Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Extrusion Process”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 145 records · Page 8

Vacuum Plasma Spray Forming of Copper Alloy Liners for Regeneratively Cooled Liquid Rocket Combustion Chambers

Vacuum plasma spray (VPS) has been demonstrated as a method to form combustion chambers from copper alloys NARloy-Z and GRCop-84. Vacuum plasma spray forming is of particular interest in the forming of CuCrNb alloys such as GRCop-84, developed by NASA s Glenn Research Center, because the alloy cannot be formed using conventional casting and forging methods. This limitation is related to the levels of chromium and niobium in the alloy, which exceed the solubility limit in copper. Until recently, the only forming process that maintained the required microstructure of CrNb intermetallics was powder metallurgy formation of a billet from powder stock, followed by extrusion. This severely limits its usefulness in structural applications, particularly the complex shapes required for combustion chamber liners. This paper discusses the techniques used to form combustion chambers from CuCrNb and NARloy-Z, which will be used in regeneratively cooled liquid rocket combustion chambers.

Zimmerman, Frank↗

Organic materials for ceramic molding processes

Ceramic molding processes are examined. Binders, wetting agents, lubricants, plasticizers, surface active agents, dispersants, etc., for pressing, rubber pressing, sip casting, injection casting, taping, extrusion, etc., are described, together with forming machines.

Saito, K.↗

Fabrication development for ODS-superalloy, air-cooled turbine blades

MA-600 is a gamma prime and oxide dispersion strengthened superalloy made by mechanical alloying. At the initiation of this program, MA-6000 was available as an experimental alloy only and did not go into production until late in the program. The objective of this program was to develop a thermal-mechanical-processing approach which would yield the necessary elongated grain structure and desirable mechanical properties after conventional press forging. Forging evaluations were performed to select optimum thermal-mechanical-processing conditions. These forging evaluations indicated that MA-6000 was extremely sensitive to die chilling. In order to conventionally hot forge the alloy, an adherent cladding, either the original extrusion can or a thick plating, was required to prevent cracking of the workpiece. Die design must reflect the requirement of cladding. MA-6000 was found to be sensitive to the forging temperature. The correct temperature required to obtain the proper grain structure after recrystallization was found to be between 1010-1065 C (1850-1950 F). The deformation level did not affect subsequent crystallization; however, sharp transition areas in tooling designs should be avoided in forming a blade shape because of the potential for grain structure discontinuities. Starting material to be used for forging should be processed so that it is capable of being zone annealed to a coarse elongated grain structure as bar stock. This conclusion means that standard processed bar materials can be used.

Moracz, D. J.↗

The Regolith of 4 Vesta: Perspectives from Howardite Meteorites and Dawn Mission Observations

4 Vesta is the largest asteroid with a basaltic surface, the only surviving differentiated asteroid recording igneous processes from the earliest phase of solar system history. The Dawn spacecraft is in orbit about Vesta pursuing a campaign of high resolution imaging and visible and infrared spectrometry of the surface; compositional mapping by gamma-ray and neutron spectrometry will follow. Vesta is heavily cratered with a surface covered by impact debris, a regolith. One important goal of the Dawn mission is to develop an understanding of regolith processes that are affecting this surface debris. Regolith characteristics are a record of interaction with the environment (e.g., impactors, dust, solar wind, galactic cosmic-rays) and give evidence of surface processes (down-gravity movement, etc.). Regolith mineralogy and composition reflect the local bedrock, with influences from regional and global mixing. Understanding regolith processes will aid in determining the lithology of underlying crust. Vesta is most likely the parent asteroid of the howardite, eucrite and diogenite meteorites. Eucrites are intrusive and extrusive mafic rocks composed mostly of ferroan low-Ca clinopyroxene and calcic plagioclase, while diogenites are cumulate magnesian orthopyroxenites. Magmatism occurred within a few million years of the formation of the solar system and then ceased. Impacts into the igneous crust produced the howardites - polymict breccias composed of mineral and lithic debris derived mostly from eucrites and diogenites. Some howardites are true regolith breccias formed by lithification of extensively impact-gardened surface debris. However, howardites have a number of significant petrologic and compositional differences from mature lunar regolith breccias and soils reflecting the different environment around Vesta compared to that at 1 AU. The most significant differences are the higher impactor flux with a lower mean impact velocity and the lower gravity. As a result, regolith processes on Vesta differ in detail from those on the Moon. Laboratory study of howardites and orbital investigation of Vesta will allow for development of robust models of regolith formation on hand sample to multi-kilometer scales.

