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NASA NTRSDate not supplied

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗
NASA NTRS1973

Application of the generalized Galerkin method to the computation of fluid flows.

The purpose of this paper is to show that most existing methods for the calculation of fluid flows can be interpreted as special applications of a single mathematical formalism. This formalism, called the generalized Galerkin method, then provides a single conceptual framework for comparing various methods in terms of convergence and accuracy. The method is presented in sufficient mathematical detail to permit its interpretation as a projection in function space. In order to demonstrate the basic thesis, finite difference, finite element, strip integral, and classical integral methods of boundary layer theory are developed by application of the method.

Murphy, J. D.↗
NASA NTRS1995

Technology Transfer

The development and application of new technologies in the United States has always been important to the economic well being of the country. The National Aeronautics and Space Administration (NASA) has been an important source of these new technologies for almost four decades. Recently, increasing global competition has emphasized the importance of fully utilizing federally funded technologies. Today NASA must meet its mission goals while at the same time, conduct research and development that contributes to securing US economic growth. NASA technologies must be quickly and effectively transferred into commercial products. In order to accomplish this task, NASA has formulated a new way of doing business with the private sector. Emphasis is placed on forming mutually beneficial partnerships between NASA and US industry. New standards have been set in response to the process that increase effectiveness, efficiency, and timely customer response. This summer I have identified potential markets for two NASA inventions: including the Radially Focused Eddy Current Sensor for Characterization of Flaws in Metallic Tubing and the Radiographic Moire. I have also worked to establish a cooperative program with TAG, private industry, and a university known as the TAG/Industry/Academia Program.

Bullock, Kimberly R.↗
NASA NTRS1992

Gas detector tube applications on Space Station Freedom

The Space Station Freedom (SSF) program requires measurements, by gas detector tubes, of trace contaminants (mainly CO and toluene didsocyanate) in the Node 2 (which is isolated from the trace contaminant control system for about 100 days during the SSF building missions) and Lab A atmosphere prior to the first entry of the crew. This paper discusses the results of an analysis of the levels of trace contaminants that can be expected in the Node 2 atmosphere at 100 days and the aspects of the detector tube design and technology which may need further developent for application in microgravity. Attention is also given to the factors governing the use of detector tubes for monitoring selected contaminants.

Shah, Burt H.↗
NASA NTRS2013

Bridging the Gap Between the iLEAPS and GEWEX Land-Surface Modeling Communities

Models of Earth's weather and climate require fluxes of momentum, energy, and moisture across the land-atmosphere interface to solve the equations of atmospheric physics and dynamics. Just as atmospheric models can, and do, differ between weather and climate applications, mostly related to issues of scale, resolved or parameterised physics,and computational requirements, so too can the land models that provide the required surface fluxes differ between weather and climate models. Here, however, the issue is less one of scale-dependent parameterisations.Computational demands can influence other minor land model differences, especially with respect to initialisation, data assimilation, and forecast skill. However, the distinction among land models (and their development and application) is largely driven by the different science and research needs of the weather and climate communities.

GEWEX↗
NASA NTRS1986

Data Management System (DMS) testbed user's manual development, volumes 1 and 2

A critical review of the network communication services contained in the Tinman User's Manual for Data Management System Test Bed (Tinman DMS User's Manual) is presented. The review is from the perspective of applying modern software engineering principles and using the Ada language effectively to ensure the test bed network communication services provide a robust capability. Overall the material on network communication services reflects a reasonably good grasp of the Ada language. Language features are appropriately used for most services. Design alternatives are offered to provide improved system performance and a basis for better application software development. Section two contains a review and suggests clarifications of the Statement of Policies and Services contained in Appendix B of the Tinman DMS User's Manual. Section three contains a review of the Network Communication Services and section four contains concluding comments.

Mcbride, John G.↗
NASA NTRS1978

Rain scavenging of solid rocket exhaust clouds

An explicit model for cloud microphysics was developed for application to the problem of co-condensation/vaporization of HCl and H2O in the presence of Al2O3 particulate nuclei. Validity of the explicit model relative to the implicit model, which has been customarily applied to atmospheric cloud studies, was demonstrated by parallel computations of H2O condensation upon (NH4)2 SO4 nuclei. A mesoscale predictive model designed to account for the impact of wet processes on atmospheric dynamics is also under development. Input data specifying the equilibrium state of HC1 and H2O vapors in contact with aqueous HC1 solutions were found to be limited, particularly in respect to temperature range.

