Results for “Steady state process” — Page 61

NASA NTRS1995

Numerical thermal analyses of heat exchangers for the stirling engine application

The Regenerator, Cooler and Heater for the NASA Space Power Research Engine (SPRE) have been analyzed in detail for laminar, incompressible and oscillatory flow conditions. Each component has been analyzed independently and in detail with the regenerator being modeled as two-parallel-plates channel with a solid wall. The ends of the channel are exposed to two reservoir maintained at different temperature thus providing an axial temperature gradient along the channel. The cooler and heater components have been modeled as circular pipes with isothermal walls. Two different types of thermal boundary conditions have been investigated for the cooler and heater, namely, symmetric and asymmetric temperature inflow. In symmetric temperature inflow the flow enters the channel with the same temperature in throughout the velocity cycle whereas, in asymmetric temperature inflow the flow enters with a different temperature in each half cycle. The study was conducted over a wide range of Maximum Reynolds number (RE(max) varying from 75 to 60000, Valensi number (Va) from 2.5 to 800, and relative amplitude of fluid displacement (A(sub r) from 0.357 to 1.34. A two dimensional Finite volume method based on the SIMPLE algorithm was used to solve the governing partial differential equations. Post processing programs were developed to effectively describe the heat transfer mechanism under oscillatory flows. The computer code was validated by comparing with existing analytical solutions for oscillating flows. The thermal field have been studied with the help of temperature contour and three dimensional plots. The instantaneous friction factor, wall heat flux and heat transfer coefficient have been examined. It has been concluded that in general, the frictional factor and heat transfer coefficient are higher under oscillatory flow conditions when the Valensi number is high. Also, the thermal efficiency decreases for lower A(r) values. Further, the usual steady state definition for the heat transfer coefficient does not seem to be valid.

Kannapareddy, Mohan Raj↗

NASA NTRS2007

Transient Numerical Modeling of Catalytic Channels

This paper presents a transient model of catalytic combustion suitable for isolated channels and monolith reactors. The model is a lumped two-phase (gas and solid) model where the gas phase is quasi-steady relative to the transient solid. Axial diffusion is neglected in the gas phase; lateral diffusion, however, is accounted for using transfer coefficients. The solid phase includes axial heat conduction and external heat loss due to convection and radiation. The combustion process utilizes detailed gas and surface reaction models. The gas-phase model becomes a system of stiff ordinary differential equations while the solid phase reduces, after discretization, into a system of stiff ordinary differential-algebraic equations. The time evolution of the system came from alternating integrations of the quasi-steady gas and transient solid. This work outlines the numerical model and presents some sensitivity studies on important parameters including internal transfer coefficients, catalytic surface site density, and external heat-loss (if applicable). The model is compared to two experiments using CO fuel: (1) steady-state conversion through an isothermal platinum (Pt) tube and (2) transient propagation of a catalytic reaction inside a small Pt tube. The model requires internal mass-transfer resistance to match the experiments at lower residence times. Under mass-transport limited conditions, the model reasonably predicted exit conversion using global mass-transfer coefficients. Near light-off, the model results did not match the experiment precisely even after adjustment of mass-transfer coefficients. Agreement improved for the first case after adjusting the surface kinetics such that the net rate of CO adsorption increased compared to O2. The CO / O2 surface mechanism came from a sub-set of reactions in a popular CH4 / O2 mechanism. For the second case, predictions improved for lean conditions with increased external heat loss or adjustment of the kinetics as in the first case. Finally, the results show that different initial surface-species distribution leads to different steady-states under certain conditions. These results demonstrate the utility of a lumped two-phase model of a transient catalytic combustor with detailed chemistry.

