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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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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Non-Intrusive Load Monitoring of EBW Processes A Second Study [Slides]

The Objective is to Determine if induced off-nominal welding disturbances: (1) Beam arc out (weld on high vapor pressure aluminum plate); (2) Pulsed beam voltage; (3) Pulsed beam current; and (4) Pulsed beam focus current can be observed in the input power to the high-voltage cabinet powering the EB gun, ie Non-Instrusive Load Monitoring (NILM).

36 MATERIALS SCIENCE↗
NASA NTRS1979

Space Shuttle communications RF switch matrix

The Shuttle Orbiter communications equipment includes phase modulation (PM) and frequency modulation (FM) channels. The PM section has the capability of routing high levels of energy (175 W) from any one of four transmitters to any one of four antennas, mutually exclusive. The FM channel uses a maximum of 15-W power routed from either of two transmitters to one of two antennas, mutually exclusive. The paper describes the design and the theory of a logic-controlled RF switch matrix devised for the purposes cited. Both PM and FM channels are computer-controlled with manual overrides. The logic interface is realized with CMOS logic for low power consumption and high noise immunity. The interior of the switch matrix is maintained at a pressure of 15 psi (90% nitrogen, 10% helium) by an electron beam-welded encapsulation. The computational results confirm the viability of the RF switch matrix concept.

Winch, R.↗
NASA NTRS1988

Bayonet for superfluid helium transfer in space

A prototype superfluid helium bayonet for potential space applications has been developed and evaluated with a low heat leak test apparatus. Measured heat leak of the 13 mm (1/2 inch) bayonet pair is 0.21 W at 1.8 K with an uncertainty of +0.09/-0.05 W. Bayonets are fabricated with thin, electron beam (EB) welded tubes which are EB welded to machined nose and flange pieces. Low heat leak structural integrity is provided by a 0.9 mm thickness of filament wound fiberglass-epoxy. Superfluid creep is restricted by KEL-F nose seals which form vacuum-tight extensions to the bayonet cold end pieces.

Mcintosh, G. E.↗
NASA NTRS1989

Creep strength of niobium alloys, Nb-1%Zr and PWC-11

A study is being conducted at NASA Lewis Research Center to determine the feasibility of using a carbide particle strengthened Nb-1 percent Zr base alloy to meet the anticipated temperature and creep resistance requirements of proposed near term space power systems. In order to provide information to aid in the determination of the suitability of the PWC-11 alloy as an alternative to Nb-1 percent Zr in space power systems this study investigated: (1) the long-time high-vacuum creep behavior of the PWC-11 material and the Nb-1 percent Zr alloy, (2) the effect of prior stress-free thermal aging on this creep behavior, (3) the effect of electron beam (EB) welding on this creep behavior, and (4) the stability of creep strengthening carbide particles.

Titran, Robert H.↗
NASA NTRS2013

Thermal Imaging for Assessment of Electron-Beam Free Form Fabrication (EBF(sup 3)) Additive Manufacturing Welds

Additive manufacturing is a rapidly growing field where 3-dimensional parts can be produced layer by layer. NASA s electron beam free-form fabrication (EBF(sup 3)) technology is being evaluated to manufacture metallic parts in a space environment. The benefits of EBF(sup 3) technology are weight savings to support space missions, rapid prototyping in a zero gravity environment, and improved vehicle readiness. The EBF(sup 3) system is composed of 3 main components: electron beam gun, multi-axis position system, and metallic wire feeder. The electron beam is used to melt the wire and the multi-axis positioning system is used to build the part layer by layer. To insure a quality weld, a near infrared (NIR) camera is used to image the melt pool and solidification areas. This paper describes the calibration and application of a NIR camera for temperature measurement. In addition, image processing techniques are presented for weld assessment metrics.

Zalameda, Joseph N.↗
NASA NTRS1999

How an Electron Beam (Eventually) Penetrates Ceramic Cloth

In anticipation of the International Space Welding Experiment (ISWE) the effect of an electron beam was investigated on Nextel AF-62 ceramic cloth designed to withstand temperatures up to 1427 C. It was anticipated that the cloth would take a static charge that would repel the beam and remain undamaged. It was found that after some seconds the impinging beam penetrated penetrated the cloth. Further, the penetration time went up significantly both at longer and at closer standoff distances. A tentative explanation appears to fit the observed facts. The electrons in the beam generate positive ions by collisions with the contaminant gas molecules in the vacuum chamber. The positive ions transfer a small but significant fraction of the beam power to the cloth. Under the impingement of the positive ions the cloth heats up until sufficient outgassing occurs to initiate arcing. Once arcing occurs the full beam power impinges on the cloth and, almost instantaneously, burns a hole.

Nunes, A. C., Jr.↗
NASA NTRS1987

Joining of ceramics for high temperature applications

Summarized is a literature survey of the methods for joining ceramics to ceramics or ceramics to metals for high temperature applications. Also mechanical properties and potential applications of the joints are considered. The joining of ceramics is usually carried out by brazing or diffusion bonding. Especially the latter has been found useful, increasing the application of bonded ceramics. The possibility of using electron beam and laser beam welding for joining ceramics has also recently been investigated. The bonding of ceramics has found numerous applications typical for high operating temperatures, i.e., sensors and thermocouples.