Dingle, A. N.↗
NASA NTRS2010

A Summary of NASA Related Contributions for the Remote Sensing of Evapotranspiration in Support of Water Management and Agriculture

The amount of evapotranspiration (ET) to the atmosphere can account for 60% or more of the water loss in many semi-arid locations, and can critically affect local economies tied to agriculture, recreation, hydroelectric power, ecosystems, and numerous other water-related areas. NASA supports many activities using satellite and Earth science data to more accurately and cost effectively estimate ET. NASA ET related work includes the research, development and application of techniques. The free and open access of NASA satellite data and products now permits a much wider application of ET mapping. Typically the NASA supported approaches ranges from large regional and continental ET mapping using MODIS (also with AIRS and CERES), GRACE (gravimetric water balance), geostationary (e.g., GOES and Meteosat for near continental sca|e), land surface modeling (i.e, Land Data Assimilation Systems) to fine scale mapping such as provided bvLandsatdata(<100 m). Usually satellite or airborne thermal imagery are used as input to an ET estimated surface energy balance based approach. There are currently several of these ET approaches under development and implementation including 'METRIC', 'SEBS', 'ALEXI/DisALEXI', etc.. One exception is an approach using GRACE satellite data that estimates the terrestrial water storage using gravimetric data over large areas and estimates ET indirectly. Also land surface modeling within the context of data assimilation and integration schemes provides the capability to integrate in situ, ancillary and satellite together to provide a spatially and synoptic estimates of ET also for use to provide for short-term ET predictions. We will summarize NASA related activities contributing to the improved estimation of ET for water management and agriculture with an emphasis on the Western U3.. This summary includes a description of ET projects in the Middle Rio Grande, Yakima, North Platte and other selected basins in the western US. We will also discuss plans to further address ET applications through working with the USDA and the Group on Earth Observations (GEO) to extend and evaluate western U.S. ET mapping to other parts of the U.S. and internationally.

Toll, David↗
NASA NTRS1991

Distributed, cooperating knowledge-based systems

Some current research in the development and application of distributed, cooperating knowledge-based systems technology is addressed. The focus of the current research is the spacecraft ground operations environment. The underlying hypothesis is that, because of the increasing size, complexity, and cost of planned systems, conventional procedural approaches to the architecture of automated systems will give way to a more comprehensive knowledge-based approach. A hallmark of these future systems will be the integration of multiple knowledge-based agents which understand the operational goals of the system and cooperate with each other and the humans in the loop to attain the goals. The current work includes the development of a reference model for knowledge-base management, the development of a formal model of cooperating knowledge-based agents, the use of testbed for prototyping and evaluating various knowledge-based concepts, and beginning work on the establishment of an object-oriented model of an intelligent end-to-end (spacecraft to user) system. An introductory discussion of these activities is presented, the major concepts and principles being investigated are highlighted, and their potential use in other application domains is indicated.

Truszkowski, Walt↗
NASA NTRS1985

Development of design criteria and qualification tests for bypass diodes in photovoltaic applications

Design criteria have been developed for bypass diodes in p-n and Schottky barrier in photovoltaic applications. A test method for assessing conformity to the design criteria is described. Junction temperatures are defined in terms of expected worst-case field conditions, including ambient temperature and solar irradiance on the photovoltaic module. The rating criteria address the maximum allowable current and heat-sink characteristics of diodes mounted inside or outside the photovoltaic module. The method establishes worst-case module-to-diode thermal interfaces and may be adapted for laboratory or field-site experiments. A list of the design criteria is given.

Otth, D. H.↗
NASA NTRS1981

Management of the Galileo attitude and articulation control flight software development

Management concepts are presented for software development for a new technology area, i.e., real-time autonomous, computer-based spacecraft control. Flight computer selection and sizing are done initially to maximize performance within constraints of size, power, and cost. A higher order language is chosen to enhance productivity. Because the computer is embedded in the control systems hardware and is tied to the iterative design process of the spacecraft, the management and configuration control of the software is different from more typical applications. The development process must permit early coding but accept late changes. Margin management must be a continuing process in the development. Validation and verification is a special problem because it is not feasible to test the software in the actual operating environment prior to launch.

