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At least 127 records · Page 7

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NASA NTRS1983

Evaluation of feasibility of measuring EHD film thickness associated with cryogenic fluids

The feasibility of measuring elastohydrodynamic (EHD) films as formed with a cryogenic (LN2) fluid is evaluated. Modifications were made to an existing twin disk EHD apparatus to allow for disk lubrication with liquid nitrogen. This disk apparatus is equipped with an X-ray system for measuring the thickness of any lubricant film that is formed between the disks. Several film thickness experiments were conducted with the apparatus which indicate that good lubrication films are filmed with LN2. In addition to the film thickness studies, failure analyses of three bearings were conducted. The HPOTP turbine end bearings had experienced axial loads of 36,000 to 44,000 N (8,000 to 10,000 lb). High continuous radial loads were also experienced, which were most likely caused by thermal growth of the inner race. The resulting high internal loads caused race spalling and ball wear to occur.

Kannel, J. W.↗

DOE OSTI2022

Status of Additive Manufacturing Capabilities for Processing Refractory Alloys Under the Mo-99 Program

The enriched 100 Mo target, denoted as aMo, that Northstar Medical Radioisotopes is developing to produce 99 Mo from an accelerator-based method is a disk-type geometry with a 0.5–0.715 mm thickness and a 29 mm outer diameter. A press and sinter method was adopted to fabricate these samples from aMo powder feedstock. Inherent porosity from the press and sinter method makes the disks more easily dissolvable during 99 Mo postprocessing. However, the disk-type geometry will be subject to thermal stresses due to temperature variations once the geometry is in line with the accelerated electron beam, causing warping and possible failure. Additive manufacturing (AM) processes such as laser powder bed fusion (LPBF) enable the manufacturing of custom, complex geometries that may otherwise be difficult to produce with more conventional methods (e.g., press and sinter approach). Therefore, the National Nuclear Security Administration’s Molybdenum-99 Program invested in developing an AM facility dedicated to processing and printing refractory powders. This report details the LPBF process, how irregular refractory powder can be prepared for LPBF, and the equipment that is available to support the program.

36 MATERIALS SCIENCE↗

NASA NTRS1987

Contingency support using adaptive telemetry extractor and expert system technologies

The 'telemetry analysis logic for operations support' prototype system constitutes an expert system that is charged with contingency planning for the NASA Hubble Space Telescope (HST); this system has demonstrated the feasibility of using an adaptive telemetry extractor/reformatter that is integrated with an expert system. A test case generated by a simulator has demonstrated the reduction of the time required for analysis of a complex series of failures to a few minutes, from the hour usually required. The HST's telemetry extractor will be able to read real-time engineering telemetry streams and disk-based data. Telemetry format changes will be handled almost instantaneously.

Bryant, Thomas↗

NASA NTRS1978

Lubrication and failure mechanisms of graphite fluoride films

An optical microscope, equipped with a vertical illuminator and two polaroid filters (one rotatable), was used to visually study 440C HT steel surfaces lubricated with rubbed graphite fluoride films. Friction and wear results were compared to visual observations as a function of sliding distance for films applied to three surface finishes - polished, sanded, and sand-blasted. In general, the lubricating process was one of initial deformation or wear of metallic asperities into flat plateaus and then the formation of thin, layer-like, dynamic films which sheared between the flats and eventually flowed through the contact area. Failure was due to depletion of the graphite fluoride with the subsequent formation of excessive powdery metallic debris that formed a heavy, powdery film on both the rider and disk surfaces.

Fusaro, R. L.↗

NASA NTRS1994

UIT: Ultraviolet surface photometry of the spiral galaxy M74 (NGC 628)

