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Systems and methods for joining BMG Composites are disclosed. Specifically, the joining of BMG Composites is implemented so as to preserve the amorphicity of their matrix phase and the microstructure of their particulate phase. Implementation of the joining method with respect to the construction of modular cellular structures that comprise BMG Composites is also discussed.
NASA's Magnetospheric MultiScale (MMS) is an unmanned constellation of four identical spacecraft designed to investigate magnetic reconnection by obtaining detailed measurements of plasma properties in Earth's magnetopause and magnetotail. Each of the four identical satellites carries a suite of instruments which characterize the ambient ion and electron energy spectrum and composition. Some of these instruments utilize microchannel plates and are sensitive to particulate contamination. In this paper, we analyze the transport of particulates during pre-launch, launch and ascent events, and use the analysis to obtain quantitative predictions of contamination impact on the instruments. Viewfactor calculation is performed by considering the gravitational and aerodynamic forces acting on the particles.
Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary toolless pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.
Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.
Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and Fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub element tests will be presented.
The members of the Solar Radiation Working Group arrived at two major solar radiation technology needs: (1) generation of a long term flight data base; and (2) development of a standardized UV testing methodology. The flight data base should include 1 to 5 year exposure of optical filters, windows, thermal control coatings, hardened coatings, polymeric films, and structural composites. The UV flux and wavelength distribution, as well as particulate radiation flux and energy, should be measured during this flight exposure. A standard testing methodology is needed to establish techniques for highly accelerated UV exposure which will correlate well with flight test data. Currently, UV can only be accelerated to about 3 solar constants and can correlate well with flight exposure data. With space missions to 30 years, acceleration rates of 30 to 100X are needed for efficient laboratory testing.
This technical memorandum describes an investigation of using friction stir welding (FSW) process for joining a variety of aluminum metal matrix composites (MMC's) reinforced with discontinuous silicon-carbide (SiC) particulate and functional gradient materials. Preliminary results show that FSW is feasible to weld aluminum MMC to MMC or to aluminum-lithium 2195 if the SiC reinforcement is <25 percent by volume fraction. However, a softening in the heat-affected zone was observed and is known to be one of the major limiting factors for joint strength. The pin tool's material is made from a low-cost steel tool H-13 material, and the pin tool's wear was excessive such that the pin tool length has to be manually adjusted for every 5 ft of weldment. Initially, boron-carbide coating was developed for pin tools, but it did not show a significant improvement in wear resistance. Basically, FSW is applicable mainly for butt joining of flat plates. Therefore, FSW of cylindrical articles such as a flange to a duct with practical diameters ranging from 2-5 in. must be fully demonstrated and compared with other proven MMC joining techniques for cylindrical articles.
Ocean color measured from satellites provides daily global, synoptic views of spectral water-leaving reflectances that can be used to generate estimates of marine inherent optical properties (IOPs). These reflectances, namely the ratio of spectral upwelled radiances to spectral downwelled irradiances, describe the light exiting a water mass that defines its color. IOPs are the spectral absorption and scattering characteristics of ocean water and its dissolved and particulate constituents. Because of their dependence on the concentration and composition of marine constituents, IOPs can be used to describe the contents of the upper ocean mixed layer. This information is critical to further our scientific understanding of biogeochemical oceanic processes, such as organic carbon production and export, phytoplankton dynamics, and responses to climatic disturbances. Given their importance, the international ocean color community has invested significant effort in improving the quality of satellite-derived IOP products, both regionally and globally. Recognizing the current influx of data products into the community and the need to improve current algorithms in anticipation of new satellite instruments (e.g., the global, hyperspectral spectroradiometer of the NASA Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission), we present a synopsis of the current state of the art in the retrieval of these core optical properties. Contemporary approaches for obtaining IOPs from satellite ocean color are reviewed and, for clarity, separated based their inversion methodology or the type of IOPs sought. Summaries of known uncertainties associated with each approach are provided, as well as common performance metrics used to evaluate them. We discuss current knowledge gaps and make recommendations for future investment for upcoming missions whose instrument characteristics diverge sufficiently from heritage and existing sensors to warrant reassessing current approaches.
