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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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A hypervelocity impact (HVI) Whipple Shield and a method for shielding a wall from penetration by high velocity particle impacts where the Whipple Shield is comprised of spaced apart inner and outer metal sheets or walls with an intermediate cloth barrier arrangement comprised of ceramic cloth and high strength cloth which are interrelated by ballistic formulae.
In order to reduce the overall weight in spaceborne electronic systems, a conventional metallic heat sink typically used for double-sided printed wiring boards was suggested to be replaced by light-weight and high-strength laminated composite materials. Through technology validation assurance (TVA) approach, it has been successfully demonstrated that using laminated composite heat sink can not only reduce the weight of the heat sink by nearly 50%, but also significantly lower the internal thermally-induced stresses that are largely responsible for potential delamination under cyclic temperature variations. With composite heat sink, both thermal and dynamic performance of the double-sided printed wiring board (PWB) exceeds that of its counterpart with metallic heat sink. Also included in this work is the original contribution to the understanding of creep behavior of the worst-case leadless chip carrier (LCC) surface mount solder joint. This was identified as the interconnection most susceptible to thermal fatigue damage in the PWB assembly.
High energy milling of NiAl in liquid nitrogen (cryomilling) leads to the formation of a discontinuously AlN particle reinforced aluminide which has shown good potential as a high strength oxidation resistant material. Experiments have demonstrated that cryomilling is repeatable, and materials with reproducible chemistries and mechanical properties result. Furthermore, it is possible to vary the AlN content through control of the milling parameters. Tensile creep as well as compressive creep testing has been undertaken on a lot of NiAl-AlN. While this material is weaker in tension than compression, the tensile strength is respectable: for example, the creep rupture life exceeds 2700 h at 1300 K, 50 MPa. Heat treatment of the particulate reinforced aluminide at 1600 K promotes AlN growth which weakens the material but does not change the deformation mechanism. Cyclic oxidation testing of lots of NiAl-AlN which were cryomilled with and without yttria reveal that Y2O3 promotes better oxidation resistance. However, the presence or absence of yttria had no affect on the mechanical properties.
The room temperature physical and mechanical properties of silicon carbide fiber-reinforced reaction-bonded silicon nitride matrix composites (SiC/RBSN) were measured, and the composite microstructure was analyzed. The composites consist of nearly 24 vol% of aligned Hi-Nicalon SiC fiber yarns in a approx. 30 vol% porous silicon nitride matrix. The fiber yarns were coated by chemical vapor deposition with a 0.8 mm layer of boron nitride (BN) followed by a 0.2 mm layer of SiC. In the as-fabricated condition, both 1-D and 2-D composites exhibited high strength and graceful failure, and showed improved properties w en compared with unreinforced matrix of comparable density. No indication of reaction between the SiC fiber and BN coating was noticed, but the outer SiC layer reacted locally with the nitridation enhancing additive in the RBSN matrix. A comparison is made between the predicted and measured values of matrix cracking strength.
As a reinforcement for structural composites, single crystal alumina fibers offer low density, high modulus, and high creep resistance. In this study, the laser heated float zone approach was employed to grow c-axis Al2O3 continuous fibers of high purity and high strength. A new melt modulation technique, laser scanning, avoids the formation of surface induced ripples and allows the growth of 50 micro-m diameter sapphire fibers with strengths (approx. 7 GPa) significantly greater than either commercially available fibers grown by the edge-defined film growth process (approx. 2-3 GPa) or laboratory fibers grown by stationary laser heating (approx. 5 GPa). The present work suggests that surface striations are the predominant defects controlling the tensile strength of laser-scanned fibers at room temperature. Several possible mechanisms for inducing surface striations are systematically discussed for several oxide fiber compositions.
The purpose of this reasearch effort was to develop high temperature, oxidation resistant thrusters which would lessen the thruster cooling requirements, resulting in increased performance and longer life for onboard propulsion systems for spacecraft. This research effort focussed on developing ceramic matrix composites (CMCs) for this application, and specifically investigated the use of HfC stabilized with TaC. This material composition can potentially operate in a stoichiometric oxygen to hydrogen ratio at a temperature of 5000 deg F (2760 deg C) in a radiatively cooled mode. Various compositions of Hafnium Carbide (HfC) and Tantalum Carbide (TaC) were deposited by chemical vapor deposition (CVD) and tested, in an attempt to identify the composition which offered the best oxidation resistance. Although it was identified that small amounts of TaC appeared to offer improved oxidation resistance over HfC alone, an optimal composition was not identified. A 251bf thruster was fabricated from a novel CMC sandwich construction with a HfC-TaC matrix, and survived two test firings, each of 5 seconds before a failure in the injector caused the run to be aborted. It was not possible to control the relative stoichiometry of the HfC and TaC composition throughout the reactor due to the large difference in the thermodynamics of the HfC and TaC formation from their respective chlorides. This also resulted in an inability to infiltrate TaC into the preform under the experimental conditions investigated. Other material compositions were fabricated and tested and two material systems; HfC-SiC functionally graded to C(sub f)/C and Re functionally graded to C(sub f)/C were selected for further testing. These functionally graded composites have use in a number of propulsion applications presently of interest to NASA and the defense industry. Their ability to withstand extremely hostile thermal environments and the light-weight and high-strength exhibited from the C(sub f)/C composite make these materials particularly suited for these applications. In the Phase III which is presently underway, Re functionally graded to C(sub f)/C is being further developed and tested for application in the thrust cells for the Linear Aerospike Engine for the X33 and RLV.