Mittlefehldt, David W.↗

Nutritional Evaluation of NASA's Rodent Food Bar Diet

Tests are being conducted on NASA's rodent Food Bar in preparation for long-term use as the rat and mouse diet aboard the International Space Station. Nutritional analyses are performed after the bars are manufactured and then repeated periodically to determine nutritional stability. The primary factors analyzed are protein, ash, fat, fiber, moisture, amino acids, fatty acids, and minerals. Nutrient levels are compared to values published in the National Research Council's dietary requirements for rodents, and also to those contained in several commonly used commercial rodent lab diets. The Food Bar is manufactured from a powdered diet to which moisture is added as it is processed through an extruder. The bars are dipped into potassium sorbate, vacuum-sealed, and irradiated. In order to determine nutrient changes during extrusion and irradiation, the powdered diet, the non-irradiated bars, and the irradiated bars are all analyzed. We have observed lower values for some nutrients (iodine, vitamin K, and iron) in the Food Bars compared with NRC requirements. Many nutrients in the Food Bars are contained at a higher level than levels in the NRC requirements. An additional factor we are investigating is the 26% moisture level in the Food Bars, which drops to about 15% within a week, compared to a stable 10% moisture in many standard lab chow diets. In addition to the nutritional analyses, the food bar is being fed to several strains of rats and mice, and feeding study and necropsy results are being observed (Barrett et al, unpublished data). Information from the nutritional analyses and from the rodent studies will enable us to recommend the formulation that will most adequately meet the rodent Food Bar requirements for long-term use aboard the Space Station.

Barrett, Joyce E.↗

Effects of thermomechanical processing on tensile and long-time creep behavior of Nb-1 percent Zr-0.1 percent C sheet

Effects of thermomechanical processing on the mechanical properties of Nb-1 wt. percent Zr-0.1 wt. percent C, a candidate alloy for use in advanced space power systems, were investigated. Sheet bars were cold rolled into 1-mm thick sheets following single, double, or triple extrusion operations at 1900 K. All the creep and tensile specimens were given a two-step heat treatment 1 hr at 1755 K + 2 hr 1475 K prior to testing. Tensile properties were determined at 300 as well as at 1350 K. Microhardness measurements were made on cold rolled, heat treated, and crept samples. Creep tests were carried out at 1350 K and 34.5 MPa for times of about 10,000 to 19,000 hr. The results show that the number of extrusions had some effects on both the microhardness and tensile properties. However, the long-time creep behavior of the samples were comparable, and all were found to have adequate properties to meet the design requirements of advanced power systems regardless of thermomechanical history. The results are discussed in correlation with processing and microstructure, and further compared to the results obtained from the testing of Nb-1 wt. percent Zr and Nb-1 wt. percent Zr-0.06 wt. percent C alloys.

Titran, Robert H.↗

Development of dispersion-strengthened XD (trademark) Cu alloys for high heat-flux applications

In a previous effort sponsored by NASA LeRC, the XD(trademark) process was used to produce ZrB2 particulate reinforcements in Cu and the resulting extruded material was microstructurally characterized and evaluated in tension over a range of temperatures. A problem that was encountered in that study was microstructural inhomogeneity resulting from the frequent presence of 'ZrB2 agglomerates' that were several microns in size. The presence of these agglomerates was attributed to improper mixing of powders in the green compact used in the XD process for elemental boron powder segregation. In this program, several milling parameters were examined in an effort to optimize this processing step; two levels of ZrB2 reinforcements were considered (7 vol. percent and 15 vol. percent). Microstructures of the reacted powder mass were examined to verify the absence of these agglomerates. Larger bathes of powder were then mixed, reacted, machined to size, canned, and extruded. The microstructure and tensile properties of these extrusions were examined, and the measured properties were correlated with the observed microstructure. Large unreacted or partially reacted Zr particles were present. These particles affected the mechanical properties deleteriously, and their presence is attributed to insufficient heat of reaction during XD synthesis. Alternate processing routes are recommended.

