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At least 1,621 records · Page 90

Feasibility Study for Casting of High Temperature Refractory Superalloy Composites

Abstract This study investigated the feasibility of using conventional casting technique to fabricate refractory wires reinforced superalloy composites. These composites were being developed for advanced rocket engine turbine blades and other high temperature applications operating up to 2000 F. Several types of refractory metal wires such as W- Th, W-Re, Mo-Hf-C and W-HF-C reinforced waspaloy were experimentally cast and heat treated at 2000 F up to 48 hrs. Scanning electron microscope analysis was conducted in regions adjacent to the wire-matrix interface to determine the reaction zone and chemical compatibility resulting from material interdiffusion. It was concluded that fabrication using conventional casting may be feasible because the wire-matrix reaction zone thickness was comparable to similar composites produced by arc-sprayed monotape with hot isostatic pressing technique, Moreover, it was also found that the chemical compatibility could be improved significantly through a slight modification of the superalloy matrix compositions.

Lee, Jonathan A.↗

Investigation of Point Doppler Velocimetry (PDV) for Transition Detection in Boundary Layers

A two-component Point Doppler Velocimeter (PDV) system has been improved through the use of vapor-limited iodine cells that have responses that are insensitive to temperature variations. Two-component PDV velocity measurements have been obtained for a 1 inch diameter uniform circular jet flow at a nominal exit velocity of 60 m/sec, corresponding to a Reynolds number of 100,000. Similar data have also been obtained for an annular jet and a swirling jet, These PDV data runs have been duplicated to judge the repeatability of these measurements, and also have been compared with hot wire anemometer data for the same flow conditions. PDV mean velocity results are repeatable to within approximately 1-2 meters per second; the PDV RMS velocity results are also quite repeatable. Exit profiles of PDV mean axial velocity data generally agree with hot wire anemometer results to within about 2 meters per second as well. However, the PDV RMS velocity results are consistently lower than the hot wire results everywhere but at the exit of the standard jet, where they are too high relative to the hot wire data. This is believed to at least be partially due to the method used to compute the RMS (Root Mean Square).

Kuhlman, John↗

A Cryogenic Magnetostrictive Actuator Using a Persistent High Temperature Superconducting Magnet: Concept and Design - Part 1

Cryogenic magnetostrictive materials, such as rare earth zinc crystals, offer high strains and high forces with minimally applied magnetic fields, making the material ideally suited for deformable optics applications. For cryogenic temperature applications the use of superconducting magnets offer the possibility of a persistent mode of operation, i.e., the magnetostrictive material will maintain a strain field without power. High temperature superconductors (HTS) are attractive options if the temperature of operation is higher than 10 degrees Kelvin (K) and below 77 K. However, HTS wires have constraints that limit the minimum radius of winding, and even if good wires can be produced, the technology for joining superconducting wires does not exist. In this paper, the design and capabilities of a rare earth zinc magnetostrictive actuator using bulk HTS is described. Bulk superconductors can be fabricated in the sizes required with excellent superconducting properties. Equivalent permanent magnets, made with this inexpensive material, are persistent, do not require a persistent switch as in HTS wires, and can be made very small. These devices are charged using a technique which is similar to the one used for charging permanent magnets, e.g., by driving them into saturation. A small normal conducting coil can be used for charging or discharging. Because of the magnetic field capability of the superconductor material, a very small amount of superconducting magnet material is needed to actuate the rare earth zinc. In this paper, several designs of actuators using YBCO and BSCCO 2212 superconducting materials are presented. Designs that include magnetic shielding to prevent interaction between adjacent actuators will also be described. Preliminary experimental results and comparison with theory for BSCCO 2212 with a magnetostrictive element will be discussed.