Two aspects of continuous flow electrophoresis were studied: (1) the structure of the flow field in continuous flow devices; and (2) the electrokinetic properties of suspended particles relevant to electrophoretic separations. Mathematical models were developed to describe flow structure and stability, with particular emphasis on effects due to buoyancy. To describe the fractionation of an arbitrary particulate sample by continuous flow electrophoresis, a general mathematical model was constructed. In this model, chamber dimensions, field strength, buffer composition, and other design variables can be altered at will to study their effects on resolution and throughput. All these mathematical models were implemented on a digital computer and the codes are available for general use. Experimental and theoretical work with particulate samples probed how particle mobility is related to buffer composition. It was found that ions on the surface of small particles are mobile, contrary to the widely accepted view. This influences particle mobility and suspension conductivity. A novel technique was used to measure the mobility of particles in concentrated suspensions.
Considerable progress in satellite remote sensing (SRS) of dust particles has been seen in the last decade. From an environmental health perspective, such an event detection, after linking it to ground particulate matter (PM) concentrations, can proxy acute exposure to respirable particles of certain properties (i.e. size, composition, and toxicity). Being affected considerably by atmospheric dust, previous studies in the Eastern Mediterranean, and in Israel in particular, have focused on mechanistic and synoptic prediction, classification, and characterization of dust events. In particular, a scheme for identifying dust days (DD) in Israel based on ground PM10 (particulate matter of size smaller than 10 nm) measurements has been suggested, which has been validated by compositional analysis. This scheme requires information regarding ground PM10 levels, which is naturally limited in places with sparse ground-monitoring coverage. In such cases, SRS may be an efficient and cost-effective alternative to ground measurements. This work demonstrates a new model for identifying DD and non-DD (NDD) over Israel based on an integration of aerosol products from different satellite platforms (Moderate Resolution Imaging Spectroradiometer (MODIS) and Ozone Monitoring Instrument (OMI)). Analysis of ground-monitoring data from 2007 to 2008 in southern Israel revealed 67 DD, with more than 88 percent occurring during winter and spring. A Classification and Regression Tree (CART) model that was applied to a database containing ground monitoring (the dependent variable) and SRS aerosol product (the independent variables) records revealed an optimal set of binary variables for the identification of DD. These variables are combinations of the following primary variables: the calendar month, ground-level relative humidity (RH), the aerosol optical depth (AOD) from MODIS, and the aerosol absorbing index (AAI) from OMI. A logistic regression that uses these variables, coded as binary variables, demonstrated 93.2 percent correct classifications of DD and NDD. Evaluation of the combined CART-logistic regression scheme in an adjacent geographical region (Gush Dan) demonstrated good results. Using SRS aerosol products for DD and NDD, identification may enable us to distinguish between health, ecological, and environmental effects that result from exposure to these distinct particle populations.
Composite panels containing up to 40 vol % discontinuous silicon carbide SiC whisker, nodule, or particulate reinforcement in several aluminum matrices are commercially fabricated and the mechanical properties and microstructual characteristics are evaluated. The yield and tensile strengths and the ductility are controlled primarily by the matrix alloy, the temper condition, and the reinforcement content. Particulate and nodule reinforcements are as effective as whisker reinforcement. Increased ductility is attributed to purer, more uniform starting materials and to more mechanical working during fabrication. Comparing mechanical properties with those of other aluminum alloys shows that these low cost, lightweight composites demonstrate very good potential for application to aerospace structures.