Ultraviolet photometry, obtained from Ultraviolet Imaging Telescope (UIT) images at 1520 A (far-UV; magnitudes m(152)) and 2490 A (near-UV; magnitudes m(249)), of the spiral galaxy M74 (NGC 628) is compared with H-alpha, R, V, and B surface photometry and with models. M74's surface brightness profiles have a central peak with an exponential falloff; the exponential scale lengths of the profiles increase with decreasing wavelength for the broad-band images. The slope of the continuum-subtracted H-alpha profile is intermediate between those of far-UV and near-UV profiles, consistent with the related origins of H-alpha and UV emission in extreme Population I material. M74's color profiles all become bluer with increasing radius. The (m(152) - m(249)) color as measured by UIT averages near 0.0 (the color of an A0 star) over the central 20 sec radius and decreases from approximately -0.2 to approximately -0.4 from 20 sec to 200 sec. The spiral arms are the dominant component of the surface photometry colors; interarm regions are slightly redder. In the UV, M74's nuclear region resembles its disk/spiral arm material in colors and morphology, unlike galaxies such as M81. No UV 'bulge' is apparent. The m(152) - m(249) colors and models of M74's central region clearly demonstrate that there is no significant population of O or B stars present in the central 10 sec. M74's UV morphology and (m(152) - m(249)) color profiles are similar to those of M33, although M74 is approximately 0.5 mag redder. M81 has a smooth UV bulge which is much redder than the nuclear regions of M74 and M33. M74 is approximately 0.4 mag bluer than M81 in its outer disk, although M81 has bright UV sources only in spiral arms more than 5 kpc from its center. We investigate possible explanations for the color profiles of the galaxies and the differences among the galaxies: abundances; reddening due to internal dust; interplanetary magnetic field (IMF) variations, and the history of formation of the dominant generations of stars. Abundance and IMF variations do not produce large enough m(152) - m(249) or UV - V color differences. Comparing model UV/optical colors with those of M74 shows that M74's disk has undergone significant star formation over the past 500 Myr, and that either the star-formation history or the extinction varies systematically across M74's disk. Comparison of M74, M33, and M81 (UV - V) colors shows that M74 colors range from the bluest of M33's colors to the bluest of M81's. The failure of reddening models to cover the range of colors, and the known abundance range in such material, leads to the conclusion that star-formation history varies significantly as a function of radius in these galaxies, and that such variation is required to explain the range of colors observed in M74, M33, and M81.

Cornett, Robert H.↗

NASA NTRS1999

Combination Space Station Handrail Clamp and Pointing Device

A device for attaching an experiment carrier to a space station handrail is provided. The device has two major components, a clamping mechanism for attachment to a space station handrail, and a pointing carrier on which an experiment package can be mounted and oriented. The handrail clamp uses an overcenter mechanism and the carrier mechanism uses an adjustable preload ball and socket for carrier positioning. The handrail clamp uses a stack of disk springs to provide a spring loaded button. This configuration provides consistent clamping force over a range of possible handrail thicknesses. Three load points are incorporated in the clamping mechanism thereby spreading the clamping load onto three separate points on the handrail. A four bar linkage is used to provide for a single actuation lever for all three load points. For additional safety, a secondary lock consisting of a capture plate and push lock keeps the clamp attached to the handrail in the event of main clamp failure. For the carrier positioning mechanism, a ball in a spring loaded socket uses friction to provide locking torque; however. the ball and socket are torque limited so that the ball ran slip under kick loads (125 pounds or greater). A lead screw attached to disk spring stacks is used to provide an adjustable spring force on the socket. A locking knob is attached to the lead screw to allow for hand manipulation of the lead screw.

Hughes, Stephen J.↗

NASA NTRS1974

Rotor burst protection program: Statistics on aircraft gas turbine engine rotor failures that occurred in US commercial aviation during 1972

Based on FAA data, results are presented that establish (1) the incidence of rotor failure, (2) the type of fragments generated, (3) whether or not these fragments were contained, (4) the causes of failure, (5) where in the engine failure occurred, (6) what engines were affected and (7) what flight conditions prevailed at failure. The rate of uncontained rotor burst was considered to be significantly high. Blade fragments were generated in 95% of the rotor bursts, 20% of which were uncontained. Although fewer disk and rim fragment bursts occurred, none were contained.

Delucia, R. A.↗

NASA NTRS1989

Failure processes within ceramic coatings at high temperatures

Plasma sprayed coatings have a complex structure which is produced by the overlaying of many molten or semi-molten particles in the diameter range of 20 to 120 microns. The failure behavior of coatings has been characterized by using acoustic emission (AE) methodology. Coatings of NiCrAlY bond coat with a zirconia-12 wt pct yttria overlay were applied to disk-shaped specimens of U-700 alloy. A waveguide of 1-mm diameter platinum was TlG welded to the specimen and allowed it to be suspended in a tubular furnace. The specimen was thermally cycled to 1150 C and the AE monitored. Analyses have been carried out with the aim of establishing parameters which are related to the crack size population. These studies have been used to postulate types of cracking mechanisms which may occur in plasma sprayed coatings during thermal cycling. It is shown that microcracking gave rise to a large amount of AE. However, this coating still survived more thermal cycles than a coating which exhibited macrocracking events.

