Engineering topics
Publications and source records attributed to Kalfayan, S. H..
Proposed process modification incorporates viscosity depressants to prevent coal from solidifying during liquefaction. Depressants reduce amount of heat needed to liquefy coal. Possible depressants are metallic soaps, such as stearate, and amides, such as stearamide and dimer acid amides.
Polyurethane binder for solid propellants endures heat sterilization without decomposition based on an ester diol. Binder resists oxidation under prolonged exposure to 135 degrees C temperature, low enough in viscosity to be handled easily during processing, and readily mixed with oxidizers, such as ammonium perchlorate. Polyurethane is also suitable material for encapsulants, potting compounds, and coatings that must be sterilized.
The binders tested were polyurethanes made from two hydroxy-terminated polybutadienes, R-45 and Butarez HT, one hydroxy-terminated butadiene-acrylonitrile copolymer, Hycar 1300X 17, and a hydroxy-terminated prepolymer, Esterdiol 560, made from the dimerized fatty acid Empol 1010. The isocyanates used most extensively were isophorone diisocyanate (IPDI) and a polymeric diisocyanate, DDI. Stress relaxation was used to examine the chemical changes that took place in the binder when subjected to the sterilization temperatures. The thermal stability of the oxidizer, ammonium perchlorate (AP), was tested by thermogravimetry in the isothermal and nonisothermal modes. The effect of particle size, recrystallization, moisture content, and doping on the heat stability of AP could be evaluated by this method. The volatile degradation products, obtained when AP samples were aged at 135 C for prolonged periods, were analyzed by mass spectroscopy.
The compatibility of elastomeric compositions of known resistance to aircraft fuels was tested for potential use in Jet A type fuels obtainable from alternate sources, such as coal. Since such fuels were not available at the time, synthetic alternate fuels were prepared by adding tetralin to a petroleum based Jet A type fuel to simulate coal derived fuels which are expected to contain higher amounts of aromatic and hydroaromatic hydrocarbons. The elastomeric compounds tested were based on butadiene-acrylonitrile rubber, a castable Thiokol polysulfide rubber, and a castable fluorosilicone rubber. Batches of various cross-link densities of these rubbers were made and their chemical stress relaxation behavior in fuel, air, and nitrogen, their swelling properties, and response to mechanical testing were determined.
A material was formulated having about 250-350 psi tensile strength and 30-80 percent elongation at 260 C for at least 24 hours in simulated brine. The relationship between these laboratory test results and sealing performance in actual or simulated test conditions is not entirely clear; however, it is believed that no conventional formation or casing packer design is likely to perform well using these materials. The synthetic effort focused on high temperature block copolymers and development of curable polystyrene. Procedures were worked out for synthesizing these new materials. Initial results with heat-cured unfilled polystyrene 'gum' at 260 C indicate a tensile strength of about 50 psi. Cast films of the first sample of polyphenyl quinoxaline-polystyrene block copolymer, which has 'graft-block' structure consisting of a polystyrene chain with pendant polyphenyl quinoxaline groups, show elastomeric behavior in the required temperature range. Its tensile strength and elongation at 260 C were 220-350 psi and 18-36 percent, respectively. All of these materials also showed satisfactory hydrolytic stability.
A material for a casing packer for service for 24 hours in a geothermal environment was developed by synthesis of new elastomers and formulation of available materials. Formulation included use of commercial elastomer gumstocks and also crosslinking of plastic (high Tg) materials. Fibrous reinforcement of fluorocarbon rubbers was emphasized. Organic fiber reinforcement did not increase hot properties significantly. Glass fiber reinforcement gave significant increase in tensile properties. Elongation was reduced, and the glass-reinforced composition examined so far did not hold up well in the geothermal environment. Colloidal asbestos fibers were also investigated. A few experiments with polyphenyl ether gave material with low tensile and high compression set. Available high styrene SBR compositions were studied. Work to date suggests that new synthetic polymers will be required for service in geothermal environments.
A method for chlorinolysis of coal is an organic solvent at a moderate temperautre and atmospheric pressure has been proven to be effective in removing sulfur, particularly the organic sulfur, from coal. Chlorine gas is bubbled through a slurry of moist coal in chlorinated solvent. The chlorinated coal is separated, hydrolyzed and the dechlorinated. Preliminary results of treating a high sulfutr (4.77%S) bituminous coal show that up to 70% organic sulfur, 90% hyritic sulfur and 76% total sulfur can be removed. The treated coal is dechlorinated by heating at 500 C. The presence of moisture helps to remove organic sulfur.
