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At least 163 records · Page 9

Welding of nickel-base superalloys having a nil-ductility range

An article made of a nickel-base superalloy having a nil-ductility range from the solidus temperature of the alloy to about 600.degree. F. below the solidus temperature is welded, as for example in the weld repair of surface cracks, by removing foreign matter from the area to be welded, first stress relieving the article, adjusting the temperature of the article to a welding temperature of from about 1800.degree. F. to about 2100.degree. F., welding a preselected area in an inert atmosphere at the welding temperature, and second stress relieving the article. Welding is preferably accomplished by striking an arc in the preselected area so as to locally melt the alloy in the preselected area, providing a filler metal having the same composition as the nickel-based superalloy of the article, and feeding the filler metal into the arc so that the filler metal is melted and fused with the article to form a weldment upon solidification.

Smashey, Russell W.↗

Welding of gamma titanium aluminide alloys

An article made of a gamma titanium aluminide alloy is welded, as for example in the weld repair of surface cracks, by removing foreign matter from the area to be welded, first stress relieving the article, cooling the entire article to a welding temperature of from about 1000.degree. F. to about 1400.degree. F., welding a preselected region in an inert atmosphere at the welding temperature, and second stress relieving the article. Welding is preferably accomplished by striking an arc in the preselected region so as to locally melt the alloy in the preselected region, providing a filler metal having the same composition as the gamma titanium aluminide alloy of the article, and feeding the filler metal into the arc so that the filler metal is melted and fused with the article to form a weldment upon solidification.

Smashey, Russell W.↗

Thermal Conductivity of Polyimide/Carbon Nanofiller Blends

In efforts to improve the thermal conductivity (TC) of Ultem(TM) 1000, it was compounded with three carbon based nano-fillers. Multiwalled carbon nanotubes (MWCNT), vapor grown carbon nanofibers (CNF) and expanded graphite (EG) were investigated. Ribbons were extruded to form samples in which the nano-fillers were aligned. Samples were also fabricated by compression molding in which the nano-fillers were randomly oriented. The thermal properties were evaluated by DSC and TGA, and the mechanical properties of the aligned samples were determined by tensile testing. The degree of dispersion and alignment of the nanoparticles were investigated with high-resolution scanning electron microscopy. The thermal conductivity of the samples was measured in both the direction of alignment as well as perpendicular to that direction using the Nanoflash technique. The results of this study will be presented.

Ghose, S.↗

Silicone nanocomposite coatings for fabrics

A silicone based coating for fabrics utilizing dual nanocomposite fillers providing enhanced mechanical and thermal properties to the silicone base. The first filler includes nanoclusters of polydimethylsiloxane (PDMS) and a metal oxide and a second filler of exfoliated clay nanoparticles. The coating is particularly suitable for inflatable fabrics used in several space, military, and consumer applications, including airbags, parachutes, rafts, boat sails, and inflatable shelters.

Eberts, Kenneth↗

Filled Co (sub X) Ni (sub 4-x) Sb (sub 12-y) Sn (sub Y) Skutterudites: Processing and Thermoelectric Properties

Skutterudites have proven to be a useful thermoelectric system as a result of their enhanced figure of merit (ZT1), cheap material cost, favorable mechanical properties, and good thermal stability. The majority of skutterudite interest in recent years has been focused on binary skutterudites like CoSb3 or CoAs3. Binary skutterudites are often double and triple filled, with a range of elements from the lanthanide series, in order to reduce the lattice component of thermal conductivity. Ternary and quaternary skutterudites, such as Co4Ge6Se6 or Ni4Sb8Sn4, provide additional paths to tune the electronic structure. The thermal conductivity can further be improved in these complex skutterudites by the introduction of fillers. The Co (sub X) Ni (sub 4-x) Sb (sub 12-y) Sn (sub Y) system has been investigated as both a p- and n-type thermoelectric material, and is stable up to 200 degrees Centigrade. Yb, Ce, and Dy fillers have been introduced into the skutterudite to study the influence of both the type and the quantity of fillers on processing conditions and thermoelectric properties. The system was processed through a multi-step technique that includes solidification, mechano-chemical alloying, and hot pressing which will be discussed along with thermoelectric transport properties.

