Surface ionization studies on refractory metals and metal alloys
Surface ionization studies on refractory metals and metal alloys used in long term contact ion engine operation
SURFACE IONIZATION↗
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Results for “alloy surface engineering”
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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High temperature environmental effects on metals
The current status of knowledge and ability to predict high-temperature environmental attack of metals is reviewed with particular reference to the gas turbine engine. Environmental attack is caused by high temperatures, combustion products, and impurities. A schematic representation of life-limiting factors of turbine components shows that environmental attack can lead to very early failures. Attention is given to high-temperature oxidation with prevailing modes of oxidation attack, and to hot corrosion and other impurity effects. Erosion attack results from the direct mechanical removal of component material by impact of hard substances like ash, sand, or dirt. Solutions to hot-corrosion problems can be found semiempirically by using improved alloys or ceramics, protective surface coatings, additives to the engine environment, and air/fuel cleanup to eliminate detrimental impurities.
Grisaffe, S. J.↗
High temperature environmental effects on metals
The gas turbine engine was used as an example to predict high temperature environmental attack on metals. Environmental attack in a gas turbine engine derives from high temperature, combustion products of the air and fuel burned, and impurities. Of all the modes of attack associated with impurity effects, hot corrosion was the most complicated mechanistically. Solutions to the hot corrosion problem were sought semi-empirically in: (1) improved alloys or ceramics; (2) protective surface coating; (3) use of additives to the engine environment; and (4) air/fuel cleanup to eliminate harmful impurities.
Grisaffe, S. J.↗
Advanced rotary engine studies
A review of rotary engine developments relevant to a stratified charge rotary aircraft engine is presented. Advantages in module size and weight, fuel efficiency, reliability, and multi-fuel capability are discussed along with developments in turbocharging, increased mean effective pressure, improved apex seal/trochoid wear surfacing materials, and high strength and temperature aluminum casting alloys. A carbureted prototype aircraft engine is also described.
Jones, C.↗
Supportability Technologies for Future Exploration Missions
Future long-duration human exploration missions will be challenged by resupply limitations and mass and volume constraints. Consequently, it will be essential that the logistics footprint required to support these missions be minimized and that capabilities be provided to make them highly autonomous from a logistics perspective. Strategies to achieve these objectives include broad implementation of commonality and standardization at all hardware levels and across all systems, repair of failed hardware at the lowest possible hardware level, and manufacture of structural and mechanical replacement components as needed. Repair at the lowest hardware levels will require the availability of compact, portable systems for diagnosis of failures in electronic systems and verification of system functionality following repair. Rework systems will be required that enable the removal and replacement of microelectronic components with minimal human intervention to minimize skill requirements and training demand for crews. Materials used in the assembly of electronic systems (e.g. solders, fluxes, conformal coatings) must be compatible with the available repair methods and the spacecraft environment. Manufacturing of replacement parts for structural and mechanical applications will require additive manufacturing systems that can generate near-net-shape parts from the range of engineering alloys employed in the spacecraft structure and in the parts utilized in other surface systems. These additive manufacturing processes will need to be supported by real-time non-destructive evaluation during layer-additive processing for on-the-fly quality control. This will provide capabilities for quality control and may serve as an input for closed-loop process control. Additionally, non-destructive methods should be available for material property determination. These nondestructive evaluation processes should be incorporated with the additive manufacturing process - providing an in-process capability to ensure that material deposited during layer-additive processing meets required material property criteria.
Watson, Kevin↗
Method of fabricating a rocket engine combustion chamber
A process for making a combustion chamber for a rocket engine wherein a copper alloy in particle form is injected into a stream of heated carrier gas in plasma form which is then projected onto the inner surface of a hollow metal jacket having the configuration of a rocket engine combustion chamber is described. The particles are in the plasma stream for a sufficient length of time to heat the particles to a temperature such that the particles will flatten and adhere to previously deposited particles but will not spatter or vaporize. After a layer is formed, cooling channels are cut in the layer, then the channels are filled with a temporary filler and another layer of particles is deposited.
Holmes, Richard R.↗
High-temperature oxidation/corrosion of iron-based superalloys
The oxidation and sulfidation of several novel iron-base superalloys were evaluated in high-temperature cyclic tests. The experimental austenitic alloys examined were modifications of NASAUT-4GA which were developed for Stirling-engine application. The weight gains and resulting surface scales were measured and analyzed. Mixed oxide scales were found to form on all specimens exposed above 871 C. The build-up of these scales led to a depletion of Mn and Cr in a zone adjacent to the oxides. In addition, the initial oxidation of the Fe-rich alloy was inhibited by a thin but tenacious Si layer which formed at the interface between oxides and the parent layer. Sulfidation tests using Na2SO4 coatings resulted in the formation of a protective spinel and alpha-Fe2O3 phases. Preferential attack of the carbide phase by hydrogen was not observed after 350 h at 871 C.