Berndt, Christopher↗

NASA NTRS1986

Advanced Gas Turbine (AGT) Technology Project

Engine testing, ceramic component fabrication and evaluation, component performance rig testing, and analytical studies comprised AGT 100 activities during the 1985 year. Ten experimental assemblies (builds) were evaluated using two engines. Accrued operating time was 120 hr of burning and 170 hr total, bringing cumulative total operating time to 395 hr, all devoid of major failures. Tests identified the generator seals as the primary working fluid leakage sources. Power transfer clutch operation was demonstrated. An alpha SiC gasifier rotor engine test resulted in blade tip failures. Recurring case vibration and shaft whip have limited gasifier shaft speeds to 84%. Ceramic components successfully engine tested now include the SiC scroll assembly, Si3N3 turbine rotor, combustor assembly, regenerator disk bulkhead, turbine vanes, piston rings, and couplings. A compressor shroud design change to reduce heat recirculation back to the inlet was executed. Ceramic components activity continues to focus on the development of state-of-the-art material strength characteristics in full-scale engine hardware. Fiber reinforced glass-ceramic composite turbine (inner) backplates were fabricated by Corning Glass Works. The BMAS/III material performed well in engine testing. Backplates of MAS material have not been engine tested.

Source record↗

NASA NTRS2006

Effectiveness of Shot Peening In Suppressing Fatigue Cracking At Non-Metallic Inclusions In Udimet(Registered Trademark)720

The fatigue lives of modern powder metallurgy disk alloys can be reduced over an order of magnitude by cracking at inherent non-metallic inclusions. The objective of this work was to study the effectiveness of shot peening in suppressing LCF crack initiation and growth at surface nonmetallic inclusions. Inclusions were carefully introduced at elevated levels during powder metallurgy processing of the nickel-base disk superalloy Udimet 720. Multiple strain-controlled fatigue tests were then performed on machined specimens with and without shot peened test sections at 427 C and 650 C. The low cycle fatigue lives and failure initiation sites varied as functions of inclusion content, shot peening, and fatigue conditions. A large majority of the failures in as-machined specimens with the introduced inclusions occurred at cracks initiating from inclusions intersecting the specimen surface. These inclusions reduced fatigue life by up to 100X, when compared to lives of material without inclusions residing at specimen surface. Large inclusions produced the greatest reductions in life for tests at low strain ranges and high strain ratios. Shot peening improved life in many cases by reducing the most severe effects of inclusions.

Barrie, Robert L.↗

NASA NTRS2018

High Speed Bearing Wear Rate Measurements for Spacecraft Active Thermal Control Fluid Pumps with a Novel Pin on Disk Apparatus

A novel pin on disc tribometer was designed and constructed to generate a high-speed, wear coefficient database for hydrodynamic bearings that are typically used in canned motors found in the active thermal control circuits of robotic and inhabited spacecraft. The primary motivation for this work was the premature failure of the active external thermal control pump on the International Space Station in 2010. During the failure investigation of this incident, the root cause was postulated to be high speed wear of the bearings. Although a detailed forensic analysis gave credibility to this theory, the lack of wear coefficient data at relevant conditions prevented validation of this finding. The database generated from the new Extreme Environment Tribometer (EET) enabled a closure calculation within 5% of the observed wear from inspections of the failed hardware. Testing in anhydrous ammonia and surrogate fluid was performed to provide a means for simplified testing in the future and to populate a preliminary database for the design of future active thermal control systems on spacecraft. The EET and test techniques developed for the measurement of high-speed wear coefficients are available to future system designers.

thermal control↗

NASA NTRS1972

Comparison of experimental and theoretical thermal fatigue lives for five nickel base alloys

The alloys Nimonic 90, IN 100, coated IN 100, B 1900, coated B 1900, MAR M200, and MAR M200DS (directionally solidified) were studied. Maximum temperatures ranged from 770 C to 1120 C (1420 F to 2050 F). Specimen geometries included tapered disks, double-edged wedges, and cambered airfoils. The disks and wedges were heated and cooled in fluidized beds. The airfoil specimens were heated by a Mach 1 natural gas burner and rapid-air-cooled, with and without spanwise loading. Life calculations included two distinct failure modes: conventional low cycle fatigue and cyclic creep. Required material properties were limited to conventional thermal, tensile, and creep rupture data. The complete life calculation system included the calculation of transient temperature distributions, thermal strains, stresses, creep damage, fatigue damage, and cycles to first crack. Calculated lives were within a factor of two for 76 of the 86 data points analyzed. Cyclic creep accounted for 81% of all the calculated damage.