Kumar, K. Sharvan↗

The structure of extruded NiAl

The deformation structure of Ni-rich NiAl extruded at 550 C has been characterized by transmission electron microscopy and by optical microscopy. Dislocations having a(100) Burgers vectors were found as complex networks, tangles, and prismatic loops. a(110) dislocations, which were rare, were concluded to arise from reactions of a(100) dislocations. Evidence of recovery and recrystallization was obtained. Extrusion was deemed to have been possible by the operation of (hko)(001) slip systems (often in plane strain flow) plus diffusion-assisted processes.

Baker, I.↗

Development of oxide dispersion strengthened turbine blade alloy by mechanical alloying

There were three nickel-base alloys containing up to 18 wt. % of refractory metal examined initially for oxide dispersion strengthening. To provide greater processing freedom, however, a leaner alloy was finally selected. This base alloy, alloy D, contained 0.05C/15Cr / 2Mo/4W/2Ta/4.5Al/2.Ti/015Zr/0.01-B/Bal. Ni. Following alloy selection, the effect of extrusion, heat treatment, and oxide volume fraction and size on microstructure and properties were examined. The optimum structure was achieved in zone annealed alloy D which contained 2.5 vol. % of 35 mm Y2O3 and which was extruded 16:1 at 1038 C.

Merrick, H. F.↗

Effect of grain size on the high temperature properties of B2 aluminides

Measurements of the slow plastic flow behavior of cobalt, iron and nickel B2 crystal structure aluminides were conducted on materials fabricated by metallurical techniques. Due to this processing, the aluminides invariably had small equiaxed grains, ranging in size from about 3 to 60 microns in diameter. Grain size was dependent on the extrusion temperature used for powder consolidation, and it proved to be remarkably stable at elevated temperatures. Mechanical properties of all three aluminides were determined via constant velocity compression testing in air between 1000 and 1400 K at strain rates ranging from approx. 10 to the minus 3 power to 10 to the minus 7 power s (-1).

Whittenberger, J. Daniel↗

Artificial Neural Network Test Support Development for the Space Shuttle PRCS Thrusters

A significant anomaly, Fuel Valve Pilot Seal Extrusion, is affecting the Shuttle Primary Reaction Control System (PRCS) Thrusters, and has caused 79 to fail. To help address this problem, a Shuttle PRCS Thruster Process Evaluation Team (TPET) was formed. The White Sands Test Facility (WSTF) and Boeing members of the TPET have identified many discrete valve current trace characteristics that are predictive of the problem. However, these are difficult and time consuming to identify and trend by manual analysis. Based on this exhaustive analysis over months, 22 thrusters previously delivered by the Depot were identified as high risk for flight failures. Although these had only recently been installed, they had to be removed from Shuttles OV103 and OV104 for reprocessing, by directive of the Shuttle Project Office. The resulting impact of the thruster removal, replacement, and valve replacement was significant (months of work and hundreds of thousands of dollars). Much of this could have been saved had the proposed Neural Network (NN) tool described in this paper been in place. In addition to the significant benefits to the Shuttle indicated above, the development and implementation of this type of testing will be the genesis for potential Quality improvements across many areas of WSTF test data analysis and will be shared with other NASA centers. Future tests can be designed to incorporate engineering experience via Artificial Neural Nets (ANN) into depot level acceptance of hardware. Additionally, results were shared with a NASA Engineering and Safety Center (NESC) Super Problem Response Team (SPRT). There was extensive interest voiced among many different personnel from several centers. There are potential spin-offs of this effort that can be directly applied to other data acquisition systems as well as vehicle health management for current and future flight vehicles.

