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Investigation of aluminum alloy welds reveals that the combinations of metallic elements with hydrogen are not capable of producing weld porosity themselves, rather they tend to increase the amount of porosity only in the presence of arc contamination by water vapor.
Various solid-solid diffusion couples were assembled from thoriated and nonthoriated nickel-base alloys, welded, and diffusion annealed at 1260 C. Concentration profiles indicated that a thoria dispersion does not affect diffusion in Cr(alloy):Ni and Ni-4.8Al:Ni types of couples unless a fine grain structure is retained by the thoria particles. Metallography revealed the presence of thoria-free bands in the thoriated-Ni side of the diffusion zone. The bands contained grain boundaries and, in some cases, non-Kirkendall porosity. A mechanism based on the operation of vacancy sources is proposed to explain the thoria-free bands. In addition, a particular DS-NiCr:Ni couple had negligible Kirkendall porosity. This behavior was related to the grain structure of the particular lot of DS-NiCr.
The results are presented of numerous studies relating to aluminum alloy welding. The subjects covered include: (1) effects of porosity on weld joint performance, (2) sources of porosity, (3) weld thermal effects, (4) residual stresses and distortion, and (5) manufacturing process system control.
Supersonic wind-tunnel tests were conducted with disk-gap-band parachute models having a nominal diameter of 1.65 meters and geometric porosities of 10.0, 12.5, and 15.0 percent. Canopy inflation characteristics, angles of attack, and drag performance are presented for deployment behind forebody base extensions which were free to oscillate in pitch and yaw. The effect of increasing suspension-line length on canopy motions and drag performance is included, and the drag performance of a model with 12.5 percent geometric porosity is compared with results from flight tests of a parachute with a nominal diameter of 12.19 meters.
The microstructures of mullite composition fibers were examined by transmission electron microscopic techniques and by X-ray diffraction analyses. Both spun and monofilament fiber structures contained little porosity, nor did the degree of porosity change after heating the monofilament to 1205 C for one half hour. Thermal exposure produced crystallite growth and nucleation from the amorphous phase in all three of the spun fibers. After 116 hours at 1426 C, the crystallites of the standard spun fibers became contiguous. In addition, the surface crystallites of these fibers were found to be more than twice as large as the interior crystallites.
Three sting-mounted winged-body models with tunnel blockages of 0.1, 1.0, and 2.0 percent were tested in the Lewis Research Center's 8- by 6- Foot Supersonic Wind Tunnel. Fuselage pressures were obtained over a Mach number range of 0.6 to 1.0 at angles of attack from 0 deg to 4 deg. Two other types of model support were investigated, which included simulated wing-tip and fuselage support-strut mountings. The effects of tunnel porosity and sidewall geometry were also investigated. Model blockage effects were small up to M sub 0 = 0.95. At higher speeds the major blockage effect observed was a displacement of the local transonic terminal shocks on the model. The effects of the wing-tip type of model support were small up to M sub 0 = 0.95, but disturbances were observed on the fuselage at higher speeds. Changes in local tunnel porosity were effective in reducing the disturbances up to M sub 0 = 0.975, but a change in sidewall geometry was not.
Filler materials proposed for use in the sputter fabrication regeneratively cooled thrust chambers were evaluated. Low melting castable alloys, CERROBEND. CERROCAST, and CERROTRU, slurry applied SERMETEL 481 and flame-sprayed aluminum were investigated as filler materials. Sputter deposition from a cylindrical cathode inverted magnestron was used to apply an OFHC copper closeout layer to filled OFHC copper ribbed-wall cylindrical substrates. The sputtered closeout layer structure was evaluated with respect to filler material contamination, predeposition machining and finishing operations, and deposition parameters. The application of aluminum by flame-spraying resulted in excessiver filler porosity. Though the outgassing from this porosity was found to be detrimental to the closeout layer structure, bond strengths in excess of 10,500 psi were achieved. Removal of the aluminum from the grooves was readily accomplished by leaching in a 7.0 molar solution of sodium hydroxide at 353 K. Of the other filler materials evaluated, CERROTRU was found to be the most suitable material with respect to completely filling the ribbed-wall cylinders and vacuum system compatibility. However, bond contamination resulted in low closeout layer bond strength with the CERROTRU filler. CERROBEND, CERROCAST, and SERMETEL 481 were found to be unacceptable as filler materials.
An investigation was conducted at Mach 1.80 in the Langley 4-foot supersonic pressure tunnel to determine the effects of variation in reefing ratio and geometric porosity on the drag and stability characteristics of four basic canopy types deployed in the wake of a cone-cylinder forebody. The basic designs included cross, hemisflo, disk-gap-band, and extended-skirt canopies; however, modular cross and standard flat canopies and a ballute were also investigated. An empirical correlation was determined which provides a fair estimation of the drag coefficients in transonic and supersonic flow for parachutes of specified geometric porosity and reefing ratio.
Theoretical expressions are obtained for the capillary-pressure limit and permeability of a fibrous wick in terms of the porosity and fiber diameter. Hysteresis in capillary pressure is included through the introduction of an empirical hysteresis constant. A partial-saturation model based on the statistical distribution of local porosity requires an additional empirical constant, the standard deviation. The theory is compared to results of a beta-ray absorption experiment that measured the liquid content of a partially saturated wick and to results of permeability measurements on partially and fully saturated wicks. A simple wick-weighing experiment is described that yields values for the empirical hysteresis constant and the standard deviation. Theoretical results are used to design an optimum wick.
