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NASA NTRS1988

Poly(imide-siloxane) segmented copolymer structural adhesives prepared by bulk and solution thermal imidization

The improved properties that have been demonstrated through thermal solution imidization in the case of polyimides and poly(imide-siloxane) segmented copolymers suggests significant potential for application of these new materials. Specifically, the enhancement in solubility, moisture reduction, and processability observed through this solution technique is quite dramatic. Previous work has shown that the presence of low amounts of siloxane does not detract significantly from the lap shear strength of these materials to titanium in the case of bulk thermal imidization synthesis. In addition, the siloxane incorporation results in the added advantage of resistance to hot, wet environments. This added durability is presumably due to the hydrophobic siloxane segments preventing the uptake of water at the critical interphase between the adhesive and the adherend. This paper discusses the extension of this work to the solution imidization synthesis technique recently developed in our laboratory. Results dealing with the absolute bond strengths as well as durability and failure surface analysis will be presented.

Bott, R. H.↗

NASA NTRS1986

Thermal barrier coating life prediction model development

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology with both performance and durability benefits. The foremost TBC benefit is the reduction of heat transferred into air-cooled components, which yields performance and durability benefits. This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY (or CoNiCrAlY) bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by Chromalloy, Klock, and Union Carbide. The second type of TBC is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal.

T E Strangman↗

NASA NTRS1989

Simulation of the low earth orbital atomic oxygen interaction with materials by means of an oxygen ion beam

Atomic oxygen is the predominant species in low-Earth orbit between the altitudes of 180 and 650 km. These highly reactive atoms are a result of photodissociation of diatomic oxygen molecules from solar photons having a wavelength less than or equal to 2430A. Spacecraft in low-Earth orbit collide with atomic oxygen in the 3P ground state at impact energies of approximately 4.2 to 4.5 eV. As a consequence, organic materials previously used for high altitude geosynchronous spacecraft are severely oxidized in the low-Earth orbital environment. The evaluation of materials durability to atomic oxygen requires ground simulation of this environment to cost effectively screen materials for durability. Directed broad beam oxygen sources are necessary to evaluate potential spacecraft materials performance before and after exposure to the simulated low-Earth orbital environment. This paper presents a description of a low energy, broad oxygen ion beam source used to simulate the low-Earth orbital atomic oxygen environment. The results of materials interaction with this beam and comparison with actual in-space tests of the same meterials will be discussed. Resulting surface morphologies appear to closely replicate those observed in space tests.

Banks, Bruce A.↗

NASA NTRS1989

Experience with advanced instrumentation in a hot section cascade

The Lewis Research Center gas turbine Hot Section Test Facility was developed to provide a real engine environment with known boundary conditions for the aerothermal performance evaluation and verification of computer design codes. This verification process requires experimental measurements in a hostile environment. The research instruments used in this facility are presented, and their characteristics and how they perform in this environment are discussed. The research instrumentation consisted of conventional pressure and temperature sensors, as well as thin-film thermocouples and heat flux gages. The hot gas temperature was measured by an aspirated temperature probe and by a dual-element, fast-response temperature probe. The data acquisition mode was both steady state and time dependent. These experiments were conducted over a wide range of gas Reynolds numbers, exit gas Mach numbers, and heat flux levels. This facility was capable of testing at temperatures up to 1600 K, and at pressures up to 18 atm. These corresponded to an airfoil exit Reynolds number range of 0.5 x 10(6) to 2.5 x 10(6) based on the airfoil chord of 5.55 cm. The results characterize the performance capability and the durability of the instrumentation. The challenge of making measurements in hostile environments is also discussed. The instruments exhibited more than adequate durability to achieve the measurement profile. About 70 percent of the thin-film thermocouples and the dual-element temperature probe survived several hundred thermal cycles and more than 35 hr at gas temperatures up to 1600 K. Within the experimental uncertainty, the steady-state and transient heat flux measurements were comparable and consistent over the range of Reynolds numbers tested.