Spera, D. A.↗

NASA NTRS1972

Comparison of experimental and theoretical thermal fatigue lives for five nickel-base alloys.

Alloys investigated were Nimonic 90, IN 100, coated IN 100, B 1900, coated B 1900, MAR M200, and MAR M200DS (directionally solidified). Maximum temperatures ranged from 770 to 1120 C. Specimen geometries included tapered disks, double-edged wedges, and cambered airfoils. The disks and wedges were heated and cooled in fluidized beds. The airfoil specimens were heated by a Mach 1 natural gas burner and rapid-air cooled, with and without spanwise loading. Life calculations included two distinct failure modes: conventional low-cycle fatigue and cyclic creep. The complete life calculation system included the calculation of transient temperature distributions, thermal strains, stresses, creep damage, fatigue damage, and finally cycles to first crack. Calculated lives were within a factor of two for 76 of the 86 data points analyzed.

Spera, D. A.↗

NASA NTRS2005

Effectiveness of Shot Peening in Suppressing Fatigue Cracking at Non-Metallic Inclusions in Udimet(trademark) 720

The fatigue lives of modern powder metallurgy disk alloys can be reduced by over an order of magnitude by surface cracking at inherent non-metallic inclusions. The objective of this work was to study the effectiveness of shot peening in suppressing LCF crack initiation and growth at surface nonmetallic inclusions. Inclusions were carefully introduced at elevated levels during powder metallurgy processing of the nickel-base disk superalloy Udimet 720. Multiple strain-controlled fatigue tests were then performed on machined specimens at 427 and 650 C in peened and unpeened conditions. Analyses were performed to compare the low cycle fatigue lives and failure initiation sites as a function of inclusion content, shot peening, and fatigue conditions. A large majority of the failures in as-machined specimens with introduced inclusions occurred at cracks initiating from inclusions intersecting the specimen surface. The inclusions could reduce fatigue life by up to 100X. Large inclusions had the greatest effect on life in tests at low strain ranges and high strain ratios. Shot peening can be used to improve life in these conditions by reducing the most severe effects of inclusions.

Barrie, Robert L.↗

NASA NTRS2002

Initial Assessment of the Effects of Nonmetallic Inclusions on Fatigue Life of Powder-Metallurgy-Processed Udimet(TM) 720

The fatigue lives of modern powder metallurgy (PM) disk alloys are influenced by variabilities in alloy microstructure and mechanical properties. These properties can vary due to the different steps of materials/component processing and machining. One of these variables, the presence of nonmetallic inclusions, has been shown to significantly degrade low-cycle fatigue (LCF) life. Nonmetallic inclusions are inherent defects in powder alloys that are a by-product of powder-processing techniques. Contamination of the powder can occur in the melt, during powder atomization, or during any of the various handling processes through consolidation. In modern nickel disk powder processing facilities, the levels of inclusion contamination have been reduced to less than 1 part per million by weight. Despite the efforts of manufacturers to ensure the cleanliness of their powder production processes, the presence of inclusions remains a source of great concern for the designer. the objective of this study was to investigate the effects on fatigue life of these inclusions. Since natural inclusions occur so infrequently, elevated levels of inclusions were carefully introduced in a nickel-based disk superalloy, Udimet 720 (registered trademark of Special Metals Corporation), produced using PM processing. Multiple strain-controlled fatigue tests were then performed on this material at 650 C. Analyses were performed to compare the LCF lives and failure initiation sites as functions of inclusion content and fatigue conditions. A large majority of the failures in specimens with introduced inclusions occurred at cracks initiating from inclusions at the specimen surface. The inclusions could reduce fatigue life by up to 100 times. These effects were found to be dependent on strain range and strain ratio. Tests at lower strain ranges and higher strain ratios produced larger effects of inclusions on life.