Pace, G. D.↗
NASA NTRS2002

Goddard Cumulus Ensemble (GCE) Model: Application for Understanding Precipitation Processes

One of the most promising methods to test the representation of cloud processes used in climate models is to use observations together with Cloud Resolving Models (CRMs). The CRMs use more sophisticated and realistic representations of cloud microphysical processes, and they can reasonably well resolve the time evolution, structure, and life cycles of clouds and cloud systems (size about 2-200 km). The CRMs also allow explicit interaction between out-going longwave (cooling) and incoming solar (heating) radiation with clouds. Observations can provide the initial conditions and validation for CRM results. The Goddard Cumulus Ensemble (GCE) Model, a cloud-resolving model, has been developed and improved at NASA/Goddard Space Flight Center over the past two decades. Dr. Joanne Simpson played a central role in GCE modeling developments and applications. She was the lead author or co-author on more than forty GCE modeling papers. In this paper, a brief discussion and review of the application of the GCE model to (1) cloud interactions and mergers, (2) convective and stratiform interaction, (3) mechanisms of cloud-radiation interaction, (4) latent heating profiles and TRMM, and (5) responses of cloud systems to large-scale processes are provided. Comparisons between the GCE model's results, other cloud-resolving model results and observations are also examined.

Tao, Wei-Kuo↗
NASA NTRS1982

Creep crack-growth: A new path-independent integral (T sub c), and computational studies

The development of valid creep fracture criteria is considered. Two path-independent integral parameters which show some degree of promise are the C* and (Delta T)sub c integrals. The mathematical aspects of these parameters are reviewed by deriving generalized vector forms of the parameters using conservation laws which are valid for arbitrary, three dimensional, cracked bodies with crack surface tractions (or applied displacements), body forces, inertial effects, and large deformations. Two principal conclusions are that (Delta T)sub c has an energy rate interpretation whereas C* does not. The development and application of fracture criteria often involves the solution of boundary/initial value problems associated with deformation and stresses. The finite element method is used for this purpose. An efficient, small displacement, infinitesimal strain, displacement based finite element model is specialized to two dimensional plane stress and plane strain and to power law creep constitutive relations. A mesh shifting/remeshing procedure is used for simulating crack growth. The model is implemented with the quartz-point node technique and also with specially developed, conforming, crack-tip singularity elements which provide for the r to the n-(1+n) power strain singularity associated with the HRR crack-tip field. Comparisons are made with a variety of analytical solutions and alternate numerical solutions for a number of problems.

Stonesifer, R. B.↗
NASA NTRS2019

Transition Detection at Cryogenic Temperatures Using a Carbon-Based Resistive Heating Layer Coupled with Temperature Sensitive Paint

This paper will highlight the development and application of a carbon-based resistive heating layer for use in transition detection at cryogenic temperatures at the National Transonic Facility (NTF) for full-flight Reynolds number testing. This study builds upon previous work that was successfully demonstrated at the 0.3-m Transonic Cryogenic Tunnel on a smaller-scale airfoil shape of regular geometry. However, the test performed at the NTF involved a semispan wing with complex geometry and significantly larger than previous tests. This required the development of new coatings to provide suitable resistances to provide adequate heating rates for transition detection. Successful implementation of this technology has the ability to greatly enhance transition detection experiments at cryogenic temperatures as well as reducing perturbation in the tunnel caused by more traditional transition detection methods.

Watkins, A. Neal↗
NASA NTRS2003

High-Temperature Oxidation-Resistant and Low Coefficient of Thermal Expansion NiAl-Base Bond Coat Developed for a Turbine Blade Application

Many critical gas turbine engine components are currently made from Ni-base superalloys that are coated with a thermal barrier coating (TBC). The TBC consists of a ZrO2-based top coat and a bond coat that is used to enhance the bonding between the superalloy substrate and the top coat. MCrAlY alloys (CoCrAlY and NiCrAlY) are currently used as bond coats and are chosen for their very good oxidation resistance. TBC life is frequently limited by the oxidation resistance of the bond coat, along with a thermal expansion mismatch between the metallic bond coat and the ceramic top coat. The aim of this investigation at the NASA Glenn Research Center was to develop a new longer life, higher temperature bond coat by improving both the oxidation resistance and the thermal expansion characteristics of the bond coat. Nickel aluminide (NiAl) has excellent high-temperature oxidation resistance and can sustain a protective Al2O3 scale to longer times and higher temperatures in comparison to MCrAlY alloys. Cryomilling of NiAl results in aluminum nitride (AlN) formation that reduces the coefficient of thermal expansion (CTE) of the alloy and enhances creep strength. Thus, additions of cryomilled NiAl-AlN to CoCrAlY were examined as a potential bond coat. In this work, the composite alloy was investigated as a stand-alone substrate to demonstrate its feasibility prior to actual use as a coating. About 85 percent of prealloyed NiAl and 15 percent of standard commercial CoCrAlY alloys were mixed and cryomilled in an attritor with stainless steel balls used as grinding media. The milling was carried out in the presence of liquid nitrogen. The milled powder was consolidated by hot extrusion or by hot isostatic pressing. From the consolidated material, oxidation coupons, four-point bend, CTE, and tensile specimens were machined. The CTE measurements were made between room temperature and 1000 C in an argon atmosphere. It is shown that the CTE of the NiAl-AlN-CoCrAlY composite bond coat is lower than that of the commercially used coating alloy 16-6. To examine the potential of NiAl-AlN-CoCrAlY as a bond coat, we subjected two samples to cyclic furnace testing. The furnace cycle consisted of 45 min at 1163 C (2125 F ) followed by 15 min of cooling out of the furnace. The current NASA baseline TBC is a NiCrAlY bond coat below the 7YSZ top coat. The average TBC life for this baseline coating on Ren N5 is 188 plus or minus 19 cycles. NiAl-AlN-CoCrAlY specimens coated with the same 7YSZ top coat were still intact even after 1000 cycles. Therefore, the NiAl-AlN-CoCrAlY as a bulk substrate material, exhibits more than 5 times the life of the current state-of-the-art material. The next step is to evaluate this material as a coating on the same superalloy substrate.