Yeh, Frederick C.↗

NASA NTRS1988

Adhesively bonded joints: Testing, analysis, and design; Proceedings of the International Symposium, Baltimore, MD, Sept. 10-12, 1986

The papers contained in this volume provide an overview of the state of the art of testing, analysis, and design of adhesively bonded joints. The papers are grouped in the following sections: mechanical testing, stress analysis, failure mechanisms, and design and durability. Specific topics discussed include determination and verification of elastic parameters for adhesives; factors influencing elastic stresses in double cantilever beam specimens; special mixed finite elements for interfacial stress analysis of adhesively bonded joints; debonding characteristics of adhesively bonded woven Kevlar composites; and environmental durability of adhesively bonded joints.

Johnson, W. S.↗

NASA NTRS1989

Advanced Turbine Technology Applications Project (ATTAP)

ATTAP activities during the past year were highlighted by an extensive materials assessment, execution of a reference powertrain design, test-bed engine design and development, ceramic component design, materials and component characterization, ceramic component process development and fabrication, component rig design and fabrication, test-bed engine fabrication, and hot gasifier rig and engine testing. Materials assessment activities entailed engine environment evaluation of domestically supplied radial gasifier turbine rotors that were available at the conclusion of the Advanced Gas Turbine (AGT) Technology Development Project as well as an extensive survey of both domestic and foreign ceramic suppliers and Government laboratories performing ceramic materials research applicable to advanced heat engines. A reference powertrain design was executed to reflect the selection of the AGT-5 as the ceramic component test-bed engine for the ATTAP. Test-bed engine development activity focused on upgrading the AGT-5 from a 1038 C (1900 F) metal engine to a durable 1371 C (2500 F) structural ceramic component test-bed engine. Ceramic component design activities included the combustor, gasifier turbine static structure, and gasifier turbine rotor. The materials and component characterization efforts have included the testing and evaluation of several candidate ceramic materials and components being developed for use in the ATTAP. Ceramic component process development and fabrication activities were initiated for the gasifier turbine rotor, gasifier turbine vanes, gasifier turbine scroll, extruded regenerator disks, and thermal insulation. Component rig development activities included combustor, hot gasifier, and regenerator rigs. Test-bed engine fabrication activities consisted of the fabrication of an all-new AGT-5 durability test-bed engine and support of all engine test activities through instrumentation/build/repair. Hot gasifier rig and test-bed engine testing activities were performed.

Source record↗

NASA NTRS1988

Tubular space truss structure for SKITTER 2 robot

The Skitter 2 is a three legged transport vehicle designed to demonstrate the principle of a tripod walker in a multitude of environments. The tubular truss model of Skitter 2 is a proof of principal design. The model will replicate the operational capabilities of Skitter 2 including its ability to self-right itself. The project's focus was on the use of light weight tubular members in the final structural design. A strong design for the body was required as it will undergo the most intense loading. Triangular geometry was used extensively in the body, providing the required structural integrity and eliminating the need for cumbersome shear panels. Both the basic femur and tibia designs also relied on the strong geometry of the triangle. An intense literature search aided in the development of the most suitable weld techniques, joints, linkages, and materials required for a durable design. The hinge design features the use of spherical rod end bearings. In order to obtain a greater range of mobility in the tibia, a four-bar linkage was designed which attaches both to the femur and the tibia. All component designs, specifically the body, femur, and the tibia were optimized using the software package IDEAS 3.8A Supertab. The package provided essential deformation and stress analysis information on each component's design. The final structure incurred only a 0.0544 inch deflection in a maximum (worst case) loading situation. The highest stress experienced by any AL6061-T6 tubular member was 1920 psi. The structural integrity of the final design facilitated the use of Aluminum 6061-T6 tubing. The tubular truss structure of Skitter 2 is an effective and highly durable design. All facets of the design are structurally sound and cost effective.

Beecham, Richard↗

NASA NTRS1988

Probabilistic structural analysis methods development for SSME

The development of probabilistic structural analysis methods is a major part of the SSME Structural Durability Program and consists of three program elements: composite load spectra, probabilistic finite element structural analysis, and probabilistic structural analysis applications. Recent progress includes: (1) the effects of the uncertainties of several factors on the HPFP blade temperature pressure and torque, (2) the evaluation of the cumulative distribution function of structural response variables based on assumed uncertainties on primitive structural variables, and (3) evaluation of the failure probability. Collectively, the results obtained demonstrate that the structural durability of critical SSME components can be probabilistically evaluated.