Horner, Garnett↗

Conductive Tether Coating for Electrodynamic Tethers

The Propulsive Small Expendable Deployer System (ProSEDS), which is an on-orbit demonstration of the propulsion capabilities of electrodynamic tethers in space, is a secondary payload on a Delta 11 unmanned expendable booster. The ProSEDS tether consists of a 5 km bare electrodynamic tether and a 1 0-km non-conductive leader tether. Near the Delta 11, 160 m of the conductive tether is insulated to prevent plasma electron collection from the plasma contactor and for other science requirements. The remainder of the 5-km conductive tether is coated with a new conductive coating to collect plasma electrons. A bare metal tether easily collects electrons from the plasma, but thermal concerns preclude this design. A highly emissive conductive polymer developed by Triton Systems, Inc. has been optimized for both conductivity and thermo-optical properties. The current design for the ProSEDS conductive tether is seven individually coated strands of 28 AWG aluminum wire, coated with an atomic oxygen-resistant conductive polymer composed of a mixture of COR (Colorless Oxygen Resistant) and polyanaline (PANI) known as C-COR (Conductive-Colorless Oxygen Resistant). The conductive-coated wire strands are cold-welded to individually coated strands of the insulated tether. The insulated tether is coated with 1 mil of polyimide and an atomic oxygen resistant polymer TOR-BP. The insulated tether must stand off the entire voltage of the tether (1 200 V) at various times during the mission. All seven wires are twisted around a Kevlar-29 core using the Hi-wire design. Extensive testing has been performed at the Marshall Space Flight Center to qualify both the conductive coating and insulating coating for use on the ProSEDS tether. The conductive coating has been exposed to a plasma to verify the coatings ability to collect electrons from the space plasma from 0 to 1500 V, and to verify the coatings ability to collect electrons after atomic oxygen exposure. The insulated coating has been tested to verify its dielectric strength both in a vacuum and air. Thermal optical properties on both coatings have been measured before and after atomic oxygen testing. The results of these tests will be presented.

Jason A Vaughn↗

Flightweight Electro-Magnet Systems

NASA has a need for lightweight high performance magnets to be used in propulsion systems involving plasmas. We report the design, construction, and testing of a six inch diameter by twelve inch long solenoid using high purity aluminum wire operating at a temperature of 77 Kelvin (K) for the current carrying element. High purity aluminum is the material of choice because of three properties that make it optimal for magnetic construction. At 77 K high purity aluminum has one of the lowest resistivities at 77 K of any metal (p = 0.254 muOMEGA-cm), thus reducing the power requirements for creating magnetic fields. Aluminum is a low-density (2.6989 g/cc) material and the end product magnet will be of low total mass compared to similar designs involving copper or other elements. The magneto-resistance of aluminum saturates at low magnetic fields and does not increase indefinitely as is the case in copper. The magnet consists of four layers of closely wound wire and is approximately 150 mm in diameter by 300 mm long. A cylinder made from G - 10 was machined with a spiral groove to hold the high purity Al wire and the wire wound on it. Following the winding, each layer was potted in STYCAST high thermal conductivity epoxy to provide insulation between the turns of the coil and mechanical strength. The magneto-resistance of the coil has been measured at the National High Magnetic Field Laboratory (NHMFL), Tallahassee, FL in externally applied fields to 10 tesla. Following these tests it was energized to the full 2 tesla field it can produce using the facilities of the NHMFL at the Los Alamos National Laboratory. The results of all of these tests will be presented.