Lemkey, F. D.↗
Hot-salt stress-corrosion of titanium alloys as related to turbine operation
In an effort to simulate typical compressor operating conditions of current turbine engines, special test facilities were designed. Air velocity, air pressure, air dewpoint, salt deposition temperature, salt concentration, and specimen surface condition were systematically controlled and their influence on hot-salt stress-corrosion evaluated. The influence of both continuous and cyclic stress-temperature exposures was determined. The relative susceptibility of a variety of titanium alloys in commonly used heat-treated conditions was determined. The effects of both environmental and material variables were used to interpret the behavior of titanium alloys under hot-salt stress-corrosion conditions found in jet engines and to appraise their future potential under such conditions.
Gray, H. R.↗
Quick Access Rocket Exhaust Rig Testing of Coated GRCop-84 Sheets Used to Aid Coating Selection for Reusable Launch Vehicles
The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition1 invented at the NASA Glenn Research Center: Cu-8(at.%)Cr-4%Nb. Many of the properties of this alloy have been shown to be far superior to those of other conventional copper alloys, such as NARloy-Z. Despite this considerable advantage, it is expected that GRCop-84 will suffer from some type of environmental degradation depending on the type of rocket fuel utilized. In a liquid hydrogen (LH2), liquid oxygen (LO2) booster engine, copper alloys undergo repeated cycles of oxidation of the copper matrix and subsequent reduction of the copper oxide, a process termed "blanching". Blanching results in increased surface roughness and poor heat-transfer capabilities, local hot spots, decreased engine performance, and premature failure of the liner material. This environmental degradation coupled with the effects of thermomechanical stresses, creep, and high thermal gradients can distort the cooling channel severely, ultimately leading to its failure.
Raj, Sai V.↗
Laser Patterning Assisted Devitrification and Domain Engineering of Amorphous and Nanocrystalline Alloys
We have investigated laser-patterning and devitrification as a novel method to realize emergent properties in modified regions at the ribbon surface consisting of periodic localized laser spots thermally treated under rapid heating and cooling conditions. Fe-based amorphous ribbons were annealed for systematically varied laser power. Extremely high heating and cooling rates on the order of 10(exp 8)-10(exp 10)K/s have been estimated by finite element analysis simulations. Observations suggest surface melting followed by rapid solidification fast enough to quench and form an amorphous structure upon cooling. Diffusion of heat occurs from the laser irradiated surface region so that a finite volume of material surrounding this region rises in temperature above the crystallization temperature relevant for conventional isothermal annealing experiments. The underlying mechanism of laser annealing and consequences of heat transients involved are discussed in terms of impacts upon micro/nanostructure, residual stresses, and magnetic domain structure surrounding the laser irradiated region. The study illustrates the potential to exploit spatially optimized phase transformations in a scalable manufacturing process of amorphous and nanocrystalline alloys to locally access otherwise inaccessible extreme heating and cooling rates.
Amorphous ribbons↗
Plasma Spraying Reclaims Compressor Housings
Plasma-spraying process used to build up material in worn and pitted areas. Newly applied material remachined to specified surface contours. Effective technique for addition of metal to out-of-tolerance magnesium-alloy turbine-engine compressor housings.
Leissler, George W.↗
Engineering Polymers as Structural Materials in Spacecraft Water Systems
The novel application of structural materials, surface treatments, and barrier coatings is desired to mitigate the rapid loss of ionic silver (Ag+) biocide observed with passive metal alloys, improve reliability, and reduce system mass. In this work, we provide an initial look at the potential replacement of these heritage alloys in spacecraft water systems with high-performance thermoplastic engineering polymers, including PEEK, PEI, and PVDF. Such materials have found increasing use as structural materials in a broad array of performance-critical applications, including in the aerospace, medical implant, and chemical processing fields. We selected a number of promising materials for investigation, compiled mechanical behavior data, and conducted theoretical performance analyses. We also identified and began to address numerous material suitability concerns as well as design requirements for pressurized components in human-rated spacecraft hardware. These include material flammability, offgassing, leaching, chemical resistance, radiation tolerance, prevention of fracture/yielding, and others. We find that there is significant potential for use of engineering polymers in spacecraft water systems, and suggest some directions for future research.