Chamis, C. C.↗

NASA NTRS1988

Ceramic matrix composites in simulated SSME environments

Future Space Shuttle Main Engine (SSME)-type rocket engines can benefit from the use of fiber-reinforced ceramix matrix composites (FRCMC). Ceramics reinforced with long continuous fibers exhibit improved tolerance to severe thermomechanical and environmental exposures. An in-house NASA-Lewis program to evaluate the durability of FRCMC in simulated SSME environments is described. Primary tests involve multiple (one second) exposures of FRCMC specimens in a hydrogen/oxygen rocket test rig. This rig generates surface heating rates of 1000 to 2500 C/second. The FRCMC durability evaluation involves measurement of retained strength as a function of thermal shock severity and number of upshock cycles. Preliminary test results for monolithic silicon nitride (Si3N4) and silicon carbide (SiC), and one type of silicon based FRCMC, are presented. The test data are examined in terms of simple thermal shock theory.

Herbell, Thomas P.↗

NASA NTRS1991

Stirling engine: Available tools for long-life assessment

A review is presented for the durability approaches applicable to long-time life assessment of Stirling engine hot-section components. The crucial elements are experimental techniques for generating long-time materials property data (both monotonic and cyclic flow and failure properties); analytic representations of slow strain rate material stress-strain response characteristics (monotonic and cyclic constitutive relations) at high temperatures and low stresses and strains; analytic creep-fatigue-environmental interaction life prediction methods applicable to long lifetimes at high temperatures and small stresses and strains; and experimental verification of life predictions. Long-lifetime design criteria for materials of interest are woefully lacking. Designing against failures due to creep, creep-rupture, fatigue, environmental attack, and creep-fatigue-environmental interaction will require considerable extrapolation. Viscoplastic constitutive models and time-temperature parameters will have to be calibrated for the hot-section materials of interest. Analysis combined with limited verification testing in a short-time regime will be required to build confidence in long-lifetime durability models.

Halford, Gary R.↗

NASA NTRS1990

Thermal barrier coating evaluation needs

A 0.025 cm (0.010 in) thick thermal barrier coating (TBC) applied to turbine airfoils in a research gas turbine engine provided component temperature reductions of up to 190 C. These impressive temperature reductions can allow increased engine operating temperatures and reduced component cooling to achieve greater engine performance without sacrificing component durability. The significant benefits of TBCs are well established in aircraft gas turbine engine applications and their use is increasing. TBCs are also under intense development for use in the Low Heat Rejection (LHR) diesel engine currently being developed and are under consideration for use in utility and marine gas turbines. However, to fully utilize the benefits of TBCs it is necessary to accurately characterize coating attributes that affect the insulation and coating durability. The purpose there is to discuss areas in which nondestructive evaluation can make significant contributions to the further development and full utilization of TBCs for aircraft gas turbine engines and low heat rejection diesel engines.

Brindley, William J.↗

NASA NTRS1991

Thermal cycle testing of Space Station Freedom solar array blanket coupons

Lewis Research Center is presently conducting thermal cycle testing of solar array blanket coupons that represent the baseline design for Space Station Freedom. Four coupons were fabricated as part of the Photovoltaic Array Environment Protection (PAEP) Program, NAS 3-25079, at Lockheed Missile and Space Company. The objective of the testing is to demonstrate the durability or operational lifetime of the solar array welded interconnect design within the durability or operational lifetime of the solar array welded interconnect design within a low earth orbit (LEO) thermal cycling environment. Secondary objectives include the observation and identification of potential failure modes and effects that may occur within the solar array blanket coupons as a result of thermal cycling. The objectives, test articles, test chamber, performance evaluation, test requirements, and test results are presented for the successful completion of 60,000 thermal cycles.