The Constellation-X Spectroscopy X-ray Telescope (SXT) will provide high-throughput, high-resolution spectroscopy of cosmic sources, from 0.25 keV to 10 keV. Key to this capability is the development of large (1.6 m diameter), lightweight optics for the SXT mirror assembly. Teams led by NASA's Marshall Space Flight Center (MSFC), by NASA's Goddard Space Flight Center (GSFC), and by Italy's Osservatorio Astronomico di Brera (OAB) are currently developing competing mirror technologies for this planned mission. Each team is making significant research progress in developing mirror technologies which satisfy the SXT requirements for lightweight optics, consistent with a system-level optical performance of better than 15 arcsec half-power diameter. The NASA Marshall Space Flight Center (MSFC), in collaboration with the Smithsonian Astrophysical Observatory (SAO), has focussed its efforts on full-shell replicated optics, of electroformed nickel alloys. Recent progress in identifying a surface treatment to effect low, controlled adhesion and, more significantly, in developing new high-strength nickel alloys make this a viable, low cost approach to satisfying the SXT requirements.
One of the major technological challenges for the Constellation X-ray Mission is the development of light-weight, high-resolution, grazing-incidence optics. NASA's Marshall Space Flight Center is developing and evaluating candidate technologies, based upon full-shell replication off precision mandrels. Here we report on recent progress in meeting the weight and imaging-performance requirements, using very thin, high-strength electroformed nickel alloys. In addition, we briefly describe MSFC's optics fabrication, metrology, and x-ray test facilities.
Aerojet in the mid 1960s, under contract to NASA, built and static hot fire tested the largest solid rocket motor (SRM) in history for the purpose of demonstrating the feasibility of utilizing large SRMs for space exploration. This program successfully fabricated two high strength steel chambers, loaded each with approximately 1,68 million pounds of propellant, and static test fired these giants with their nozzles up from an underground silo located adjacent to the Florida everglades. Maximum thrust and total impulse in excess of 5,000,000 lbf and 3,470,000,000 lbf-sec were achieved. Flames from the second firing, conducted at night, were seen over eighty miles away. For comparative purposes: the thrust developed was nearly 100 times that of a Minuteman III second stage and the 260 in.-dia cross-section was over 3 times that of the Space Shuttle SRM.
One of the major technological challenges for the Constellation X-ray Mission is the development of light-weight, high-resolution, grazing-incidence optics. NASA's Marshall Space Flight Center is developing and evaluating candidate technologies, based upon full-shell replication off precision mandrels. Here we report on recent progress in meeting the weight and imaging-performance requirements, using very thin, high- strength electroformed nickel alloys, In addition, we briefly describe MSFC's optics fabrication, metrology, and x-ray test facilities.
We are developing high-energy grazing-incidence replicated optics for a balloon-borne hard-x-ray telescope. When completed, the instrument will have 170 cm2 of effective collecting area at 40 keV and 130 square cm at 60 keV with <= 30 arc seconds half power diameter. This payload will offer unprecedented sensitivity in the hard-x-ray region, with around 250 microCrab sensitivity on long-duration flights and 50-100 microCrab on ultra- long-duration balloon missions The payload consists of 16 mirror modules, each with 14 nested mirrors made from a high-strength nickel alloy, and a corresponding array of 16 focal plane detectors. An engineering demonstration flight is scheduled for the Spring of 2000, using just two mirror modules each with 3 shells, above a pair of gas-scintillation-proportional counters. This flight is intended to test a newly designed gondola pointing and aspect system and the stability of the optical bench design. The first scientific flight of the full payload is scheduled for the Fall of 2002. Full details of the payload and its capabilities will be presented together with data from various mirror-module tests. If available data from the first flight will also be presented.
One of the major technological challenges for the Constellation X-ray Mission is the development of light-weight, high-resolution, grazing-incidence optics. NASA's Marshall Space Flight Center is developing and evaluating candidate technologies, based upon full-shell replication off precision mandrels. Here we report on recent progress in meeting the weight and imaging-performance requirements, using very thin, high-strength electroformed nickel alloys. In addition, we briefly describe MSFC's optics fabrication, metrology, and x-ray test facilities.
The room temperature physical and mechanical properties of silicon carbide fiber-reinforced reaction-bonded silicon nitride matrix composites (SiC/RBSN) were measured, and the composite microstructure was analyzed. The composites consist of nearly 24 vol% of aligned Hi-Nicalon SiC fiber yarns in a approx. 30 vo1% porous silicon nitride matrix. The fiber yarns were coated by chemical vapor deposition with a 0.8 micron layer of boron nitride (BN) followed by a 0.2 micron layer of SiC. In the as-fabricated condition, both 1-D and 2-D composites exhibited high strength and graceful failure, and showed improved properties when compared with unreinforced matrix of comparable density. No indication of reaction between the SiC fiber and BN coating was noticed, but the outer SiC layer reacted locally with the nitridation enhancing additive in the RBSN matrix. A comparison is made between the predicted and measured values of matrix cracking strength.