Tests were conducted in the Ames Research Center 40- by 80-Foot Wind Tunnel to determine how porosity of wing spoilers on a B-747 airplane would affect the rolling moments imposed on an aircraft following in the wake. It was found that spoilers with 40 percent porosity and hole diameter to thickness ratio of 1.1 were just as effective in reducing the rolling moment imposed on the follower as solid spoilers, for the case of two spoilers per wing panel (6.4 percent semispan each) with a following model whose span was 20 percent of the span of the generator. When a larger following model was tested, whose span was 50 percent of that of the generator, the effectiveness of the two spoilers per wing was substantially reduced.
The effect of diffuser wall acoustic treatment on inlet total pressure loss was experimentally determined. Data were obtained by testing an inlet model with 10 different acoustically treated diffusers differing only in the design of the Helmholtz resonator acoustic treatment. Tests were conducted in a wind tunnel at forward velocities to 41 meters per second for inlet throat Mach numbers of .5 to .8 and angles of attack as high as 50 degrees. Results indicate a pressure loss penalty due to acoustic treatment that increases linearly with the porosity of the acoustic facing sheet. For a surface porosity of 14 percent the total pressure loss was 21 percent greater than that for an untreated inlet.
The feasibility of using porous composite materials (Kevlar, Doweave, and Leno Weave) as lightweight, efficient laminar flow control (LFC) surface materials is compared to the metallic 319L stainless Dynapore surfaces and electron beam drilled composite surfaces. Areas investigated include: (1) selection of the LFC-suitable surface materials, structural materials, and fabrication techniques for the LFC aircraft skins; (2) aerodynamic static air flow test results in terms of pressure drop through the LFC panel and the corresponding effective porosity; (3) structural design definition and analyses of the panels, and (4) contamination effects on static drop and effective porosity. Conclusions are presented and discussed.
Experimental determination of the effect of diffuser wall acoustic treatment on inlet total pressure loss. Data were obtained by testing an inlet model with 10 different acoustically treated diffusers differing only in the design of the Helmholtz resonator acoustic treatment. Tests were conducted in a wind tunnel at forward velocities to 41 meters per second for inlet throat Mach numbers of .5 to .8 and angles of attack as high as 50 degrees. Results indicate a pressure loss penalty due to acoustic treatment that increases linearly with the porosity of the acoustic facing sheet. For a surface porosity of 14% the total pressure loss was 21% greater than that for an untreated inlet. The penalty resulting from treatment increased for average throat Mach numbers above approximately .7 where local regions of sonic or supersonic surface flow were encountered. Pressure loss over the treatment was not affected by the presence of noise.
Measurements were performed to determine the pressure drops for gaseous flow through porous materials of different microstructures, porosities, and thickness under isothermal and nonisothermal conditions at various temperature levels. Results were satisfactorily correlated by a simple equation relating the friction factor to the Reynolds number and porosities.
Nine inch diameter samples of the material which will provide thermal and acoustic protection between the nozzle and outer skirt on the space shuttle solid rocket boosters were subjected to heating tests to determine the porosity of the material and the thermal response to a step change in heating. For the porosity measurements a steady state flow of air at 70 F, 500 F, and 1000 F was passed through a sample of the curtain material and measurements of the flow rates were made at different pressure drops across the sample. For the transient measurements, a sample of the curtain material was subjected to a step change in temperature as air was passed through the sample. Measurements of the heat flow through the sample were made as a function of time after the input of the heat pulse. The sample consisted of three layers of curtain panels. Each panel was made of combinations of quartz and fiberglass cloth between which a fiberfrax filler material had been stitched. The hardware design and test procedures were described. Data are provided in engineering units for the flow conditions and and temperatures at which measurements were conducted.
The porosity and platability of various materials were investigated to determine a suitable substrate for nickel-plated electrodes. Immersion, ultrasonics, and flow-through plating techniques were tried using nonproprietary formulations, and proprietary phosphide and boride baths. Modifications to the selected material include variations in formulation and treatment, carbon loading to increase conductivity, and the incorporation of a grid. Problems to be solved relate to determining conductivities and porosities as a function of amount of nickel plated on the plastics; loading; charge and discharge curves of electrodes at different current densities; cell performance; and long-term degradation of electrodes.
The effect of the microstructure of reaction bonded silicon nitride on strength is examined. The morphologies of the various microconstituents (alpha-matte, beta-spikes, residual silicon and porosity) each play a role in determining the strength of the material. While density and hence percent porosity greatly affect strength, it is shown that the pore size and pore size distribution affect strength with equal importance. By minimizing the pore size and distribution and maximizing the alpha-beta ratio, a reaction bonded material (2.4 kg/cu m) has been produced with a room temperature modulus of rupture (three-point bending) of 297 MPa from a low green density starting material (1.5 kg/cu m).
Partial melting is likely to have occurred throughout much of the moon due to heating during accretion and the volumetric heating of radioactive isotopes. Important problems that have received relatively little attention concern the migration of the resulting magmas to form surface or near surface volcanic rock. In the paper the basic mechanism for the migration of the magma through the lunar asthenosphere is considered. A porous flow model is proposed. The magma behaves like a liquid flowing through a porous matrix. The volume fraction of liquid present determines the saturated porosity. The differential buoyancy of the magma drives it upwards. It is shown that the per cent partial melt in the lunar interior will only slightly exceed that required to provide interconnecting porosity. Assuming that the radioactive isotopes are preferentially segregated into the magma, the time dependence of the partial melting of the lunar interior is found. It is shown that the total degree of partial melting of the deep lunar interior is likely to be between five and ten per cent.