Lehr, Mark E.↗

A Volume Flux Approach to Cryolava Dome Emplacement on Europa

We previously modeled a subset of domes on Europa with morphologies consistent with emplacement by viscous extrusions of cryolava. These models assumed instantaneous emplacement of a fixed volume of fluid onto the surface, followed by relaxation to form domes. However, this approach only allowed for the investigation of late-stage eruptive processes far from the vent and provided little insight into how cryolavas arrived at the surface. Consideration of dome emplacement as cryolavas erupt at the surface is therefore pertinent. A volume flux approach, in which lava erupts from the vent at a constant rate, was successfully applied to the formation of steep-sided volcanic domes on Venus. These domes are believed to have formed in the same manner as candi-date cryolava domes on Europa. In order to gain a more complete understanding of the potential for the emplacement of Europa domes via extrusive volcanism, we have applied this new volume flux approach to the formation of putative cryovolcanic domes on Europa. Assuming as in that europan cryolavas are briny, aqueous solutions which may or may not contain some ice crystal fraction, we present the results of this modeling and explore theories for the formation of low-albedo moats that surround some domes.

Cryolava Dome Emplacement↗

Creep Testing of High-Temperature Cu-8 Cr-4 Nb Alloy Completed

A Cu-8 at.% Cr-4 at.% Nb (Cu-8 Cr-4 Nb) alloy is under development for high-temperature, high heatflux applications, such as actively cooled, hypersonic vehicle heat exchangers and rocket engine combustion chambers. Cu-8 Cr-4 Nb offers a superior combination of strength and conductivity. It has also shown exceptional low-cycle fatigue properties. Following preliminary testing to determine the best processing route, a more detailed testing program was initiated to determine the creep lives and creep rates of Cu-8 Cr-4 Nb alloy specimens produced by extrusion. Testing was conducted at the NASA Lewis Research Center with constant-load vacuum creep units. Considering expected operating temperatures and mission lives, we developed a test matrix to accurately determine the creep properties of Cu-8 Cr-4 Nb between 500 and 800 C. Six bars of Cu-8 Cr-4 Nb were extruded. From these bars, 54 creep samples were machined and tested. The figure on the left shows the steady-state, or second-stage, creep rates for the samples. Comparison data for NARloy-Z (Cu-3 wt % Ag-0.5 wt % Zr), the alloy currently used in combustion chamber liners, were not unavailable. Therefore the steady-state creep rates for Cu at similar temperatures are presented. As expected, in comparison to pure Cu, the creep rates for Cu-8 Cr-4 Nb are much lower. The lives of the samples are presented in the figure on the right. As shown, Cu-8 Cr-4 Nb at 800 C is comparable to NARloy-Z at 648 C. At equivalent temperatures, Cu-8 Cr-4 Nb enjoys a 20 to 50 percent advantage in stress for a given life and 1 to 3 orders of magnitude greater life at a given stress. The improved properties allow for design tradeoffs and improvements in new and existing heat exchangers such as the next generation of combustion chamber liners. Average creep rates for Cu-8 Cr-4 Nb and pure Cu are shown. Average creep lives for Cu-8 Cr- 4 Nb and NARloy-Z are also shown. Currently, two companies are interested in the commercial usage of the Cu-8 Cr-4 Nb alloy. The Rocketdyne Division of Rockwell International is conducting independent testing to analyze the properties for their projected needs in advanced rocket engine applications. Metallamics, a company based in Traverse City, Michigan, is entering into a Space Act Agreement to evaluate and test Cu-Cr-Nb alloys as materials for welding electrodes that are used in robotic welding operations. Creep rate is one of the alloy properties that determines the degree to which a welding electrode will mushroom or expand at the tip. A material with a low creep rate will resist mushrooming and give the electrode a longer life, minimizing downtime. This application holds the potential for large-scale usage of the alloy in the automotive and other industries. Success here would dramatically decrease the cost of the alloy and increase availability for aerospace applications.

Source record↗

Crustal development in the terrestrial planets

The development of planetary crusts may be divided into primary, resulting from melting during accretion, and secondary crusts developed by partial melting from planetary mantles. The Mercurian crust is probably primary with no compelling evidence of later basaltic extrusions. Reflectance spectral evidence for the existence Fe2(+) is equivocal. The Viking Lander XRF data on Mars indicate basaltic material at both sites 4,000 km apart. Surface aeolian processes would be expected to provide a homogeneous average of the crust, but no evidence of more siliceous material is present. This conclusion is weakly supported by the Russian gamma ray data. No evidence for granite appears from the Russian Venera XRF data which indicates MORB-type and alkali basalt (4% K2O) surface compositions. The highlands of Ishtar Terra and Aphrodite probably owe their elevation to tectonic processes rather than compositional effects. Venus may thus resemble the early Archean Earth. The terrestrial granitic continental crust is a product of episodic multiple partial melting events, probably a consequence of the presence of surface water.