Struk, Peter M.↗

NASA NTRS2017

Updates on Modeling the Water Cycle with the NASA Ames Mars Global Climate Model

Global Circulation Models (GCMs) have made steady progress in simulating the current Mars water cycle. It is now widely recognized that clouds are a critical component that can significantly affect the nature of the simulated water cycle. Two processes in particular are key to implementing clouds in a GCM: the microphysical processes of formation and dissipation, and their radiative effects on heating/ cooling rates. Together, these processes alter the thermal structure, change the dynamics, and regulate inter-hemispheric transport. We have made considerable progress representing these processes in the NASA Ames GCM, particularly in the presence of radiatively active water ice clouds. We present the current state of our group's water cycle modeling efforts, show results from selected simulations, highlight some of the issues, and discuss avenues for further investigation.

Global Circulation Models (GCMs)↗

DOE OSTI2021

Compositional patterning in irradiated alloys: Effective potentials and effective interfacial energy

Compositional patterning (CP) in binary alloys during energetic particle irradiation is studied using a kinetic model that considers two competing kinetic processes, a thermally activated one promoting macroscopic phase separation (MPS) of the concentration field c(r,t) and a forced one resulting in finite-range random atomic mixing. The forced mixing is modeled by a Gaussian relocation distribution with a characteristic distance R. A series of approximate kinetic models are introduced by expanding the mixing function into a series of n terms, thus replacing the non-local evaluations of the concentration field c(r'-r,t) by local derivatives of c(r,t). This approach makes it possible to obtain exact effective potentials and build steady-state diagrams for each order-n model. Phase field (PF) simulations using these order-n models reveal that near the onset of patterning, phase evolution is accurately described using an order-3 model, which changes smoothly from an extended Cahn-Hilliard free energy in the MPS regime to a one-mode Swift-Hohenberg functional in the CP regime. Deeper into the patterning regime, higher-order models are required to achieve convergence, yielding square-like concentration profiles characteristic of a strong segregation regime. These higher-order effective free energies are analogous to multimodal Swift-Hohenberg functionals. Here, a new definition for the effective interfacial energy is proposed in the CP regime, since the interfacial area is no longer an excess quantity in that regime, precluding the use of the standard thermodynamic definition of interfacial energy.

36 MATERIALS SCIENCE↗

NASA NTRS1996

A dynamic response model for pressure sensors in continuum and high Knudsen number flows with large temperature gradients

This paper develops a dynamic model for pressure sensors in continuum and rarefied flows with longitudinal temperature gradients. The model was developed from the unsteady Navier-Stokes momentum, energy, and continuity equations and was linearized using small perturbations. The energy equation was decoupled from momentum and continuity assuming a polytropic flow process. Rarefied flow conditions were accounted for using a slip flow boundary condition at the tubing wall. The equations were radially averaged and solved assuming gas properties remain constant along a small tubing element. This fundamental solution was used as a building block for arbitrary geometries where fluid properties may also vary longitudinally in the tube. The problem was solved recursively starting at the transducer and working upstream in the tube. Dynamic frequency response tests were performed for continuum flow conditions in the presence of temperature gradients. These tests validated the recursive formulation of the model. Model steady-state behavior was analyzed using the final value theorem. Tests were performed for rarefied flow conditions and compared to the model steady-state response to evaluate the regime of applicability. Model comparisons were excellent for Knudsen numbers up to 0.6. Beyond this point, molecular affects caused model analyses to become inaccurate.

Whitmore, Stephen A.↗

NASA NTRS1974

A high power TWT power processing system

A power processing system (PPS) is designed for a space-type high power (200W RF) multi-collector traveling-wave tube (TWT). The basic power circuit is presented along with the simplified block diagram and the input, output, and general requirements for the PPS design are tabulated. The paper covers the PPS design as to critical TWT/PPS interface requirements, high voltage cathode/collector supply, high voltage components material, packaging, grounding and isolation, and electrical performance. The use of a single two loop control system for the regulation of cathode and collector voltages is shown to give high efficiency, excellent steady-state and transient performance characteristics, and complete protection for TWT and PPS components under transient conditions.