Scheiman, David A.↗

NASA NTRS1991

Evaluation of thermal control coatings for use on solar dynamic radiators in low Earth orbit

Thermal control coatings with high thermal emittance and low solar absorptance are needed for Space Station Freedom (SSF) solar dynamic power module radiator (SDR) surfaces for efficient heat rejection. Additionally, these coatings must be durable to low earth orbital (LEO) environmental effects of atomic oxygen, ultraviolet radiation and deep thermal cycles which occur as a result of start-up and shut-down of the solar dynamic power system. Eleven candidate coatings were characterized for their solar absorptance and emittance before and after exposure to ultraviolet (UV) radiation (200 to 400 nm), vacuum UV (VUV) radiation (100 to 200 nm) and atomic oxygen. Results indicated that the most durable and best performing coatings were white paint thermal control coatings Z-93, zinc oxide pigment in potassium silicate binder, and YB-71, zinc orthotitanate pigment in potassium silicate binder. Optical micrographs of these materials exposed to the individual environmental effects of atomic oxygen and vacuum thermal cycling showed that no surface cracking occurred.

Dever, Joyce A.↗

NASA NTRS1990

The development of composite materials for spacecraft precision reflector panels

One of the critical technology needs for large precision reflectors required for future astrophysics and optical communications is in the area of structural materials. Therefore, a major area of the Precision Segmented Reflector Program at NASA is to develop lightweight composite reflector panels with durable, space environmentally stable materials which maintain both surface figure and required surface accuracy necessary for space telescope applications. Results from the materials research and development program at NASA Langley Research Center are discussed. Advanced materials that meet the reflector panel requirements are identified. Thermal, mechanical and durability properties of candidate materials after exposure to simulated space environments are compared to the baseline material.

Tompkins, Stephen S.↗

NASA NTRS1991

Evaluation of thermal control coatings for use on solar dynamic radiators in low earth orbit

Dever, Joyce A.↗

NASA NTRS1990

ATTAP/AGT101 - Year 2 progress in ceramic technology development

The progress made by the Advanced Turbine Technology Applications Project (ATTAP) is summarized, with emphasis on the following areas: ceramic materials assessment and characterization, ceramic impact damage assessment, ceramic combustor evaluation, turbine inlet particle separator development, impact-tolerant turbine designs, and net-shape ceramic component fabrications. In the evolutionary ceramics development in the Automotive Gas Turbine (AGT101) and ATTAP programs initial designs were conceived to reduce stresses by using well-established criteria: bodies of revolution were preferred over nonaxisymmetric geometries, sharp corners were avoided, the contact area between components was kept as large as possible, and small parts were preferred over large when feasible. Projects discussed include: initial ceramic component fabrication by ceramic suppliers in 1990, engine test to 1371 C in 1991, 100-hr test bed engine durability test in 1991, and 300-hr test bed engine durability in 1992.

Kidwell, J. R.↗

NASA NTRS1990

The effect of atomic oxygen on altered and coated Kapton surfaces for spacecraft applications in low earth orbit

A commercially applied silicon oxide coating on Kapton and an alternative material with Si groups on the surface were evaluated for durability with respect to atomic oxygen in both a random plasma and a directed atomic oxygen beam system. It is found that the alternative to Kapton, DuPont 93-1, is not adequately protecting to last 15 years in LEO, the desired operation time of the Space Station Freedom. The coated Kapton is considered to be promising due to the adherence of the coating and lack of extensive tearing at undercut defect sites. Fewer defects in the coating and elimination of long scratches and uncoated areas would substantially improve the durability of this material.

Rutledge, Sharon K.↗

NASA NTRS1990

Vacuum ultraviolet radiation and thermal cycling effects on atomic oxygen protective photovoltaic array blanket materials

The importance of synergistic environmental exposure is demonstrated through the evaluation of DuPont 93-1 in simulated LEO environment. Changes in optical properties, surface condition, and mass loss data are described. The qualitative results indicate the necessity for exposure of materials to a series of simulated LEO environments in order to properly determine synergistic effects and demonstrate the overall LEO durability of candidate materials. It is shown that synergistic effects may occur with vacuum thermal cycling combined with VUV radiation followed by atomic oxygen exposure. Testing the durability of candidate solar array blanket materials in a test sequence with necessary synergistic effects makes it possible to determine the appropriate material for providing structural support and maintaining the proper operating temperature for solar cells in the SSF Photovaltaic Power System.

Brady, J.↗