Economical, low-temperature chlorinolysis converts sulfur to water-soluble sulfates. Sulfates are removed by washing. Subsequent steps dry coal and remove chlorine. Chlorine and solvents can be reused.
Heat-aging studies were conducted on fluororubber (copolymers of vinylidene fluoride and perfluoropropylene) using N,N-dicinnamylidene-1,6-hexanediamine, a Schiff's base of 1,6-hexanediamine, and MgO as acid acceptor. The principal technique employed was chemical stress relaxation for determining network changes brought about in the heat-aged fluororubber. This technique was backed up by swelling measurements, gel permeation chromatography, and IR spectroscopy. Stress relaxation curves are plotted for a wide range of variation in parameters (time, crosslinking density, state of curing, temperature, intermittent and continuous relaxation).
Composite beam connected to strain gauge and mounted on test specimen is capable of amplifying small strains by factor of 10. Tests indicate that resulting output can be 10 times greater than standard method.
Two relaxometers allow testing of elastomers in various fluids. First relaxometer uses fork-like loading spacer interposed between loading lever and support ring, so that sample is stretched predetermined amount. In second relaxometer, degree of initial elongation is set by means of adjustable collar, which, when locked in place on piston rod, enables sample to be stretched predetermined length.
The continuation of a study to ascertain the nature, extent, and the rate of chemical changes that take place in certain selected elastomers is reported. Under discussion is Viton B, regarded as a temperature and fuel resistant fluorocarbon rubber. The kinetic analysis of the chemical stress relaxation, and infrared and gel permeation chromatography analysis results are discussed.
Methods were developed to determine the coefficient of friction and the extent of stick-slip of magnetic recording tapes. After a preliminary phase during which experimental procedures were established and screening of candidate tapes was carried out, the frictional and stick-slip behavior of four selected tapes, using four different kinds of magnetic heads, was studied at various temperatures, under dry and humid conditions, and in various gaseous atmospheres, such as argon, helium, nitrogen and air. The effects of tape speed and outgassing on the drag properties of the tapes were also studied. A rank was assigned to each tape and magnetic head as a result of these tests. This study helped in the selection of a magnetic tape in a flight project, and will be useful in the consideration of tapes and magnetic heads for future spacecraft applications.
Methods were developed for measuring frictional forces acting on a magnetic tape in motion or at rest, as well as the extent of stick slip. The effects of factors such as temperature, humidity, kind of gaseous atmosphere, and tape speed on the frictional interaction between various tapes and heads were investigated. Results were instrumental in the selection of a tape for the Mariner Mars 1971 spacecraft. Studies are reported on the stick slip behavior of tapes and the performance of a metallic tape, compared with the usual plastic tapes.
Spacecraft sterilization is a vital factor in projects for the successful biological exploration of other planets. The microorganisms of major concern are the fungi and bacteria. Sterilization procedures are oriented toward the destruction of bacterial spores. Gaseous sterilants are examined, giving attention to formaldehyde, beta-propiolactone, ethylene oxide, and the chemistry of the bactericidal action of sterilants. Radiation has been seriously considered as another method for spacecraft sterilization. Dry heat sterilization is discussed together with the effects of ethylene oxide decontamination and dry heat sterilization on materials.
Aerospace applications of elastomers are considered, including: propellant binders, bladder materials for liquid propellant expulsion systems, and fuel tank sealants for high-speed aircraft. A comprehensive molecular theory for mechanical properties of these materials has been developed but has only been tested experimentally in cases where chemical degradation processes are excluded. Hence, a study is being conducted to ascertain the nature, extent, and rate of chemical changes that take place in some elastomers of interest. Chemical changes that may take place in the fluorosilicone elastomer, LS 420, which is regarded as a fuel and high-temperature-resistant rubber are investigated. The kinetic analysis of the chemical stress relaxation and gel permeation chromatography studies comprise the major portion of the report.
Properties of samples are tested, after thermal exposure, and values are compared with unexposed samples. Thermal stability or compatibility ratings of formulated or compounded organic polymers using trade names are made and degree of change in measured properties is assessed. Products are rated compatible, marginal, or not compatible.
Simulated Venusian atmosphere effects on polymeric plastic and rubber materials, comparing with high temperature air and nitrogen exposures