Source record↗
NASA NTRS1979

Frost formation on an airfoil: A mathematical model 1

A computer model to predict the frost formation process on a flat plate was developed for application to most environmental conditions under which frost occurs. The model was analytically based on a generalized frost thermal conductivity expression, on frost density and thickness rate equations, and on modified heat and mass transfer coefficients designed to fit the available experimental data. The broad experimental ranges reflected by the extremes in ambient humidities, wall temperatures, and convective flow properties in the various publications which were examined served to severely test the flexibility of the model. An efficient numerical integration scheme was developed to solve for the frost surface temperature, density, and thickness under the changing environmental conditions. The comparison of results with experimental data was very encouraging.

Dietenberger, M.↗
NASA NTRS1999

Realistic NLTE Radiative Transfer for Modeling Stellar Winds

This NASA grant supported the development of codes to solve the non-LTE multi-level spherical radiative transfer problem in the presence of velocity fields. Much of this work was done in collaboration with Graham Harper (CASA, University of Colorado). These codes were developed for application to the cool, low-velocity winds of evolved late-type stars. Particular emphasis was placed on modeling the wind of lambda Velorum (K4 lb), the brightest K supergiant in the sky, based on extensive observations of the ultraviolet spectrum with the HST/GHRS from GO program 5307. Several solution techniques were examined, including the Eddington factor Approach described in detail by Bennett & Harper (1997). An Eddington factor variant of Harper's S-MULTI code (Harper 1994) for stationary atmospheres was developed and implemented, although full convergence was not realized. The ratio of wind terminal velocity to turbulent velocity is large (approx. 0.3-0.5) in these cool star winds so this assumption of stationarity provides reasonable starting models. Final models, incorporating specified wind laws, were converged using the comoving CRD S-MULTI code. Details of the solution procedure were published by Bennett & Harper (1997). Our analysis of the wind of lambda Vel, based on wind absorption superimposed on chromospheric emission lines in the ultraviolet, can be found in Carpenter et al. (1999). In this paper, we compare observed wind absorption features to an exact CRD calculation in the comoving frame, and also to a much quicker, but approximate, method using the SEI (Sobolev with Exact Integration) code of Lamers, Cerruti-Sola, & Perinotto (1987). Carpenter et al. (1999) provide detailed comparisons of the exact CRD and approximate SEI results and discuss when SEI is adequate to use for computing wind line profiles. Unfortunately, the observational material is insufficient to unambiguously determine the wind acceleration law for lambda Vel. Relatively few unblended Fe II lines of optical depth sensitive to the wind acceleration region are present in the existing HST/GHRS data set. Most of the Fe II lines are either too optically thick (resulting in a board, black wind absorption profile) or too optically thin (resulting in no wind absorption feature present). Also, most of the ultraviolet spectra obtained from HST GO-5307 was at medium resolution (R approx. 40,000, corresponding to a velocity resolution of 7.5 km/s). This is simply inadequate to resolve the turbulence in the outer wind; a key parameter in theoretical wind models. We can now say that an unambiguous determination of the wind velocity law in lambda Vel will require complete coverage of the ultraviolet spectrum at high dispersion (R approx. 10(exp 5), or 3 km/s). This is now feasible usin, the STIS echelle spectrograph on-board HST.

Bennett, Philip D.↗