Farber, B. F.↗

NASA NTRS1980

The enhanced oxidation of SO2 by NO2 on carbon particulates

The oxidation of SO2 on carbon particles in dry air and in air at 65% relative humidity (RH) was found to be greatly enhanced by the presence of gaseous NO2. Exposures of 20-80ppm SO2 + 10ppm NO2 on 1-mg samples of commercial carbon black were found to produce both sorption and desorption coverages (weight retained after desorption into N2) of over one order of magnitude greater than for corresponding SO2 exposures. Significant agglomeration and wetting were observed to occur progressively during exposures at 65% RH, and samples, even after 150-h exposure, rarely reached steady-state weight gain. The wetting may have regenerated fresh reactive carbon surface. Sorptions conducted in nitrogen atmospheres, rather than in air, appeared to produce slightly higher sorptions and weight retentions for equivalent exposure concentrations and times, indicating that NO2 served as the oxidizer and that molecular oxygen, or some trace constitutents in air, may have weakly inhibited the oxidation by NO2. Wet chemical analysis of the desorbed phase indicated that sulfate, presumably H2SO4 accounted for over half of the retained weight. Measurements of pH from water-quenched samples indicated a highly acidic surface phase, and suggested the oxidation process could proceed in an acidic environment.

Cofer, W. R., III↗

NASA NTRS2011

Magnetic Shielding of the Channel Walls in a Hall Plasma Accelerator

In a qualification life test of a Hall thruster it was found that the erosion of the acceleration channel practically stopped after approx 5,600 h. Numerical simulations using a two-dimensional axisymmetric plasma solver with a magnetic field-aligned mesh reveal that when the channel receded from its early-in-life to its steady-state configuration the following changes occurred near the wall: (1) reduction of the electric field parallel to the wall that prohibited ions from acquiring significant impact kinetic energy before entering the sheath, (2) reduction of the potential fall in the sheath that further diminished the total energy ions gained before striking the material, and (3) reduction of the ion number density that decreased the flux of ions to the wall. All these changes, found to have been induced by the magnetic field, constituted collectively an effective shielding of the walls from any significant ion bombardment. Thus, we term this process in Hall thrusters "magnetic shielding."

ion density↗

NASA NTRS2015

Dormancy and Recovery Testing for Biological Wastewater Processors

Bioreactors, such as aerated membrane type bioreactors have been proposed and studied for a number of years as an alternate approach for treating wastewater streams for space exploration. Several challenges remain before these types of bioreactors can be used in space settings, including transporting the bioreactors with their microbial communities to space, whether that be the International Space Station or beyond, or procedures for safing the systems and placing them into dormant state for later start-up. Little information is available on such operations as it is not common practice for terrestrial systems. This study explored several dormancy processes for established bioreactors to determine optimal storage and recovery conditions. Procedures focused on complete isolation of the microbial communities from an operational standpoint and observing the effects of: 1) storage temperature, and 2) storage with or without the reactor bulk fluid. The first consideration was tested from a microbial integrity and power consumption standpoint; both room temperature (25 C) and cold (4 C) storage conditions were studied. The second consideration was explored; again, for microbial integrity as well as plausible real-world scenarios of how terrestrially established bioreactors would be transported to microgravity and stored for periods of time between operations. Biofilms were stored without the reactor bulk fluid to simulate transport of established biofilms into microgravity, while biofilms stored with the reactor bulk fluid simulated the most simplistic storage condition to implement operations for extended periods of nonuse. Dormancy condition did not have an influence on recovery in initial studies with immature biofilms (48 days old), however, a lengthy recovery time was required (20+ days). Bioreactors with fully established biofilms (13 months) were able to recover from a 7-month dormancy period to steady state operation within 4 days (approximately 1 residence cycle). Results indicate a need for future testing on biofilm age and health and further exploration of dormancy length.