Thermoelectricity↗

Overview of Aeroacoustic Testing of the High-Lift Common Research Model

This paper presents an overview of the experimental data obtained in a 2020/2021 aeroacoustic test of the high-lift variant of the common research model. The breadth of the aerodynamic and acoustic measurements is highlighted along with some key results. Aerodynamic data were observed to be consistent with previous observations, and the acoustic measurements were repeatable once some background noise and shear layer issues were resolved. The primary purpose of the test was to evaluate the noise reduction potential of slat noise reduction devices, and a slat-gap filler was found to produce substantial noise reduction over a broad frequency range. The gap filler was designed to meet practical implementation considerations at full scale and constructed out of shape-memory alloys that would allow the slat to be articulated. However, additional structural testing will be required to demonstrate the performance of the gap filler during slat deployment and retraction. Over 3,500 test points were collected during the test, and only a small fraction of the experimental data has been processed in a preliminary manner. Nonetheless, the results presented demonstrate the quality of the dataset and reveal some insights about slat noise.

Aeroacoustics↗

Thermo-Poro-Mechanical Modeling of RTV Intumescence

Room temperature vulcanizing (RTV) silicone is a high-temperature adhesive used as a gap-filler between heatshield tiles in numerous entry missions. Its propensity to intumesce, or swell upon exposure to heat, is a well-known effect that needs to be carefully quantified during design. At tile interfaces of charring ablators, intumescence, combined with differential recession, could cause the gap filler to protrude past the ablator outer mold line, forming a “fence”. Fencing can in turn cause transition to turbulence of the flow wetting the heat shield, leading to augmented surface heating. Recent experiments conducted at the Plasmatron X facility, the high enthalpy wind tunnel of the Center for Hypersonics and Entry Systems Studies, have shown prominent fencing of RTV gap fillers in PICA, under both nitrogen and air plasmas. Similar observations are well known in the arcjet literature. Further experiments under controlled environment, performed using in situ X-ray micro-computed tomography (micro-CT) at the Advanced Light Source (ALS), have shown heating rate-dependent swelling and shrinkage of RTV during pyrolysis. To simulate RTV intumescence, a novel model was introduced in the Porous Materials Analysis Toolbox based on OpenFOAM, PATO, to account for pore-pressure buildup within both closed- and open-pores. The governing equation for the thermo-poro-mechanical response were developed, assuming linear elasticity for the charring silicone. A new multi-pyrolysis model that tracks non-monotonic advancement of material properties with pyrolysis was proposed. This model addresses the limitations of state-of-the-art ablator models to capture the different stages of thermal degradation and coupled thermomechanics. Swelling of RTV was simulated using the new thermo-poro-mechanical model and compared against in situ micro-CT data. Results showed good agreement in intumescence height and temperature profiles at all heating rates, indicating that the key factor contributing to RTV swelling is the internal pressure build-up within closed- and open-pores. As RTV is cured into a soft (rubbery) compound with low-porosity and permeability, initial temperature increase and pyrolysis gas production cause a significant increase of internal pressure, causing a pronounced volume growth. As thermal degradation progresses, rigidization of the silicone occurs due to char hardening which counteract volume shrinkage after gas pressure relief. Overall, our model shows that accounting for changes in properties such porosity, permeability and key thermomechanical coefficients is crucial for capturing the RTV volume change during ablation and enable a predictive capability for heatshield tile interface response. A plan for future calibration of thermomechanical properties evolution during degradation is discussed, as a key next step to close the new model.