Gabb, T. P.↗

NASA NTRSDate not supplied

Development of an Additively Manufactured Turbine Blade Tuned Mass Absorber

An innovative concept using a tuned mass absorber for resonant response reduction of turbine blades that is integrally fabricated into the blades using additive manufactured has been developed. Avoiding high resonant response and resulting high cycle fatigue failure is a major concern of the $100B worldwide turbine industry, which encompasses power generation, jet engines and rocket engine turbomachinery. Blade failure is potentially catastrophic, and although preventative measures using dampers do exist, these solutions are extremely expensive to develop and are not always effective. In addition, many of the existing techniques do not work for newer integrally bladed disks (or blisks), where there is no inherent damping in the assembly. The proposed concept, in which a tuned mass absorber re-arranges the structural dynamics and moves energy from the blade to the absorber, is designed specifically for blisks, and is intentionally linear, enabling accurate response prediction during design. Single blade prototypes have been analyzed, fabricated, and tested, and different absorber concepts have shown a reduction in response of up to 60%. After an extensive commercialization and prior art search, MSFC determined the innovation merited the generation and submission of a patent application in August ’21. Funding is now being sought to fabricate a 20-bladed blisk which would be spun at operational speeds with substantially higher and more realistic pressure loads in a special spin facility. Successful completion of this program would raise the TRL from 3/4 to 6/7, significantly improving the viability for adoption of the concept not only in rocket engines but other industrial applications as well.

Turbine Blades↗

NASA NTRS1978

New lunar microcrater evidence against a time varying meteoroid flux

An attempt to measure the relative times of formation of 25 microcraters on lunar rock 60015 is discussed which was carried out as part of a study of the flux of interplanetary dust and possible time variations of that flux over periods of 1000 to 1 million yr. The data obtained could indicate that the formation rate of 100-micron-sized pits was lower in the past as compared with the formation rate of micron-sized pits, that the flux of particles forming 100-micron-sized pits may have varied relative to that of particles forming micron-sized pits, or that 100-micron-sized pits are forming now at a higher rate, relative to the formation rate of accretionary disks, than in the past. The last suggestion is shown to be almost untenable, and the overall results are found to lead to a logical paradox. It is concluded that the attempt probably failed and that the reason for failure raises serious questions regarding the use of lunar rock surfaces as meteoroid detectors.

Hartung, J. B.↗

NASA NTRS1999

Edge-Flames in Von Karman Swirling Flows

Classical understanding of diffusion flames dictates that they, unlike the premixed flames, do not possess a characteristic propagation velocity and are constrained by stoichiometric requirements at the flame surface. However, it has been commonly observed that when local extinction occurs within a diffusion flame sheet, the edges that are formed propagate with distinct speeds. In general, the propagation speed of these edges depend on their geometrical shape (concave, convex, or straight) among other factors. Recently, Buckmaster investigated the dynamics of straight diffusion flame edges separating burning and quenched regions using simplified one-dimensional models. He showed that these flame edges can have positive, negative, or zero velocity depending on the Damkoehler number of the equilibrium diffusion flame that support them. It was also shown that this unsteady flame-edge behavior is intrinsically linked to S-curve behavior of the diffusion flame with varying Damkoehler number. When the system Damkoehler number lies between the extinction and ignition limits, flame edges can propagate as an "ignition wave" or as a "failure wave," and for a critical Damkoehler number remain as a stationary flame-edge. We have extend Buckmaster's 1-d model to more general edge-flame configurations where the edges appear as "flame holes" or as "flame disks". These two configurations along with the straight-edge case cover the entire range of possible edge-flame geometry observable in planar diffusion-flame sheets. A generalized map of edge-flame propagation velocities as a function of the system Damkoehler number and the edge-flame radius is presented. Experimentally we show that edge flames can be created using diffusion flames embedded in von Karman boundary layers. In a von Karman boundary layer, the flow is generated by spinning a solid (fuel) disk in a quiescent ambient gas. Under normal gravity we were able to produce "flame disks" over a range of fuel-disk rotational velocities varying from 0 to 20 revolutions per second, by orienting the burning surface of the fuel disk facing downward.

Nayagam, Vedha↗