Dormancy↗

NASA NTRS2015

Dormancy and Recovery Testing for Biological Wastewater Processors

Bioreactors, such as the aerated hollow fiber membrane type, have been proposed and studied for a number of years as an alternate approach for treating wastewater streams for space exploration. Several challenges remain to be resolved before these types of bioreactors can be used in space settings, including transporting the bioreactors with intact and active biofilms, whether that be to the International Space Station or beyond, or procedures for safing the systems and placing them into a dormant state for later start-up. Little information is available on such operations as it is not common practice for terrestrial systems. This study explored several dormancy processes for established bioreactors to determine optimal storage and recovery conditions. Procedures focused on complete isolation of the microbial communities from an operational standpoint and observing the effects of: 1) storage temperature, and 2) storage with or without the reactor bulk fluid. The first consideration was tested from a microbial integrity and power consumption standpoint; both ambient temperature (25 C) and cold (4 C) storage conditions were studied. The second consideration was explored; again, for microbial integrity as well as plausible real-world scenarios of how terrestrially established bioreactors would be transported to microgravity and stored for periods of time between operations. Biofilms were stored without the reactor bulk fluid to simulate transport of established biofilms into microgravity, while biofilms stored with the reactor bulk fluid simulated the most simplistic storage condition to implement operations for extended periods of nonuse. Dormancy condition did not have an influence on recovery in initial studies with immature biofilms (48 days old), however a lengthy recovery time was required (20+ days). Bioreactors with fully established biofilms (13 months) were able to recover from a 7-month dormancy period to steady state operation within 4 days (approx. 1 residence cycle). Results indicate a need for future testing on biofilm age and health and further exploration of dormancy length.

Recovery Testing↗

NASA NTRS1989

Using NASTRAN To Analyze Vibrations Of Rotor Blades

Report gives information on use of NASTRAN computer program in finite-element analysis of rotating flexible blades like in compressors and on turboprop engines. Predicts steady-state components of deflections and stresses under centrifugal forces, generates data for plots of natural frequency versus rotational speed, and provides vibration-mode data for calculations of flutter. Describes use of NASTRAN solution sequence 64 for geometrical nonlinear analysis and solution sequence 63 for determination of frequencies and vibrational-mode shapes. Includes sample problem with NASTRAN input data. Emphasizes key factors in analysis of rotating blades, such as setting angle and centrifugal softening effects. Combined analyses of solution sequences 64 and 63 reduces computer time and number of output listings, in comparison with separate analyses. In central-processing-unit time cut in half.

Lawrence, Charles↗

NASA NTRS1999

Steady-State Characterization of Bacteriorhodopsin-D85N Photocycle

An operational characterization of the photocycle of the genetic mutant D85N of bacteriorhodopsin, BR-D85N, is presented. Steady-state bleach spectra and pump-probe absorbance data are obtained with thick hydrated films containing BR-D85N embedded in a gelatin host. Simple two- and three-state models are used to analyze the photocycle dynamics and extract relevant information such as pure-state absorption spectra, photochemical-transition quantum efficiencies, and thermal lifetimes of dominant states appearing in the photocycle, the knowledge of which should aid in the analysis of optical recording and retrieval of data in films incorporating this photochromic material. The remarkable characteristics of this material and their implications from the viewpoint of optical data storage and processing are discussed.

Timucin, Dogan A.↗

NASA NTRS2008

Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility: Steady Predictions - Part 1

Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. Advanced numerical tools assume greater significance in supporting testing and design of high altitude testing facilities and plume induced testing environments of high thrust engines because of the greater inter-dependence and synergy in the functioning of the different sub-systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Facility designs in this case will require a complex network of diffuser ducts, steam ejector trains, fast operating valves, cooling water systems and flow diverters that need to be characterized for steady state performance. In this paper, we will demonstrate with the use of CFD analyses s advanced capability to evaluate supersonic diffuser and steam ejector performance in a sub-scale A-3 facility at NASA Stennis Space Center (SSC) where extensive testing was performed. Furthermore, the focus in this paper relates to modeling of critical sub-systems and components used in facilities such as the A-3 facility. The work here will address deficiencies in empirical models and current CFD analyses that are used for design of supersonic diffusers/turning vanes/ejectors as well as analyses for confined plumes and venting processes. The primary areas that will be addressed are: (1) supersonic diffuser performance including analyses of thermal loads (2) accurate shock capturing in the diffuser duct; (3) effect of turning duct on the performance of the facility (4) prediction of mass flow rates and performance classification for steam ejectors (5) comparisons with test data from sub-scale diffuser testing and assessment of confidence levels in CFD based flowpath modeling of the facility. The analyses tools used here expand on the multi-element unstructured CFD which has been tailored and validated for impingement dynamics of dry plumes, complex valve/feed systems, and high pressure propellant delivery systems used in engine and component test stands at NASA SSC. The analyses performed in the evaluation of the sub-scale diffuser facility explored several important factors that influence modeling and understanding of facility operation such as (a) importance of modeling the facility with Real Gas approximation, (b) approximating the cluster of steam ejector nozzles as a single annular nozzle, (c) existence of mixed subsonic/supersonic flow downstream of the turning duct, and (d) inadequacy of two-equation turbulence models in predicting the correct pressurization in the turning duct and expansion of the second stage steam ejectors. The procedure used for modeling the facility was as follows: (i) The engine, test cell and first stage ejectors were simulated with an axisymmetric approximation (ii) the turning duct, second stage ejectors and the piping downstream of the second stage ejectors were analyzed with a three-dimensional simulation utilizing a half-plane symmetry approximation. The solution i.e. primitive variables such as pressure, velocity components, temperature and turbulence quantities were passed from the first computational domain and specified as a supersonic boundary condition for the second simulation. (iii) The third domain comprised of the exit diffuser and the region in the vicinity of the facility (primary included to get the correct shock structure at the exit of the facility and entrainment characteristics). The first set of simulations comprising the engine, test cell and first stage ejectors was carried out both as a turbulent real gas calculation as well as a turbulent perfect gas calculation. A comparison for the two cases (Real Turbulent and Perfect gas turbulent) of the Ma Number distribution and temperature distributions are shown in Figures 1 and 2 respectively. The Mach Number distribution shows small yet distinct differences between the two cases such as locations of shocks/shock reflections and a slightly different impingement point on the wall of the diffuser from the expansion at the exit of the nozzle. Similarly the temperature distribution indicates different flow recirculation patterns in the test cell. Both cases capture all the essential flow phenomena such as the shock-boundary layer interaction, plume expansion, expansion of the first stage ejectors, mixing between the engine plume and the first stage ejector flow and pressurization due to the first stage ejectors. The final paper will discuss thermal loads on the walls of the diffuser and cooling mechanisms investigated.

Allgood, Daniel C.↗

NASA NTRS2010

Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility: Steady Predictions - Part 1

Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. Advanced numerical tools assume greater significance in supporting testing and design of high altitude testing facilities and plume induced testing environments of high thrust engines because of the greater inter-dependence and synergy in the functioning of the different sub-systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Facility designs in this case will require a complex network of diffuser ducts, steam ejector trains, fast operating valves, cooling water systems and flow diverters that need to be characterized for steady state performance. In this paper, we will demonstrate with the use of CFD analyses s advanced capability to evaluate supersonic diffuser and steam ejector performance in a sub-scale A-3 facility at NASA Stennis Space Center (SSC) where extensive testing was performed. Furthermore, the focus in this paper relates to modeling of critical sub-systems and components used in facilities such as the A-3 facility. The work here will address deficiencies in empirical models and current CFD analyses that are used for design of supersonic diffusers/turning vanes/ejectors as well as analyses for confined plumes and venting processes. The primary areas that will be addressed are: (1) supersonic diffuser performance including analyses of thermal loads (2) accurate shock capturing in the diffuser duct; (3) effect of turning duct on the performance of the facility (4) prediction of mass flow rates and performance classification for steam ejectors (5) comparisons with test data from sub-scale diffuser testing and assessment of confidence levels in CFD based flowpath modeling of the facility. The analyses tools used here expand on the multi-element unstructured CFD which has been tailored and validated for impingement dynamics of dry plumes, complex valve/feed systems, and high pressure propellant delivery systems used in engine and component test stands at NASA SSC. The analyses performed in the evaluation of the sub-scale diffuser facility explored several important factors that influence modeling and understanding of facility operation such as (a) importance of modeling the facility with Real Gas approximation, (b) approximating the cluster of steam ejector nozzles as a single annular nozzle, (c) existence of mixed subsonic/supersonic flow downstream of the turning duct, and (d) inadequacy of two-equation turbulence models in predicting the correct pressurization in the turning duct and expansion of the second stage steam ejectors. The procedure used for modeling the facility was as follows: (i) The engine, test cell and first stage ejectors were simulated with an axisymmetric approximation (ii) the turning duct, second stage ejectors and the piping downstream of the second stage ejectors were analyzed with a three-dimensional simulation utilizing a half-plane symmetry approximation. The solution i.e. primitive variables such as pressure, velocity components, temperature and turbulence quantities were passed from the first computational domain and specified as a supersonic boundary condition for the second simulation. (iii) The third domain comprised of the exit diffuser and the region in the vicinity of the facility (primary included to get the correct shock structure at the exit of the facility and entrainment characteristics). The first set of simulations comprising the engine, test cell and first stage ejectors was carried out both as a turbulent real gas calculation as well as a turbulent perfect gas calculation. A comparison for the two cases (Real Turbulent and Perfect gas turbulent) of the Ma Number distribution and temperature distributions are shown in Figures 1 and 2 respectively.

Allgood, Daniel C.↗

DOE OSTI2021

On the merit of hot ion mode for tearing mode stabilization

The stabilization of tearing modes with rf driven current benefits from the cooperative feedback loop between rf power deposition and electron temperature within the island. This effect, termed rf current condensation, can greatly enhance and localize the current driven within magnetic islands. It has previously been shown that the condensation effect opens the possibility of passive stabilization with broad rf profiles, as would be typical of LHCD for steady state operation. Here, we show that this self-healing effect can be dramatically amplified by operation in a hot ion mode, due to the additional electron heat source provided by the hotter ions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1994

A statistical survey of the central plasma sheet

We present a statistical analysis of the ion plasma properties and magnetic field of the central plasma sheet at distances from 10 to 23 R(sub E) from the Earth. This study incorporates International Sun-Earth Explorer (ISEE) 1 plasma sheet samples accumulated with the University of Iowa Lepedea plasma analyzer during 1979. Our study of the bulk properties of the ion plasma shows that there is relatively little change as a result of increasing geomagnetic activity. The main macroscopic effect is an increase in plasma temperature. When the transverse profile of the plasma sheet is examined, it is clear that this increase in temperature occurs preferentially at high latitudes. The magnetic field shows an increase in magnitude in the vicinity of the neutral sheet periods of high geomagnetic activity. The radial profiles of the density, temperature, plasma, and magnetic pressures show a gradient in total energy density in the plasma sheet. The convective velocities are systematically directed earthward, and there is a bias toward positive V(sub y) on the duskside of the magnetotail. We infer that particle motion can be attributed to a pressure gradient, combined with steady state convective electric fields. We compute the convective electric fields from our measured bulk velocities, arriving at a pattern similar to that observed at low altitudes. The cross-tail electric field E(sub y) is dominant near the neutral sheet region, but at high latitudes E(sub z) is a major component. Our results suggest that the plasma sheet boundary layer, rather than the central plasma sheet, is a region of diverging electric fields. The picture of the plasma sheet that emerges from our study is that of a stable reservoir of hot plasma in which thermodynamic, rather than dynamic, processes is important.