There is a need for lightweight, durable materials and structures to reduce the weight of propulsion systems. Polymer matrix composites (PMC's) are promising materials for aerospace applications because of their high strength-to-weight ratio relative to metals. Unfortunately, they are limited to applications where they are not exposed to hightemperature oxidizing atmospheres and/or particulates from ingested air. This is because oxidation and erosion occur on the surface, leading to weight loss, nodulation, and/or cracking on the surface, and a consequent decline of mechanical properties over time. Although prior research has shown that oxidation can be slowed when metallic or ceramic coatings are applied onto PMC's, there remains a need for erosion-resistant coatings that protect PMC's from high-velocity particulates in the engine flow path. These erosionresistant coatings could extend the life of polymer composites. Polymer composites are heavily damaged without an erosion-resistant coating because they are not as hard as metallic engine structures. The effectiveness and life of the coatings depends on their inherent properties as well as on the interaction between the coating and the PMC. Since polymers, in general, have high thermal expansion coefficients in comparison to metals and ceramics, failure of the coatings often occurs at this interface. The objective of this research is to develop strategies to improve this interface and tailor overlays for erosion resistance. The bondcoat, which was developed at the NASA Glenn Research Center, is composed of zinc blended with polyimides to improve the compatibility between the PMC and the overlay material. Initial coating trials at AADC produced vanes that had poor bonding between the overlay and bondcoats. Subsequently, Glenn successfully demonstrated that high-quality plasma-sprayed erosion coating systems could be applied to these guide vanes. Inlet guide vanes from AE 3007 engines fiber composites were coated using a coating system composed of a bondcoat and a hard topcoat. Optimization of the plasma spray process has led to plans for future erosion testing in gas turbine engine environments.
A series of alumina-yttria-stabilized zirconia composites containing either a high aspect ratio (5 and 30 mol%) hexagonal platelet alumina or an alumina low aspect ratio (5 and 30 mol%) spherical particulate was used to determine the effect of the aspect ratio on the temperature-dependent impedance of the composite material. The highest impedance across the temperature range of 373 to 1073 K is attributed to the grain boundary of the hexagonal platelet second phase in this alumina zirconia composite.
An extension is preseted of the evaluation of graphite/aluminum metal matrix composites (MMC) for space structures application. A tubular DWG graphite/aluminum truss assembly was fabricated having the structural integrity and thermal stability needed for space application. DWG is a proprietary thin ply continuous graphite reinforced aluminum composite. The truss end fittings were constructed using the discontinuous ceramic particulate reinforced MMC DWAl 20 (trademark). Thermal stability was incorporated in the truss by utilizing high stiffness, negative coefficient of thermal expansion (CTE) P100 graphite fibers in a 6061 aluminum matrix, crossplied to provide minimized CTE in the assembled truss. Tube CTE was designed to be slightly negative to offset the effects of the end fitting and sleeve, CTE values of which are approx. 1/2 that of aluminum. In the design of the truss configuration, the CTE contribution of each component was evaluated to establish the component dimension and layup configuration required to provide a net zero CTE in the subassemblies which would then translate to a zero CTE for the entire truss bay produced.
Nonvolatile residue (NVR), sometimes referred to as molecular contamination is the term used for the total composition of the inorganic and high boiling point organic components in particulates and molecular films deposited on critical surfaces surrounding space structures, with the particulate and NVR contamination originating primarily from pre-launch operations. The "nonvolatile" suggestion from the terminology NVR implies that the collected residue will not experience much loss under ambient conditions. NVR has been shown to have a dramatic impact on the ability to perform optical measurements from platforms based in space. Such contaminants can be detected early by the controlled application of various detection techniques and contamination analyses. Contamination analyses are the techniques used to determine if materials, components, and subsystems can be expected to meet the performance requirements of a system. Of particular concern is the quantity of NVR contaminants that might be deposited on critical payload surfaces from these sources. Subsequent chemical analysis of the contaminant samples by infrared spectroscopy and gas chromatography mass spectrometry identifies the components, gives semi-quantitative estimates of contaminant thickness, indicates possible sources of the NVR, and provides guidance for effective cleanup procedures. In this report, a method for the collection and determination of the mass of NVR was generated by the authors at NASA Langley Research Center. This report describes the method developed and implemented for collecting NVR contaminants, and procedures for gravimetric and chemical analysis of the residue obtained. The result of this NVR analysis collaboration will help pave the way for Langley's ability to certify flight hardware outgassing requirements in support of flight projects such as Stratospheric Aerosol and Gas Experiment III (SAGE III), Clouds and the Earth's Radiant Energy System (CERES), Materials International Space Station Experiment - X (MISSE-X), and Doppler Aerosol Wind Lidar (DAWN).