RTV↗

Thermo-Poro-Mechanical Modeling of RTV Intumescence

Room temperature vulcanizing (RTV) silicone is a high-temperature adhesive used as a gap-filler between heatshield tiles in numerous entry missions. Its propensity to intumesce, or swell upon exposure to heat, is a well-known effect that needs to be carefully quantified during design. At tile interfaces of charring ablators, intumescence, combined with differential recession, could cause the gap filler to protrude past the ablator outer mold line, forming a “fence”. Fencing can in turn cause transition to turbulence of the flow wetting the heat shield, leading to augmented surface heating. Recent experiments conducted at the Plasmatron X facility, the high enthalpy wind tunnel of the Center for Hypersonics and Entry Systems Studies, have shown prominent fencing of RTV gap fillers in PICA, under both nitrogen and air plasmas. Similar observations are well known in the arcjet literature. Further experiments under controlled environment, performed using in situ X-ray micro-computed tomography (micro-CT) at the Advanced Light Source (ALS), have shown heating rate-dependent swelling and shrinkage of RTV during pyrolysis. To simulate RTV intumescence, a novel model was introduced in the Porous Materials Analysis Toolbox based on OpenFOAM, PATO, to account for pore-pressure buildup within both closed- and open-pores. The governing equation for the thermo-poro-mechanical response were developed, assuming linear elasticity for the charring silicone. A new multi-pyrolysis model that tracks non-monotonic advancement of material properties with pyrolysis was proposed. This model addresses the limitations of state-of-the-art ablator models to capture the different stages of thermal degradation and coupled thermomechanics. Swelling of RTV was simulated using the new thermo-poro-mechanical model and compared against in situ micro-CT data. Results showed good agreement in intumescence height and temperature profiles at all heating rates, indicating that the key factor contributing to RTV swelling is the internal pressure build-up within closed- and open-pores. As RTV is cured into a soft (rubbery) compound with low-porosity and permeability, initial temperature increase and pyrolysis gas production cause a significant increase of internal pressure, causing a pronounced volume growth. As thermal degradation progresses, rigidization of the silicone occurs due to char hardening which counteract volume shrinkage after gas pressure relief. Overall, our model shows that accounting for changes in properties such porosity, permeability and key thermomechanical coefficients is crucial for capturing the RTV volume change during ablation and enable a predictive capability for heatshield tile interface response. A plan for future calibration of thermomechanical properties evolution during degradation is discussed, as a key next step to close the new model.

silicone intumescence↗

Fully Coupled Aeroelastic Stability Analysis of Adaptive Shape Memory Alloy Structural Technologies for Airframe Noise Reduction

This final report documents work performed by ATA Engineering, Inc., (ATA) to develop computational models and analyze the coupled fluid-structure response of two types of noise treatments applied to the leading-edge-slat component of a high-lift system typical of modern transport aircraft. The first treatment is a slat-gap filler (SGF), which closes the gap between the suction surfaces of a deployed slat and an aircraft main wing, and the second treatment is a slat-cove filler (SCF), which replaces the recirculating flow on the slat cove with a surface that promotes flow attachment. The representative airframe chosen for this work was NASA’s High-Lift Common Research Model (CRM-HL) in a baseline high-lift configuration. Superelastic shape memory alloys (SMAs) have been identified as enabling materials for these structural treatments. Since the technology elements rely upon having a highly reconfigurable structure, designs were assessed for their static aeroelastic deflection as well as their dynamic aeroelastic stability using coupled computational fluid dynamics (CFD) and nonlinear computational structural dynamics (NL-CSD) tools. Specifically, fluid-structure interaction (FSI) problems were solved computationally using the CFD solver Loci/CHEM and the NL-CSD solver Abaqus. As a part of the overall project, a similar capability was implemented using the CFD solver FUN3D coupled to Abaqus, although that work is documented in a separate report and that FSI framework was not used to analyze any of NASA’s SGF and SCF configurations. The technical approach consisted of solving for the flow field around the entire vehicle using a global CFD model, followed by extraction of relevant local subdomain data for CFD and NL-CSD co-simulations. The SGF design was analyzed using both 2D and 3D co-simulations to predict quasi-static aeroelastic deformations and to assess dynamic aeroelastic stability, whereas the SCF was analyzed in 2D only. SGF static aeroelastic response predictions focused on characterizing the deformed shape, with maximum displacements predicted to be on the order of magnitude of the technology element panel thickness. SGF dynamic aeroelastic response predictions used Partial Floquet analysis of the temporal evolution of selected nodal displacements to quantify the sign and magnitude of aeroelastic damping. Results suggest that the CRM-HL operating conditions would result in a dynamically stable response. The simulated dynamic pressure was also increased up to a factor of about four, and resulting responses suggest that predicted dynamic stability would be achieved with some margin.