Huang, C. Y.↗

NASA NTRS2004

Pilots Rate Augmented Generalized Predictive Control for Reconfiguration

The objective of this paper is to report the results from the research being conducted in reconfigurable fight controls at NASA Ames. A study was conducted with three NASA Dryden test pilots to evaluate two approaches of reconfiguring an aircraft's control system when failures occur in the control surfaces and engine. NASA Ames is investigating both a Neural Generalized Predictive Control scheme and a Neural Network based Dynamic Inverse controller. This paper highlights the Predictive Control scheme where a simple augmentation to reduce zero steady-state error led to the neural network predictor model becoming redundant for the task. Instead of using a neural network predictor model, a nominal single point linear model was used and then augmented with an error corrector. This paper shows that the Generalized Predictive Controller and the Dynamic Inverse Neural Network controller perform equally well at reconfiguration, but with less rate requirements from the actuators. Also presented are the pilot ratings for each controller for various failure scenarios and two samples of the required control actuation during reconfiguration. Finally, the paper concludes by stepping through the Generalized Predictive Control's reconfiguration process for an elevator failure.

Soloway, Don↗

NASA NTRS1995

Creep Testing of High-Temperature Cu-8 Cr-4 Nb Alloy Completed

A Cu-8 at.% Cr-4 at.% Nb (Cu-8 Cr-4 Nb) alloy is under development for high-temperature, high heatflux applications, such as actively cooled, hypersonic vehicle heat exchangers and rocket engine combustion chambers. Cu-8 Cr-4 Nb offers a superior combination of strength and conductivity. It has also shown exceptional low-cycle fatigue properties. Following preliminary testing to determine the best processing route, a more detailed testing program was initiated to determine the creep lives and creep rates of Cu-8 Cr-4 Nb alloy specimens produced by extrusion. Testing was conducted at the NASA Lewis Research Center with constant-load vacuum creep units. Considering expected operating temperatures and mission lives, we developed a test matrix to accurately determine the creep properties of Cu-8 Cr-4 Nb between 500 and 800 C. Six bars of Cu-8 Cr-4 Nb were extruded. From these bars, 54 creep samples were machined and tested. The figure on the left shows the steady-state, or second-stage, creep rates for the samples. Comparison data for NARloy-Z (Cu-3 wt % Ag-0.5 wt % Zr), the alloy currently used in combustion chamber liners, were not unavailable. Therefore the steady-state creep rates for Cu at similar temperatures are presented. As expected, in comparison to pure Cu, the creep rates for Cu-8 Cr-4 Nb are much lower. The lives of the samples are presented in the figure on the right. As shown, Cu-8 Cr-4 Nb at 800 C is comparable to NARloy-Z at 648 C. At equivalent temperatures, Cu-8 Cr-4 Nb enjoys a 20 to 50 percent advantage in stress for a given life and 1 to 3 orders of magnitude greater life at a given stress. The improved properties allow for design tradeoffs and improvements in new and existing heat exchangers such as the next generation of combustion chamber liners. Average creep rates for Cu-8 Cr-4 Nb and pure Cu are shown. Average creep lives for Cu-8 Cr- 4 Nb and NARloy-Z are also shown. Currently, two companies are interested in the commercial usage of the Cu-8 Cr-4 Nb alloy. The Rocketdyne Division of Rockwell International is conducting independent testing to analyze the properties for their projected needs in advanced rocket engine applications. Metallamics, a company based in Traverse City, Michigan, is entering into a Space Act Agreement to evaluate and test Cu-Cr-Nb alloys as materials for welding electrodes that are used in robotic welding operations. Creep rate is one of the alloy properties that determines the degree to which a welding electrode will mushroom or expand at the tip. A material with a low creep rate will resist mushrooming and give the electrode a longer life, minimizing downtime. This application holds the potential for large-scale usage of the alloy in the automotive and other industries. Success here would dramatically decrease the cost of the alloy and increase availability for aerospace applications.

Source record↗