Reliability considerations in electronic transformers for space applications.
Quality and reliability control of spacecraft toroidal transformers noting material selection, termination techniques, performance testing, etc
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Quality and reliability control of spacecraft toroidal transformers noting material selection, termination techniques, performance testing, etc
Performance tests on separator materials for silver zinc batteries
The work being carried out at the University of Florida Solar Energy and Energy Conversion Laboratory in converting solar energy, our only income, into other needed and useful forms of energy is described. A treatment such as this demonstrates, in proper perspective, how solar energy can benefit mankind with its many problems of shortages and pollution. Descriptions were given of the conversion processes, equipment, and performance. The testing of materials, solar water heating, space heating, cooking and baking, solar distillation, refrigeration and air-conditioning, work with the solar furnace, conversion to mechanical power, hot air engines, solar-heated sewage digestion, conversion to electricity, and other devices will be discussed.
The search for advanced measurement techniques for determining long term compatibility of materials with propellants was conducted in several parts. A comprehensive survey of the existing measurement and testing technology for determining material-propellant interactions was performed. Selections were made from those existing techniques which were determined could meet or be made to meet the requirements. Areas of refinement or changes were recommended for improvement of others. Investigations were also performed to determine the feasibility and advantages of developing and using new techniques to achieve significant improvements over existing ones. The most interesting demonstration was that of the new technique, the volatile metal chelate analysis. Rivaling the neutron activation analysis in terms of sensitivity and specificity, the volatile metal chelate technique was fully demonstrated.
Completion of testing and failure analysis of MDC 40 Ahr silver zinc cells containing largely inorganic separators was accomplished. The results showed that the wet stand and cycle life objectives of the silver zinc cell development program were accomplished. Building, testing and failure analysis of two plate cells employing three optimum separators selected on the basis of extensive screening tests, was performed. The best separator material as a result of these tests was doped calcium zirconate.
An overview of major causes of device yield degradation is presented. The relationships of device types to critical processes and typical defects are discussed, and the influence of the defect on device yield and performance is demonstrated. Various defect characterization techniques are described and applied. A correlation of device failure, defect type, and cause of defect is presented in tabular form with accompanying illustrations.
The Space Shuttle Main Propulsion System provides the impulse to transfer the reusable Orbiter of the Space Shuttle Transportation system and its payload from earth to earth orbit. Both cryogenic and solid rocket propulsion systems are utilized. The selected systems are characterized by (1) reusability wherever possible to reduce program cost, (2) design pressures, and other important design parameters, for the liquid propellant engine significantly higher than past programs for increased performance, and (3) advanced materials and manufacturing processes to withstand the extreme environments. The approaches for solution of these varied problems are emphasized.
Advanced high temperature hydraulic system rod sealing requirements can be met by using seals made of nonelastomeric (plastic) materials in applications where elastomers do not have adequate life. Exploratory seal designs were optimized for advanced applications using machinable polyimide materials. These seals demonstrated equivalent flight hour lives of 12,500 at 350 F and 9,875 at 400 F in advanced hydraulic system simulation. Successful operation was also attained under simulated space shuttle applications; 96 reentry thermal cycles and 1,438 hours of vacuum storage. Tests of less expensive molded plastic seals indicated a need for improved materials to provide equivalent performance to the machined seals.
The response of a lunar-sized object to the impact of meteoroids no more than about 100 km in radius is studied by means of a numerical model. The partitioning of impact energy into the kinetic and internal energy of the ejecta is obtained by using the conservation of mass, momentum, and energy conservation equations in finite-difference form within an Eulerian framework with approximate equations of state. The calculations are performed for a 15 km/sec impact of an iron object 5 cm in radius on a gabbroic anorthosite surface. Ejecta ballistic analysis is then performed. Most of the material lost escaping the moon is lunar crust material. Only 0.2% of the meteoroid escapes, all in the vapor phase.
Approach results in synthesis of addition polyimide adhesives with exceptional high temperature capabilities that show excellent potential for bonding titanium metal, polyimide/graphite composites, and combinations of these materials. Adhesives compatible with materials used in high performance aircraft and spacecraft structures also prove highly desirable in many other applications involving similar adherents.