Fluid Structure Interaction↗

Aeroelastic Stability Assessment Methodology and Application to Slat Noise Treatments on the High-Lift Common Research Model

This work supports a larger effort at NASA to reduce airframe noise and, thus, environmental noise around airports. The leading-edge slat of conventional high-lift systems is a prominent source of airframe noise, and two technologies were previously identified as promising for noise reduction without significant aerodynamic or weight penalty: the slat cove filler (SCF) and the slat gap filler (SGF). NASA fabricated a 10%-scale semispan aircraft model for wind tunnel testing based upon the High-Lift Common Research Model (CRM-HL). NASA embarked on a test campaign with the 10% CRM-HL to determine the noise reduction effectiveness and other performance metrics of 3D SCF and SGF treatments in flow conditions representative of flight. The highly flexible SCF and SGF treatments posed a risk to the model and aeroelastic instability would compromise research integrity, so aeroelastic stability assessment was required. This work briefly describes the 10% CRM-HL, design of the SCF and SGF treatments to the model, and supporting fluid structure interaction (FSI) research. Relations for static and dynamic aeroelastic similitude are then developed for convenience of reference, and simplifications are introduced of particular utility to the cases considered in this study. The similitude relations are employed to assess the stability of the treatments under wind tunnel flow conditions based upon known behaviors from the supporting research. It is shown that the treatments are safe for test under the anticipated wind tunnel flow conditions with significant margins/factors of safety. It is furthermore demonstrated that the SCF is more susceptible to aeroelastic instability than the SGF, which has implications for flight feasibility.

Similitude↗

Structural and High-Temperature Tensile Properties of Special Pitch-Coke Graphites

The room-temperature structural properties and the tensile properties up to 5000 F (275O C) were determined for ten grades of specially prepared petroleum-coke coal-tar-pitch graphites which were graphitized at 5430 F (3000 C). One impregnation with coal-tar pitch increased the bulk density from 1.41 to 1.57 g/cm3 and the maximum strength at 4500 F (2500 C) from 4000 to 5700 psi. None of the processing parameters studied had a marked effect on the closed porosity or the X-ray structure or the per cent graphitization. The coarse-particle filler resulted in the lowest coefficient of thermal expansion and the fine-particle filler in the highest coefficient. A marked improvement in uniformity of tensile strength was observed. A standard-deviation analysis gave a one-sigma value of approximately 150 psi for one of these special grades and values of 340-420 psi for three commercial grades.

GRAPHITE↗

Studies of Lubricating Materials in Vacuum

Lubricating materials for use in a vacuum environment have been the subject of a series of experimental investigations. Evaporation properties were evaluated for solid polymeric compositions. Friction and wear studies explored the behavior during sliding contact for series of polymeric compositions, binary alloys containing soft film-forming phases, complex alloys with film-forming materials, and a burnished MoS2 film. Friction and wear experiments were conducted at 10(exp-9)mm Hg with a 3/16-inch-radius-hemisphere rider specimen sliding on the flat surface of a rotating 2-1/2-inch-diameter disk specimen with materials that had low rates of evaporation. The influence of fillers in polytetrafluoroethylene (PTFE) on decomposition during vacuum friction studies was determined with a mass spectrometer. A real advantage in reducing decomposition and improving friction wear properties is gained by adding fillers (e.g., copper) that improve thermal conductivity through the composite materials. A polyimide and an epoxy-MoS2 composition material were found to have better friction and wear properties than PTFE compositions. A series of alloys (cast binary as well as more complex alloys) that contained microinclusions of potential film-forming material was studied. These materials replaced the normal surface oxides as they were worn away on sliding contact. Iron sulfide, nickel oxide, and tin are typical film-forming materials employed and were demonstrated to be effective in inhibiting surface welding and reducing friction. A burnished MoS2 film applied to type 440-C stainless steel in argon with a rotating soft wire brush had good endurance properties but somewhat higher friction than commercially available bonded films. An oil film applied to the burnished MoS2 markedly reduced its endurance life.