Taylor, S. R.↗

The tectonics of Mercury

The probable tectonic history of Mercury and the relative sequence of events are discussed on the basis of data collected by the Mariner-10 spacecraft. Results indicate that Mercury's tectonic activity was confined to its early history; its endogenic activity was principally due to a small change in the shape of its lithosphere, caused by tidal despinning, and a small change in area caused by shrinkage due to cooling. Exogenic processes, in particular the impact activity, have produced more abundant tectonic features. Many features associated with the Caloris basin are due to loading of Mercury's thick lithosphere by extrusive lavas or subsidence due to magma withdrawal. It is emphasized that tectonic features observed on Mercury yield insight into the earliest tectonic events on planets like Mars and, perhaps, the earth, where subsequent events obscured or erased the most ancient tectonic records.

Melosh, H. J.↗

A Photographic Atlas of Rock Breakdown Features in Geomorphic Environments

A primary goal of geomorphological enquiry is to make genetic associations between process and form. In rock breakdown studies, the links between process, inheritance and lithology are not well constrained. In particular, there is a need to establish an understanding of feature persistence. That is, to determine the extent to which in situ rock breakdown (e.g., aeolian abrasion or salt weathering) masks signatures of earlier geomorphic transport processes (e.g., fluvial transport or crater ejecta). Equally important is the extent to which breakdown during geomorphic transport masks the imprint of past weathering. The use of rock features in this way raises the important question: Can features on the surface of a rock reliably indicate its geomorphic history? This has not been determined for rock surfaces on Earth or other planets. A first step towards constraining the links between process, inheritance, and morphology is to identify pristine features produced by different process regimes. The purpose of this atlas is to provide a comprehensive image collection of breakdown features commonly observed on boulders in different geomorphic environments. The atlas is intended as a tool for planetary geoscientists and their students to assist in identifying features found on rocks on planetary surfaces. In compiling this atlas, we have attempted to include features that have formed 'recently' and where the potential for modification by another geomorphic process is low. However, we acknowledge that this is, in fact, difficult to achieve when selecting rocks in their natural environment. We group breakdown features according to their formative environment and process. In selecting images for inclusion in the atlas we were mindful to cover a wide range of climatic zones. For example, in the weathering chapter, clast features are shown from locations such as the hyper-arid polar desert of Antarctica and the semi-arid canyons of central Australia. This is important as some features (e.g., alveoli) occur across climate regimes. We have drawn on the published geomorphological literature and our own field experience. We use, where possible, images of extrusive igneous rocks as the data returned from Mars, Venus and the Moon indicates that this is the predominant rock type. One of the purposes of this atlas is to expand the range of surface features that are known to indicate a particular geomorphic environment or process history. The surface features on boulders in some environments such as aeolian and weathering are well understood. In contrast, those in fluvial or ejecta environments are not. Therefore we have presented a comprehensive assemblage of features that are likely to be produced in each of the geomorphic environments. We hope that this atlas will trigger more research on diagnostic features, particularly their morphometry and detailed morphology, their persistence and rates of formation. In this first edition of the atlas we detail the features found on clasts in three geomorphic environments: aeolian, fluvial and weathering. Future editions of the atlas will include chapters on ejecta, micro-impacts, coastal, colluvial, glacial and structural features.

Bourke, Mary C.↗

Solid propellant processing factor in rocket motor design

The ways are described by which propellant processing is affected by choices made in designing rocket engines. Tradeoff studies, design proof or scaleup studies, and special design features are presented that are required to obtain high product quality, and optimum processing costs. Processing is considered to include the operational steps involved with the lining and preparation of the motor case for the grain; the procurement of propellant raw materials; and propellant mixing, casting or extrusion, curing, machining, and finishing. The design criteria, recommended practices, and propellant formulations are included.

Source record↗