Goodrich, Roy G.↗

A 10 Kelvin 3 Tesla Magnet for Space Flight ADR Systems

Many future space flight missions are expected to use adiabatic demagnetization refrigerators (ADRs) to reach detector operating temperatures well below one Kelvin. The goal is to operate each ADR with a mechanical cooler as its heat sink, thus avoiding the use of liquid cryogens. Although mechanical coolers are being developed to operate at temperatures of 6 Kelvin and below, there is a large efficiency cost associated with operating them at the bottom of their temperature range. For the multi-stage ADR system being developed at Goddard Space Flight Center, the goal is to operate with a 10 Kelvin mechanical cooler heat sink. With currently available paramagnetic materials, the highest temperature ADR stage in such a system will require a magnetic field of approximately three Tesla. Thus the goal is to develop a small, lightweight three Tesla superconducting magnet for operation at 10 Kelvin. It is important that this magnet have a low current/field ratio. Because traditional NbTi magnets do not operate safely above about six Kelvin, a magnet with a higher Tc is required. The primary focus has been on Nb3Sn magnets. Since standard Nb3Sn wire must be coated with thick insulation, wound on a magnet mandrel and then reacted, standard Nb,Sn magnets are quite heavy and require high currents Superconducting Systems developed a Nb3Sn wire which can be drawn down to small diameter, reacted, coated with thin insulation and then wound on a small diameter coil form. By using this smaller wire and operating closer to the wire s critical current, it should be possible to reduce the mass and operating current of 10 Kelvin magnets. Using this "react-then-wind" technology, Superconducting Systems has produced prototype 10 Kelvin magnets. This paper describes the development and testing of these magnets and discusses the outlook for including 10 Kelvin magnets on space-flight missions.

Tuttle, Jim↗

A Cryogenic Magnetostrictive Actuator using a Persistent High Temperature Superconducting Magnet, Part 1: Concept and Design: Concept and Design - Part 1

Cryogenic magnetostrictive materials, such as rare earth zinc crystals, offer high strains and high forces with minimally applied magnetic fields, making the material ideally suited for deformable optics applications. For cryogenic temperature applications, such as Next Generation Space Telescope (NGST), the use of superconducting magnets offer the possibility of a persistent mode of operation, i.e., the magnetostrictive material will maintain a strain field without power. High temperature superconductors (HTS) are attractive options if the temperature of operation is higher than 10 degrees Kelvin (K) and below 77 K. However, HTS wires have constraints that limit the minimum radius of winding, and even if good wires can be produced, the technology for joining superconducting wires does not exist. In this paper, the design and capabilities of a rare earth zinc magnetostrictive actuator using bulk HTS is described. Bulk superconductors can be fabricated in the sizes required with excellent superconducting properties. Equivalent permanent magnets, made with this inexpensive material, are persistent, do not require a persistent switch as in HTS wires, and can be made very small. These devices are charged using a technique which is similar to the one used for charging permanent magnets, e.g., by driving them into saturation. A small normal conducting coil can be used for charging or discharging. Very fast charging and discharging of HTS tubes, as short as 100 microseconds, has been demonstrated. Because of the magnetic field capability of the superconductor material, a very small amount of superconducting magnet material is needed to actuate the rare earth zinc. In this paper, several designs of actuators using YBCO and BSCCO 2212 superconducting materials are presented. Designs that include magnetic shielding to prevent interaction between adjacent actuators will also be described. Preliminary experimental results and comparison with theory for BSSCO 2212 with a magnetostrictive element will be discussed.

Horner, Garnett C.↗

Attachment of Free Filament Thermocouples for Temperature Measurements on Ceramic Matrix Composites

At the NASA Lewis Research Center, a new installation technique utilizing convoluted wire thermocouples (TC's) was developed and proven to produce very good adhesion on CMC's, even in a burner rig environment. Because of their unique convoluted design, such TC's of various types and sizes adhere to flat or curved CMC specimens with no sign of delamination, open circuits, or interactions-even after testing in a Mach 0.3 burner rig to 1200 C (2200 F) for several thermal cycles and at several hours at high temperatures. Large differences in thermal expansion between metal thermocouples and low-expansion materials, such as CMC's, normally generate large stresses in the wires. These stresses cause straight wires to detach, but convoluted wires that are bonded with strips of coating allow bending in the unbonded portion to relieve these expansion stresses.