WEAR↗

Space thermal control development

The results of experimental investigations on a number of various phase change materials (PCMs) and PCMs in combination with metals and other materials are reported. The evaluations include the following PCM system performance characteristics: PCM and PCM/filler thermal diffusivities, the effects of long-term thermal cycling, PCM-container compatibility, and catalyst effectiveness and stability. Three PCMs demonstrated performance acceptable enough to be considered for use in prototype aluminum thermal control devices. These three PCMs are lithium nitrate trihydrate with zinc hydroxy nitrate catalyst, acetamide, and myristic acid. Of the fillers tested, aluminum honeycomb filler was found to offer the most increase in system thermal diffusivity.

Hoover, M. J.↗

Development of a silicone ablator for high-heat-flux and high-shear-rate condition

A silicone material was developed which gives suitable ablative protection in the high heat flux, high shear environments encountered in severe reentry applications, such as nose cones for ballistic vehicles and protection of leading edges or other critical areas of a vehicle. In addition, the ease of handling, low application cost, and room temperature cure make such a silicon material suitable nozzles for the large rockets necessary for vehicle launching. The development of this product is traced from the selection of suitable polymers through the choice of fillers and the finalization of filler loadings.

Campbell, R. A.↗

Thermal conductivity of filled RTV compounds

Sealant materials with high thermal conductivity, and electrically nonconductive were studied for applications. Alumina and other thermally conductive fillers were examined for room temperature vulcanizing (RTV) use. The guarded hot plate apparatus, and its operation are described, and results of the thermal conductivity tests are discussed. It was found that magnesium oxide is significantly better than aluminum oxide as a filler enhancing the thermal conductivity of RTV. Recommendations for future studies are included.

Mauk, C. E.↗

Thermal control and heat storage by melting and freezing. Space thermal control development

Current results of an experimental study of increasing phase change material thermal diffusivity by means of solid fillers are reported. Aluminum honeycomb appears to offer the best improvement of any of the fillers investigated to date. Details of the experimental method developed in the present study for rapidly determining thermal diffusivities with a precision of about 10 percent are also reported. Further concepts regarding phase change material thermal diffusivity enhancement and of phase change material operation are discussed.

Grodzka, P. G.↗

Rubber compositions for hydrazine service

Forty-three compounds were formulated and tested for physical properties and hydrazine compatibility. Variables introduced include silicon dioxide filler loading level and particle size. Both butyl and ethylene-propylene rubbers were employed as well as various vulcanization systems. The data showed that compounds containing butyl and butyl blended with ethylene propylene could not be distinguished from ethylene propylene alone as far as chemical properties were concerned. A trend noted was that a filler level with higher silicon dioxide loading exhibited better hydrazine compatibility. Particle size variation did not show any consistent trends. Any of the vulcanization systems employed appeared to be satisfactory. A refined technique for dissolving aluminum cores from EPT-10 bladders was also tested.

Repar, J.↗

Factors influence flexibility resistivity and zinc dendrite penetration rate of inorganic separators for alkaline batteries

Developmental work resulted in a formulation which can improve the flexibility of the inorganic-organic-type separator for silver-zinc and nickel-zinc alkaline batteries. The effects of various fillers and reactive organic additives on separator volume resistivity are described. The effects of various inert fillers on the zinc dendrite penetration rate of the separator are shown. Conclusions regarding the operating mechanism of the separator are presented.

Sheibley, D. W.↗