Vilpas, Martti↗
NASA NTRS1986

Program for Heat Flow in Welding

Program contains numerical model of temperature distribution in vicinity of weld. Weld model used to produce estimated welding power requirements, welding-power-loss analysis, heat-affected-zone temperature history, and weld-puddle cross-section plots. Applied to gas/tungsten-arc, plasma-arc, electron-beam, and laser-beam welds on wide plates under steady conditions. User predicts power requirements and temperature distributions. Weld model written in BASIC.

Nunes, A. C., Jr.↗
NASA NTRS2008

Thermal Stir Welding Development at Marshall Space Flight Center

Solid state welding processes have become the focus of welding process development at NASA's Marshall Space Flight Center. Unlike fusion weld processes such as tungsten inert gas (TIG), variable polarity plasma arc (VPPA), electron beam (EB), etc., solid state welding processes do not melt the material during welding. The resultant microstructure can be characterized as a dynamically recrystallized morphology much different than the casted, dentritic structure typical of fusion weld processes. The primary benefits of solid state processes over fusion weld processes include superior mechanic properties and the elimination of thermal distortion and residual stresses. These solid state processes attributes have profoundly influenced the direction of advanced welding research and development within the NASA agency. Thermal Stir Welding (TSW) is a new solid state welding process being developed at the Marshall Space Flight Center. Unlike friction stir welding, the heating, stirring and forging elements of the weld process can be decoupled for independent control. An induction coil induces energy into a workpiece to attain a desired plastic temperature. An independently controlled stir rod, captured within non-rotating containment plates, then stirs the plasticized material followed by forging plates/rollers that work the stirred weld joint. The independent control (decoupling) of heating, stirring and forging allows, theoretically, for the precision control of microstructure morphology. The TSW process is being used to evaluate the solid state joining of Haynes 230 for ARES J-2X applications. It is also being developed for 500-in (12.5 mm) thick commercially pure grade 2 titanium for navy applications. Other interests include Inconel 718 and stainless steel. This presentation will provide metallurgical and mechanical property data for these high melting temperature alloys.

Ding, Robert J.↗
NASA NTRS1972

High Power Laser Welding

A review of recent developments in high power, carbon dixoide laser welding is presented. Deep penetration welding in stainless steel to 0.5-in. thick, high speed welding in thin gage rimmed steel and gas shielded welding in Ti-6Al-4V alloy are described. The effects of laser power, power density, focusing optics, gas-shielding techniques, material properties and weld speed on weld quality and penetration are discussed. It is shown that laser welding performance in thin materials is comparable to that of electron beams. It is further shown that high quality welds, as evidenced by NDT, mechanical and metal-lographic tests, can be achieved. The potential of the laser for industrial welding applications is indicated.

Banas, C. M.↗
NASA NTRS1986

Physics of Fusion Welding

Applicabilities and limitations of three techniques analyzed. NASA technical memorandum discusses physics of electron-beam, gas/ tungsten-arc, and laser-beam welding. From comparison of capabilities and limitations of each technique with regard to various welding conditions and materials, possible to develop criteria for selecting best welding technique in specific application. All three techniques classified as fusion welding; small volume of workpiece melted by intense heat source. Heat source moved along seam, leaving in wake solid metal that joins seam edges together.

Nunes, A. C., Jr.↗
NASA NTRS2010

Finned Carbon-Carbon Heat Pipe with Potassium Working Fluid

This elemental space radiator heat pipe is designed to operate in the 700 to 875 K temperature range. It consists of a C-C (carbon-carbon) shell made from poly-acrylonitride fibers that are woven in an angle interlock pattern and densified with pitch at high process temperature with integrally woven fins. The fins are 2.5 cm long and 1 mm thick, and provide an extended radiating surface at the colder condenser section of the heat pipe. The weave pattern features a continuous fiber bath from the inner tube surface to the outside edges of the fins to maximize the thermal conductance, and to thus minimize the temperature drop at the condenser end. The heat pipe and radiator element together are less than one-third the mass of conventional heat pipes of the same heat rejection surface area. To prevent the molten potassium working fluid from eroding the C C heat pipe wall, the shell is lined with a thin-walled, metallic tube liner (Nb-1 wt.% Zr), which is an integral part of a hermetic metal subassembly which is furnace-brazed to the inner surface of the C-C tube. The hermetic metal liner subassembly includes end caps and fill tubes fabricated from the same Nb-1Zr alloy. A combination of laser and electron beam methods is used to weld the end caps and fill tubes. A tungsten/inert gas weld seals the fill tubes after cleaning and charging the heat pipes with potassium. The external section of this liner, which was formed by a "Uniscan" rolling process, transitions to a larger wall thickness. This section, which protrudes beyond the C-C shell, constitutes the "evaporator" part of the heat pipe, while the section inside the shell constitutes the condenser of the heat pipe (see figure).

Juhasz, Albert J.↗