Lei, Jih-Fen↗

Validation of Multi-Dimensional Stirling Engine Design Codes: Measurements in the 90-Degree Turn Test Section

The work to be presented herein was motivated largely by a desire to improve the understanding of oscillatory fluid mechanics inside a Stirling engine. To this end, a CFD project was undertaken at Cleveland State University with the goal of accurately predicting the fluid dynamics within an engine or engine component. Along with the CFD efforts, a code validation project was undertaken at the University of Minnesota. The material covered herein consists of four main parts. In section 1, an experimental investigation of a small aspect ratio impinging jet is discussed. Included in this discussion is a description of the test facilities and instrumentation. A presentation of the collected data is given and comments are made. Next, in section 2, a parallel experimental investigation is presented in which the same geometry as that of section 1 is used, but the flow conditions are changed from steady unidirectional flow to sinusoidally oscillating flow. In section Two, collected data are presented and comments are made. In section 3, a comparison is made between the results of sections 1 and 2, namely, sinusoidally oscillating flow results are compared to steady, unidirectional flow results from the same geometry. Finally, in section 4, a comparison is made between experimentally collected data (the main subject of this work) and CFD generated results. Furthermore, in appendix A, an introductory description of the primary measurement tool used in the experimental process the hot wire anemometer is given for the unfamiliar. The anemometer calibration procedure is described in appendix B. A portfolio of data reduction and data processing codes is provided in appendix C and lastly, a DVD and a roadmap of its contents is provided in an appendix D. 1.0 Unidirectional Flow Investigations 1.1 Introduction This unidirectional experimental program was undertaken to complement an oscillatory flow investigation conducted at the University of Minnesota. The oscillatory investigation is discussed thoroughly in section 2. We defer the description of the motivation behind these experiments until the introduction of section 2. The work that is discussed in this thesis began (chronologically) with oscillatory flow visualization experiments. It was decided that it would be valuable and important to investigate the flow under unidirectional conditions in the same geometry as that of the oscillatory experiments. The thought was that the unidirectional case would be less complicated to model with a CFD program (a moving boundary would be replaced with a steady state boundary condition). Thus, a series of unidirectional experiments were carried out to capture the important features of the flow within the test section. The purpose of these experiments was to provide a data set for comparison to CFD generated velocity fields. Hot-wire anemometry data were taken and flow visualization was conducted as a standard for code validation. The flow geometry was simple, such that it could be easily gridded in a CFD program. However, the geometry provided separation and transition zones, shear layers and recirculation zones. These characteristics made the flow complex and challenging for CFD computation. We comment that the order of experiments that produced this report is as follows: experimental flow visualization under oscillatory flow conditions was carried out; this was followed by unidirectional flow visualization and hot wire anemometry; finally, oscillatory hot wire anemometry was conducted. We present the results out of chronological order for the following reason: the unidirectional results are easier

Simon, Terrence W.↗

Adjustable reed for weaving net-shaped tailored fabrics

An apparatus and method for forming woven fabrics through the use of an adjustable reed. The adjustable reed has multiple groups of reed wires that guide the warp yarns. The groups of reed wires move on reed rails parallel to the warp direction. In addition, rail expanders permit the space between the reed wires to be modified and telescoping rods attached to the rail sliders can be turned to permit the reed wires to be skewed to alter the fill yarn angle. These adjustments to the reed permit simultaneous variation of fill yarn angles and fabric widths and allow these variations to be made during fabrication, without the need to halt production.

Farley, Gary L.↗

External Tank (ET) Bipod Fitting Bolted Attachment Locking Insert Performance

Following STS-107, the External Tank (ET) Project implemented corrective actions and configuration changes at the ET bipod fitting. Among the corrective actions, the existing bolt lock wire which provided resistance to potential bolt rotation was removed. The lock wire removal was because of concerns with creating voids during foam application and potential for lock wire to become debris. The bolts had been previously lubricated to facilitate assembly but, because of elimination of the lock wire, the ET Project wanted to enable the locking feature of the insert. Thus, the lubrication was removed from bolt threads and instead applied to the washer under the bolt head. Lubrication is necessary to maximize joint pre-load while remaining within the bolt torque specification. The locking feature is implemented by thread crimping in at four places in the insert. As the bolt is torqued into the insert the bolt threads its way past the crimped parts of the insert. This provides the locking of the bolt, as torque is required to loosen the joint after clamping.