Replicated electroformed light-weight nickel alloy mirrors can have high strength, low areal density (<3kg/m2), smooth finish, and controllable alloy composition. Progress at NASA MSFC SOMTC in developing normal incidence replicated Nickel mirrors will be reported.
Lockheed Martin Space Systems, Michoud Operations in New Orleans, LA is the manufacturer of the External Fuel Tanks (ET) for the Space Transportation System (STS). The ET contains and delivers the propellants used by the Orbiters three main engines. Additionally, it also serves as the structural backbone for the Orbiter and the two Solid Rocket Boosters (SRB), which combined, constitute the STS. In 1994, NASA established that in order to launch the International Space Station, the performance of the STS must be improved. One option was to reduce the weight of the ET, which would enable sufficient increase in performance. With the development of the Weldalite(R) series of Al-Cu-Li alloys in the late 1980's, Lockheed Martin was postured to replace the current A12219 fuel tanks with the high strength, light weight A12195 alloy. With the use of A12195 and some component redesign, the weight of the Super Lightweight (SLWT) ET was reduced by approximately 7,000 pounds, which added as much capability to the Space Shuttle. Since June 1998, seven STS missions have been successful with the use of the SLWT ET's.
Through-canopy crew egress, such as in the Harrier (AV-8B) aircraft, expands escape envelopes by reducing seat ejection delays in waiting for canopy jettison. Adverse aircraft attitude and reduced forward flight speed can further increase the times for canopy jettison. However, the advent of heavy, high-strength polycarbonate canopies for bird-strike resistance has not only increased jettison times, but has made seat penetration impossible. The goal of the effort described in this paper was to demonstrate a method of explosively fracturing the F-16 polycarbonate canopy to allow through-canopy crew ejection. The objectives of this effort were to: 1. Mount the explosive materials on the exterior of the canopy within the mold line, 2. Minimize visual obstructions, 3. Minimize internal debris on explosive activation, 4. Operate within less than 10 ms, 5. Maintain the shape of the canopy after functioning to prevent major pieces from entering the cockpit, and 6. Minimize the resistance of the canopy to seat penetration. All goals and objectives were met in a full-scale test demonstration. In addition to expanding crew escape envelopes, this canopy fracture approach offers the potential for reducing system complexity, weight and cost, while increasing overall reliability, compared to current canopy jettison approaches. To comply with International Traffic in Arms Regulations (ITAR) and permit public disclosure, this document addresses only the principles of explosive fracturing of the F-16 canopy materials and the end result. ITAR regulations restrict information on improving the performance of weapon systems. Therefore, details on the explosive loads and final assembly of this canopy fracture approach, necessary to assure functional performance, are not included.
A detailed fatigue characterization of Alloy 10, a high strength nickel-based disk alloy, was conducted on test coupons machined from a 'pancake' forging. Smooth bar, strain controlled fatigue testing at various R-ratios was run at representative bore, 750 F, and rim, 1300 F, temperatures. This was followed by notch fatigue testing (Kt=2) run under load control. Analysis of the fatigue data using a Smith-Watson-Topper approach and finite element analysis of the notch root was employed to understand material behavior in these tests. Smooth bar fatigue data showed a significant R-ratio dependence at either test temperature which could be accounted for using a Smith-Watson-Topper parameter (SWT). In general, fatigue life was longer at 750 F than 1300 F for a given SWT. For notch fatigue tests, life was longer at 750 F than 1300 F but only at higher stresses. This was attributed to differences in alloy strength. At lower stresses, finite element analysis suggested that convergence of fatigue life at both temperatures resulted from relaxation of stresses at the notch root in the 1300 F tests.
Methods to improve the high temperature, dwell crack growth resistance of Alloy 10, a high strength, nickel-base disk alloy, were studied. Two approaches, heat treat variations and composition modifications, were investigated. Under the heat treat approach, solution temperature, cooling rates, and stabilization, were studied. It was found that higher solution temperatures, which promote coarser grain sizes, coupled with a 1550 F stabilization treatment were found to significantly reduce dwell crack growth rates at 1300 F Changes in the niobium and tantalum content were found to have a much smaller impact on crack growth behavior. Lowering the niobium:tantalum ratio did improve crack growth resistance and this effect was most pronounced for coarse grain microstructures. Based on these findings, a coarse grain microstructure for Alloy 10 appears to be the best option for improving dwell crack growth resistance, especially in the rim of a disk where temperatures can reach or exceed 1300 T. Further, the use of advanced processing technologies, which can produce a coarse grain rim and fine grain bore, would be the preferred option for Alloy 10 to obtain the optimal balance between tensile, creep, and crack growth requirements for small gas turbine engines.