Lance Dean Delzeit↗
Electronic materials high-T(sub c) superconductivity polymers and composites structural materials surface science and catalysts industry participation
The fifth year of the Center for Advanced Materials was marked primarily by the significant scientific accomplishments of the research programs. The Electronics Materials program continued its work on the growth and characterization of gallium arsenide crystals, and the development of theories to understand the nature and distribution of defects in the crystals. The High Tc Superconductivity Program continued to make significant contributions to the field in theoretical and experimental work on both bulk materials and thin films and devices. The Ceramic Processing group developed a new technique for cladding YBCO superconductors for high current applications in work with the Electric Power Research Institute. The Polymers and Composites program published a number of important studies involving atomistic simulations of polymer surfaces with excellent correlations to experimental results. The new Enzymatic Synthesis of Materials project produced its first fluorinated polymers and successfully began engineering enzymes designed for materials synthesis. The structural Materials Program continued work on novel alloys, development of processing methods for advanced ceramics, and characterization of mechanical properties of these materials, including the newly documented characterization of cyclic fatigue crack propagation behavior in toughened ceramics. Finally, the Surface Science and Catalysis program made significant contributions to the understanding of microporous catalysts and the nature of surface structures and interface compounds.
Source record↗
Electro-chemical grinding
Electro-chemical grinding technique has rotation speed control, constant feed rates, and contour control. Hypersonic engine parts of nickel alloys can be almost 100% machined, keeping tool pressure at virtual zero. Technique eliminates galling and permits constant surface finish and burr-free interrupted cutting.
Feagans, P. L.↗
X-Ray Computed Tomography of Apollo Drive Tube 73001 as Part of the Apollo Next Generation Sample Analysis Program
Introduction: Starting in 2019, the Apollo Next Generation Sample Analysis (ANGSA) Program has enabled consortium studies of specially curated Apollo samples that were previously unstudied (or under studied). This program was intended as a participating scientist program for these Apollo samples, as well as a preparation for upcoming lunar sample return missions (e.g., Artemis). The work began with studies of unsealed core tube 73002 [1,2] that is the upper ~35 cm of an Apollo 17 double drive tube (~70 cm total depth) collected on the landslide deposit near Lara Crater at Station 3 in the Taurus Littrow Valley. More recently the program extended to the study of a variety of frozen Apollo 17 samples [3], as well as the gas extraction [4] and dissection [5] of 73001, the lower half of the station 3 double drive tube. Sample 73001 was sealed under vacuum on the Moon in a Core Sample Vacuum Container (CSVC). In this abstract we will examine the role of X-ray Computed Tomography (XCT) during the preliminary examination process for sealed core 73001, including: (1) engineering scans to aid in understanding the gas extraction process, (2) whole-core scanning prior to opening to inform extrusion and dissection work, and (3) individual particle scanning to characterize rock fragment lithologies for follow on studies. Methodology: Sample 73001 is a 33 cm long, 4 cm diameter regolith sample collected inside a lunar drive tube (~1 mm aluminum walls). That drive tube was sealed inside a 0.5 mm thick stainless steel (SS) CSVC. XCT scans for engineering purposes were done on the Nikon XTH 320 system at Johnson Space Center using the 225 kV multi-metal reflection source at 215 kV, 179 A, and a 38.49 m voxel size. Individual >4 mm particles separated from the core during processing (then triply sealed in Teflon bags) were also scanned at JSC using the 180 kV source at 90 kV, 33 A, and a 2.98 – 10.65 m voxel size. Whole-core scans were done at the University of Texas High-Resolution X-ray Computed Tomography Facility (UTCT) on the 225 kV reflection source on the North Star Imaging cabinet XCT system. These scans included: (1) a series of 9 overlapping super-resolution scans each covering a ~4 cm length of the tube at 190 kV, 180 µA, and a 12.9 µm voxel size and (2) a lower resolution continuous helical scan of the entire core at 190 kV, 180 µA, and a 51.8 µm voxel size. Progress and Results: Before piercing and extracting the gas from sample 73001, an XCT scan of the bottom portion of the CSVC was used to confirm the location of the Teflon cap on the inner drive tube and whether there was an “air” gap between the Teflon cap and the CSVC. This was to ensure the Teflon cap (which immobilized the soil inside the drive tube) was not accidentally pierced during gas extraction. Similarly, after piercing, the bottom and top portions of the CSVC were scanned in order to capture engineering knowledge about the results of the piercing process, as well as the metal knife edge vacuum seal (SS into an In-Ag alloy). Both scans will provide constraints on future work of this type, both for the design of tools used on the lunar surface during Artemis, as well as how we open future samples of this type. An unexpected finding from these engineering scans was that the device in the drive tube that immobilizes the regolith (the keeper) was not seated in the tube properly. This meant that (1) the drive tube could not be removed from the CSVC for the trip to UTCT, and (2) the procedure for opening and extruding the drive tube had to be modified. Had either of these things not been known prior to opening the CSVC, it could have led to an inability to XCT scan the whole core at high resolution and/or potential disruption of the core stratigraphy during extrusion. At UTCT, the entire length of the core was scanned at high resolution (12.9 microns per voxel). This scan serves multiple purposes: (1) A lower resolution (and uncorrected) version of these scans stitched together was used to help inform the processors of potential pitfalls during extrusion and dissection (voids, angular fragments at the edges of the sample, etc.); and (2) the full resolution corrected data will serve as the permanent in situ record of the stratigraphy of the sample and will enable future researchers to perform a variety of analyses. All 121 >4 mm particles separated during dissection pass 1 of sample 73001 have been individually scanned. These scans clearly show the lithology of each particle while keeping the particles in pristine condition (they are individually triply bagged in Teflon within our N2 purged processing cabinets). Because of the dust adhering to particle exteriors, it would otherwise be impossible to determine lithologies in a non-contaminating way. Thus far the types of lithologies seen in sample 73001 (e.g., regolith breccias, impact-melt breccias, agglutinates, and bas-alts) are similar to those previously identified in sample 73002 [2]. By the time of the meeting, all particles from all 3 dissection passes will have been scanned and statistics on the different lithologies in 73001 compiled. References: [1] Shearer et al. (2020) 51st LPSC, abstract 1181. [2] Zeigler et al. (2020) 51st LPSC, abstract 3023. [3] Kent et al. (2022) This Volume. [4] McDonald et al. (2022) European Lunar Symposium. [5] Gross et al (2022) This volume.
Moon↗
Alloy Design Workbench-Surface Modeling Package Developed
NASA Glenn Research Center's Computational Materials Group has integrated a graphical user interface with in-house-developed surface modeling capabilities, with the goal of using computationally efficient atomistic simulations to aid the development of advanced aerospace materials, through the modeling of alloy surfaces, surface alloys, and segregation. The software is also ideal for modeling nanomaterials, since surface and interfacial effects can dominate material behavior and properties at this level. Through the combination of an accurate atomistic surface modeling methodology and an efficient computational engine, it is now possible to directly model these types of surface phenomenon and metallic nanostructures without a supercomputer. Fulfilling a High Operating Temperature Propulsion Components (HOTPC) project level-I milestone, a graphical user interface was created for a suite of quantum approximate atomistic materials modeling Fortran programs developed at Glenn. The resulting "Alloy Design Workbench-Surface Modeling Package" (ADW-SMP) is the combination of proven quantum approximate Bozzolo-Ferrante-Smith (BFS) algorithms (refs. 1 and 2) with a productivity-enhancing graphical front end. Written in the portable, platform independent Java programming language, the graphical user interface calls on extensively tested Fortran programs running in the background for the detailed computational tasks. Designed to run on desktop computers, the package has been deployed on PC, Mac, and SGI computer systems. The graphical user interface integrates two modes of computational materials exploration. One mode uses Monte Carlo simulations to determine lowest energy equilibrium configurations. The second approach is an interactive "what if" comparison of atomic configuration energies, designed to provide real-time insight into the underlying drivers of alloying processes.
Abel, Phillip B.↗
Hot-salt stress-corrosion of titanium alloys as related to turbine engine operation.
Demonstration that the major variables influencing hot-salt stress-corrosion of titanium alloys are alloy processing conditions, heat-to-heat variations and composition, surface condition, and cyclic exposures. Under simulated compressor environmental conditions the commonly used 64 alloy is creep limited and not stress-corrosion limited. Cyclic exposures to stress-corrosion conditions are not as detrimental as continuous exposures for equivalent total times.
Gray, H. R.↗
Alloy chemistry and microstructural control to meet the demands of the automotive Stirling engine
The automotive Stirling engine now under development by DOE/NASA as an alternative to the internal combustion engine, imposes severe materials requirements for the hot portion of the engine. Materials selected must be low cost and contain a minimum of strategic elements so that availability is not a problem. Heater head tubes contain high pressure hydrogen on the inside and are exposed to hot combustion gases on the outside surface. The cylinders and regenerator housings must be readily castable into complex shapes having varying wall thicknesses and be amenable to brazing and welding operations. Also, high strength, oxidation resistance, resistance to hydrogen permeation, cyclic operation, and long-life are required. A research program conducted by NASA Lewis focused on alloy chemistry and microstructural control to achieve the desired properties over the life of the engine. Results of alloy selection, characterization, evaluation, and actual engine testing of selected materials are presented.
Stephens, J. R.↗