Larsen, Curtis E.↗

Current collector for AMTEC

An electrode having higher power output is formed of an open mesh current collector such as expanded nickel covering an electrode film applied to a tube of beta-alumina solid electrolyte (BASE). A plurality of cross-members such as spaced, parallel loops of molybdenum metal wire surround the BASE tube. The loops are electrically connected by a bus wire. As the AMTEC cell is heated, the grid of expanded nickel expands more than the BASE tube and the surrounding loop of wire and become diffusion welded to the electrode film and to the wire loops.

Williams, Roger M.↗

PdCr Based High Temperature Static Strain Gage

The program at NASA Lewis Research Center to develop a high temperature static strain gage system for the hypersonic vehicle and turbine engine research has emphasized a palladium- 13wt%chromium (PdCr) alloy. Gages made from this alloy are being developed in both fine wire and thin film form. The wire gage system had platinum wire as a temperature compensator and was coated with a special alumina and zirconia mixture overcoat. This PdCr compensated wire gage responded linearly to the imposed strain to at least i000 microstrain. The strain sensitivity of the gage did not vary much with temperature. The apparent strain of this compensated gage was significantly lower than that of the other gages. It varied within 300 microstrain from room temperature to 800 deg. C with a reproducibility within 50 microstrain between thermal cycles to 800 deg. C. This is a significant advance over the 400 deg. C barrier of previous techniques for resistance static strain gages. The sputtered thin film PdCr strain gage, whose size was 8x8 mm and 10 micron thick, has demonstrated the possibility of extending the use of the PdCr strain gage to a temperature of approximately 1000 deg. C.

Lei, Jih-Fen↗

Auxiliary Components for Kilopixel Transition Edge Sensor Arrays

We have fabricated transition edge sensor bolometer focal plane arrays sensitive to mm-submillimeter (0.1-3 THz) radiation for the Atacama Cosmology Telescope (ACT), which will probe the cosmic microwave background at 0.147,0.215, and 0.279 GHz. Central to the performance of these bolometers is a set of auxiliary resistive components. Here we discuss shunt resistors, which allow for tight optimization of bolometer time constant and sensitivity. Our shunt resistors consist of AuPd strips grown atop of interdigitated superconducting MoN, wires. We can tailor the shunt resistance by altering the dimensions of the AuPd strips and the pitch and width of the MoN, wires and can fabricate over 1000 shunts on a single 4" wafer. By modeling the resistance dependence of these parameters, a variety of different 0.77 +I-0.13 mOhm shunt resistors have been fabricated. This variety includes different shunts possessing MoN, wires with wire width equal to 1.5 and 10 microns and pitch equal to 4.5 and 26 microns, respectively. Our ability to set the resistance of the shunts hints at the scalability of our design. We have also integrated a Si02 capping layer into our shunt resistor fabrication scheme, which inhibits metal corrosion and eventual degradation of the shunt. Consequently, their robustness coupled with their high packing density makes these resistive components attractive for future kilopixel detector arrays.

Brown, Ari-David↗

Lightweight electrical connector split backshell

An electrical connector split backshell is provided, comprising two substantially identical backshell halves. Each half includes a first side and a cam projecting therefrom along an axis perpendicular thereto, the cam having an alignment tooth with a constant radius and an engagement section with a radius that increases with angular distance from the alignment tooth. Each half further includes a second side parallel to the first side and a circular sector opening disposed in the second side, the circular sector opening including an inner surface configured as a ramp with a constant radius, the ramp being configured to engage with an engagement section of a cam of the other half, the circular sector opening further including a relieved pocket configured to receive an alignment tooth of the cam of the other half. Each half further includes a back side perpendicular to the first and second sides and a wire bundle notch disposed in the back side, the wire bundle notch configured to align with a wire bundle notch of the other half to form a wire bundle opening. The two substantially identical halves are rotatably coupled by engaging the engagement section of each half to the ramp of the other half.

