved thermal protection and fuel passage geometry in combination with fuel passage surface treatment to minimize coking at these extreme fuel and air temperatures. Heat transfer models of several fuel injector concepts were used to optimize the thermal protection, while sample tube coking tests were run to evaluate the effect of surface finish, coatings and tube material on the coking rate. Based on heat transfer analysis, additional air gaps, reduced fuel passage flow area and use of ceramic tip components reduced local fuel wetted wall temperatures by more than 200 F (100 K) when compared to a current production fuel nozzle. Sample tube coking test results showed the importance of surface finish on the fuel coking rate. Therefore, a one micro-inch (0.025 micron) roughness was specified for all fuel passage surfaces. A novel flow divider valve in the tip was also employed to reduce weight, allow room for additional thermal protection, and provide back pressure to reduce the risk of fuel vaporization. The fuel nozzle was fabricated and evaluated in a series of high temperature coking tests. Initial results of these tests indicate that thermal protection and surface treatments were partially successful in preventing nozzle fouling, but additional refinement of the internal flowpath is needed to prevent buildup of coke particles that partially blocked the spin slots which meter the nozzle fuel flow.

R. W. Stickles↗
NASA NTRS2005

The Effect of Ultrapolish on a Transonic Axial Rotor

Back-to-back testing has been done using NASA fan rotor 67 in the Glenn Research Center W8 Axial Compressor Test Facility. The rotor was baseline tested with a normal industrial RMS surface finish of 0.5-0.6 m (20-24 microinches) at 60, 80 and 100% of design speed. At design speed the tip relative Mach number was 1.38. The blades were then removed from the facility and ultrapolished to a surface finish of 0.125 m (5 microinch) or less and retested. At 100% speed near the design point, the ultrapolished blades showed approximately 0.3 - 0.5% increase in adiabatic efficiency. The difference was greater near maximum flow. Due to increased relative measurement error at 60 and 80% speed, the performance difference between the normal and ultrapolished blades was indeterminate at these speeds.

Roberts, William B.↗
DOE OSTI2020

Single-Step Shear-Based Deformation Processing of Electrical Conductor Wires

Commercial electrical conductor wires are currently produced from aluminum alloys by multi-step deformation processing involving rolling and drawing. These processes typically require 10 to 20 steps of deformation, since the plastic strain or reduction that can be imposed in a single step is limited by material workability and process mechanics. Here, we demonstrate a fundamentally different, single-step approach to produce flat wire aluminum products using machining-based deformation that also ensures adequate material workability in the formed product. Two process routes are proposed: (1) chip formation by free-machining (FM), with a post-machining, light drawing reduction (<20%) to achieve desired finish and (2) constrained chip formation by large strain extrusion machining (LSEM). Using commercially pure aluminum conductor alloys (Al 1100 and EC1350) as representative material systems, we demonstrate key features of the machining-based processing, including (a) single-step processing to achieve flat wire geometries, (b) surface finish (Ra = 0.2 to 1.0 μm) comparable to that of commercial wire products made by drawing/rolling, (c) deformation control independent of wire size, and (d) hardness increases of 50–150% over that of annealed wires, while retaining high electrical conductivity (>56% IACS). Here, the wire microstructure, which can also be varied via the large-strain deformation parameters, is correlated with mechanical and electrical properties. Implications for commercial manufacture of flat wire products are discussed.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Effect of milling machine roughness and wing dihedral on the supersonic aerodynamic characteristics of a highly swept wing

An experimental investigation was conducted to assess the effect of surface finish on the longitudinal and lateral aerodynamic characteristics of a highly-swept wing at supersonic speeds. A study of the effects of wing dihedral was also made. Included in the tests were four wing models: three models having 22.5 degrees of outboard dihedral, identical except for surface finish, and a zero-dihedral, smooth model of the same planform for reference. Of the three dihedral models, two were taken directly from the milling machine without smoothing: one having a maximum scallop height of 0.002 inches and the other a maximum scallop height of 0.005 inches. The third dihedral model was handfinished to a smooth surface. Tests were conducted in Test Section 1 of the Unitary Plan Wind Tunnel at NASA-Langley over a range of Mach numbers from 1.8 to 2.8, a range of angle of attack from -5 to 8 degrees, and at a Reynolds numbers per foot of 2 x 10(6). Selected data were also taken at a Reynolds number per foot of 6 x 10(6). Drag coefficient increases, with corresponding lift-drag ratio decreases were the primary aerodynamic effects attributed to increased surface roughness due to milling machine grooves. These drag and lift-drag ratio increments due to roughness increased as Reynolds number increased.

Darden, Christine M.↗
NASA NTRS1992

Investigation of rotor blade roughness effects on turbine performance

The cold air test program was completed on the SSME (Space Shuttle Main Engine) HPFTP (High Pressure Fuel Turbopump) turbine with production nozzle vane rings and polished coated rotor blades with a smooth surface finish of 30 microinch (0.76 micrometer) RMS (Root Mean Square). The smooth blades were polished by an abrasive flow machining process. The test results were compared with the air test results from production rough coated rotor blades with a surface finish of up to 400 microinch (10.16 micrometer) RMS. Turbine efficiency was higher for the smooth blades over the entire range tested. Efficiency increased 2.1 percentage points at the SSME 104 percent RPL (Rated Power Level) condition. This efficiency improvement could reduce the SSME HPFTP turbine inlet temperature by 57 degrees Rankine (32 degrees Kelvin) increasing turbine durability. The turbine flow parameter increased and the mid-span outlet swirl angle became more axial with the smooth rotor blades.