Development of the plasma sprayed graded, layered ZRO2/CoCrAlY seal system for gas turbine engine blade tip seal applications up to 1589 K (2400 F) surface temperature was continued. The effect of changing ZRO2/CoCrAlY ratios in the intermediate layers on thermal stresses was evaluated analytically with the goal of identifying the materials combinations which would minimize thermal stresses in the seal system. Three methods of inducing compressive residual stresses in the sprayed seal materials to offset tensile thermal stresses were analyzed. The most promising method, thermal prestraining, was selected based upon potential, feasibility and complexity considerations. The plasma spray equipment was modified to heat, control and monitor the substrate temperature during spraying. Specimens were fabricated and experimentally evaluated to: (1) substantiate the capability of the thermal prestrain method to develop compressive residual stresses in the sprayed structure and (2) define the effect of spraying on a heated substate on abradability, erosion and thermal shock characteristics of the seal system. Thermal stress analysis, including residual stresses and material properties variations, was performed and correlated with thermal shock test results. Seal system performance was assessed and recommendations for further development were made.
An investigation is conducted of the physical and chemical conditions in an expanding supernova envelope, taking into account the likelihood of grain formation and the chemical composition of the grains. An 'onionskin' presupernova model is used to estimate the chemical and isotopic abundance in the various shells of ejected supernova material. Condensation calculations are performed over a range of pressures and chemical compositions for each of these shells in order to determine the type of grains which could be produced in supernova ejecta. Only grains that are stable under the physical conditions encountered in the presolar nebula can survive and retain their anomalous composition. Two regions in the presolar nebula are considered, and the possible surviving grains are deduced from the appropriate condensation sequences.
Results of screening tests of materials for relative toxicity under specific sets of conditions are presented. Variations in the material, in lab animals, and in the test presently permit identification of major rather than minor differences among materials. Correlation with relative performance in real fire situations is based on a limited number of comparisons.
A program is presented which was aimed at determining the feasibility of using high temperature reactions of alkali metals and silicon halides to produce low cost solar-grade silicon. Experiments are being conducted to evaluate product separation and collection processes, measure heat release parameters for scaling purposes, and determine the effects of the reactants and/or products on materials of reactor construction. During the current reporting period, the results of heat release experiments were used to design and construct a new type of thick-wall graphite reactor to produce larger quantities of silicon. A reactor test facility was constructed. Material compatibility tests were performed for Na in contact with graphite and several coated graphites. All samples were rapidly degraded at T = 1200K, while samples retained structural strength at 1700K. Pyrolytic graphite coatings cracked and separated from substances in all cases.
Early time two dimensional finite difference calculations of laboratory scale hypervelocity impact of 0.3 g spherical 2024 aluminum projectiles into homogeneous plasticene clay targets were performed. Analysis of resulting material motions showed that energy and momentum were coupled quickly from the aluminum projectile to the target material. In the process of coupling, some of the plasticene clay target was vaporized while the projectile become severely deformed. The velocity flow field developed within the target was shown to have features similar to those found in calculations of near surface explosion cratering. Specific application of Maxwell's analytic Z-Model showed that this model can be used to describe the early time flow fields resulting from the impact cratering calculations as well, provided the flow field centers are located beneath the target surface and most of the projectile momentum is dissipated before the model is applied.
Approximately 512 bibliographies are presented for the time period from FY 77 to FY 79. Several non-SCR publications and a few papers not included in the last publication are included. Topics include propulsion, stratospheric emissions impact, materials and structure, aerodynamic performance, and stability and control.
The papers deal essentially with the instrumentation needs of the transportation industry, machinery diagnostics, and energy research. The sessions covered include: acoustic emission, reentry vehicle ground and flight testing, performance of nose tip materials, instrumentation for solar heating and cooling systems, vibration measurement, data acquisition and analysis, system for aerospace pressure measurements, wind tunnel instrumentation and control, energy source instrumentation, nondestructive testing, pressure and flow measurements, automated test facilities, strain measurements, electrooptical instrumentation, thermal measurements, microcomputer applications in instrumentation and automation, flight testing, blast pressure measurement, two-phase liquid/gas mass flow measurement, and machinery monitoring and instrumentation.
The key to concentrator cost effectiveness is the proper design of the reflector surface panels. The low cost concentrator reflective surface design is based on use of a thin, backsilvered mirror glass reflector bonded to a molded structural plastic substrate. This combination of reflective panel material offers excellent optical performance at low cost. The design approach, rationale for the selected configuration, and the development status are described. Reflective panel development and demonstration results are also presented.