Goldman, Elliot↗

Nanowire electron scattering spectroscopy

Methods and devices for spectroscopic identification of molecules using nanoscale wires are disclosed. According to one of the methods, nanoscale wires are provided, electrons are injected into the nanoscale wire; and inelastic electron scattering is measured via excitation of low-lying vibrational energy levels of molecules bound to the nanoscale wire.

Hunt, Brian D.↗

Magnesium Diboride Current Leads

A recently discovered superconductor, magnesium diboride (MgB2), can be used to fabricate conducting leads used in cryogenic applications. Dis covered to be superconducting in 2001, MgB2 has the advantage of remaining superconducting at higher temperatures than the previously used material, NbTi. The purpose of these leads is to provide 2 A of electricity to motors located in a 1.3 K environment. The providing environment is a relatively warm 17 K. Requirements for these leads are to survive temperature fluctuations in the 5 K and 11 K heat sinks, and not conduct excessive heat into the 1.3 K environment. Test data showed that each lead in the assembly could conduct 5 A at 4 K, which, when scaled to 17 K, still provided more than the required 2 A. The lead assembly consists of 12 steelclad MgB2 wires, a tensioned Kevlar support, a thermal heat sink interface at 4 K, and base plates. The wires are soldered to heavy copper leads at the 17 K end, and to thin copper-clad NbTi leads at the 1.3 K end. The leads were designed, fabricated, and tested at the Forschungszentrum Karlsruhe - Institut foer Technische Physik before inclusion in Goddard's XRS (X-Ray Spectrometer) instrument onboard the Astro-E2 spacecraft. A key factor is that MgB2 remains superconducting up to 30 K, which means that it does not introduce joule heating as a resistive wire would. Because the required temperature ranges are 1.3-17 K, this provides a large margin of safety. Previous designs lost superconductivity at around 8 K. The disadvantage to MgB2 is that it is a brittle ceramic, and making thin wires from it is challenging. The solution was to encase the leads in thin steel tubes for strength. Previous designs were so brittle as to risk instrument survival. MgB2 leads can be used in any cryogenic application where small currents need to be conducted at below 30 K. Because previous designs would superconduct only at up to 8 K, this new design would be ideal for the 8-30 K range.

Panek, John↗

Modular Rake of Pitot Probes

The figure presents selected views of a modular rake of 17 pitot probes for measuring both transient and steady-state pressures in a supersonic wind tunnel. In addition to pitot tubes visible in the figure, the probe modules contain (1) high-frequency dynamic-pressure transducers connected through wires to remote monitoring circuitry and (2) flow passages that lead to tubes that, in turn, lead to remote steady-state pressure transducers. Prior pitot-probe rakes were fabricated as unitary structures, into which the individual pitot probes were brazed. Repair or replacement of individual probes was difficult, costly, and time-consuming because (1) it was necessary to remove entire rakes in order to unbraze individual malfunctioning probes and (2) the heat of unbrazing a failed probe and of brazing a new probe in place could damage adjacent probes. In contrast, the modules in the present probe are designed to be relatively quickly and easily replaceable with no heating and, in many cases, without need for removal of the entire rake from the wind tunnel. To remove a malfunctioning probe, one first removes a screw-mounted V-cross-section cover that holds the probe and adjacent probes in place. Then one removes a screw-mounted cover plate to gain access to the steady-state pressure tubes and dynamicpressure wires. Next, one disconnects the tube and wires of the affected probe. Finally, one installs a new probe in the reverse of the aforementioned sequence. The wire connections can be made by soldering, but to facilitate removal and installation, they can be made via miniature plugs and sockets. The connections between the probe flow passages and the tubes leading to the remote pressure sensors can be made by use of any of a variety of readily available flexible tubes that can be easily pulled off and slid back on for removal and installation, respectively.

Dunlap, Timothy A.↗