Boynton, J. L.↗
NASA NTRS1983

Thermal conductance measurements of pressed OFHC copper contacts at liquid helium temperatures

The thermal conductance of oxygen-free high conductivity (OFHC) copper sample pairs with surface finishes ranging from 0.1 to 1.6-micrometers rms roughness was investigated over the range of 1.6 to 6.0-K under applied contact forces up to 670 N. The thermal conductance increases with increasing contact force; however, no correlation can be drawn with respect to surface finish.

Salerno, L. J.↗
NASA NTRS1985

Thermal conductance measurements of pressed OFHC copper contacts at liquid helium temperatures

The thermal conductance of oxygen-free high conductivity (COFHC) copper sample pairs with surface finishes ranging from 0.1 to 1.6-micrometers rms roughness was investigated over the range of 1.6 to 6.0-K under applied contact forces up to 670 N. The thermal conductance increases with increasing contact force; however, no correlation can be drawn with respect to surface finish.

Salerno, L. J.↗
NASA NTRS2007

Fatigue Life of Haynes 188 Superalloy in Direct Connect Combustor Durability Rig

The Direct Connect Combustor Durability Rig (DCR) will provide NASA a flexible and efficient test bed to demonstrate the durability of actively cooled scramjet engine structure, static and dynamic sealing technologies, and thermal management techniques. The DCR shall be hydrogen fueled and cooled, and test hydrogen coolded structural panels at Mach 5 and 7. Actively cooled Haynes 188 superalloy DCR structural panels exposed to the combustion environment shall have electrodischarge machined (EDM) internal cooling holes with flowing liquid hydrogen. Hydrogen combustion could therefore produce severe thermal conditions that could challenge low cycle fatigue durability of this material. The objective of this study was to assess low cycle fatigue capability of Haynes 188 for DCR application. Tests were performed at 25 and 650 C, in hydrogen and helium environments, using specimens with low stress ground (LSG) and electro-discharge machined (EDM) surface finish. Initial fatigue tests in helium and hydrogen indicate the low cycle fatigue life capability of Haynes 188 in hydrogen appears quite satisfactory for the DCR application. Fatigue capability did not decrease with increasing test temperature. Fatigue capability also did not decrease with EDM surface finish. Failure evaluations indicate retention of ductility in all conditions. Additional tests are planned to reconfirm these positive trends.

Gabb, TIm↗
NASA NTRS1986

Thermal conductance of pressed aluminum and stainless steel contacts at liquid helium temperatures

The thermal conductance of aluminum and stainless steel 304 sample pairs with surface finishes ranging from 0.1 to 1.6 microns rms roughness was investigated over a temperature range from 1.6 to 6.0 k. The thermal conductance follows a simple power law function of temperature, with the exponent ranging from 0.5 to 2.25, increases asymptotically with increasing applied force, and exhibits an anomaly for surface finishes in the 0.4 micron region.

Salerno, L. J.↗
NASA NTRS1988

Thermal conductance of pressed aluminum and stainless steel contacts at liquid helium temperatures

The thermal conductance of aluminum and stainless steel 304 sample pairs with surface finishes ranging from 0.1 to 1.6 microns rms roughness was investigated over a temperature range from 1.6 to 6.0 K. The thermal conductance follows a simple power law function of temperature, with the exponent ranging from 0.5 to 2.25, increases asymptotically with increasing applied force, and exhibits an anomaly for surface finishes in the 0.4 micron region.

Salerno, L. J.↗
NASA NTRS2001

Ultra-Light Precision Membrane Optics

SRS Technologies and NASA Marshall Space Flight Center have conducted a research effort to explore the possibility of developing ultra-lightweight membrane optics for future imaging applications. High precision optical flats and spherical mirrors were produced under this research effort. The thin film mirrors were manufactured using surface replication casting of CPI(Trademark), a polyimide material developed specifically for UV hardness and thermal stability. In the course of this program, numerous polyimide films were cast with surface finishes better than 1.5 nanometers rms and thickness variation of less than 63 nanometers. Precision membrane optical flats were manufactured demonstrating better than 1/13 wave figure error when measured at 633 nanometers. The aerial density of these films is 0.037 kilograms per square meter. Several 0.5-meter spherical mirrors were also manufactured. These mirrors had excellent surface finish (1.5 nanometers rms) and figure error on the order of tens of microns. This places their figure error within the demonstrated correctability of advanced wavefront correction technologies such as real time holography.

Moore, Jim↗
NASA NTRS1991

Evaluation of the interfacial bond properties between carbon phenolic and glass phenolic composites

The effects of moisture and surface finish on the mechanical and physical properties of the interfacial bond between carbon/phenolic (C/P) and glass/phenolic (G/P) composite materials have been studied. Test results indicate that moisture substantially degrades the integrity of the interfacial bond between C/P and G/P materials. The apparent effect of the autoclave curing of the C/P material reduces the ultimate interlaminar shear length of the C/P material by 20 percent compared to the hydroclave curing of the C/P material. The variation in applied surface finishes is found to have no appreciable effect on the ultimate interlaminar shear strength of the interface in the wet laminate.

Jordan, K.↗