The goals of the trace chemistry group were to identify the processes relevant to aerosol and aerosol precursor formation occurring within aircraft gas turbine engines; that is, within the combustor, turbine, and nozzle. The topics of discussion focused on whether the chemistry of aerosol formation is homogeneous or heterogeneous; what species are important for aerosol and aerosol precursor formation; what modeling/theoretical activities to pursue; what experiments to carry out that both support modeling activities and elucidate fundamental processes; and the role of particulates in aerosol and aerosol precursor formation. The consensus of the group was that attention should be focused on SO2, SO3, and aerosols. Of immediate concern is the measurement of the concentration of the species SO3, SO2, H2SO4 OH, HO2, H2O2, O, NO, NO2, HONO, HNO3, CO, and CO2 and particulates in various engines, both those currently in use and those in development. The recommendation was that concentration measurements should be made at both the combustor exit and the engine exit. At each location the above species were classified into one of four categories of decreasing importance, Priority I through IV, as follows: Combustor exit: Priority I species - SO3:SO2 ratio, SO3, SO2, and particulates; Priority II species: OH and O; Priority III species - NO and NO2; and Priority IV species - CO and CO2. For the Engine exit: Priority I species - SO3:SO2 ratio, SO3, SO2,H2SO4, and particulates; Priority II species: OH,HO2, H2O2, and O; Priority III species - NO, NO2, HONO, and HNO3; and Priority IV species - CO and CO2. Table I summarizes the anticipated concentration range of each of these species. For particulate matter, the quantities of interest are the number density, size distribution, and composition. In order to provide data for validating multidimensional reacting flow models, it would be desirable to make 2-D, time-resolved measurements of the concentrations of the above species and, in addition, of the pressure, temperature, and velocity. A near term goal of the experimental program should be to confirm the nonlinear effects of sulfur speciation, and if present, to provide an explanation for them. It is also desirable to examine if the particulate matter retains any sulfur. The recommendation is to examine the effects on SOx production of variations in fuel-bound sulfur and aromatic content (which may affect the amount of particulates formed). These experiments should help us to understand if there is a coupling between particulate formation and SO, concentration. Similarly, any coupling with NOx can be examined either by introducing NOx into the combustion air or by using fuel-bound nitrogen. Also of immediate urgency is the need to establish and validate a detailed mechanism for sulfur oxidation/aerosol formation, whose chemistry is concluded to be homogeneous, because there is not enough surface area for heterogeneous effects. It is envisaged that this work will involve both experimental and theoretical programs. The experimental work will require, in addition to the measurements described above, fundamental studies in devices such as flow reactors and shock tubes. Complementing this effort should be modeling and theoretical activities. One impediment to the successful modeling of sulfur oxidation is the lack of reliable data for thermodynamic and transport properties for several species, such as aqueous nitric acid, sulfur oxides, and sulfuric acid. Quantum mechanical calculations are recommended as a convenient means of deriving values for these properties. Such calculations would also help establish rate constants for several important reactions for which experimental measurements are inherently fraught with uncertainty. Efforts to implement sufficiently detailed chemistry into computational fluid dynamic codes should be continued. Zero- and one-dimensional flow models are also useful vehicles for elucidating the minimal set of species and reactions that must be included in two- and three-dimensional modeling studies.
Satellite-retrieved aerosol optical properties have been extensively used to estimate ground-level fine particulate matter (PM2.5) concentrations in support of air pollution health effects research and air quality assessment at the urban to global scales. However, a large proportion, approximately 70%, of satellite observations of aerosols are missing as a result of cloud-cover, surface brightness, and snow-cover. The resulting PM2.5 estimates could therefore be biased due to this non-random data missingness. Cloud-cover in particular has the potential to impact ground-level PM2.5 concentrations through complex chemical and physical processes. We developed a series of statistical models using the Multi-Angle Implementation of Atmospheric Correction (MAIAC) aerosol product at 1 km resolution with information from the MODIS cloud product and meteorological information to investigate the extent to which cloud parameters and associated meteorological conditions impact ground-level aerosols at two urban sites in the US: Atlanta and San Francisco. We find that changes in temperature, wind speed, relative humidity, planetary boundary layer height, convective available potential energy, precipitation, cloud effective radius, cloud optical depth, and cloud emissivity are associated with changes in PM2.5 concentration and composition, and the changes differ by overpass time and cloud phase as well as between the San Francisco and Atlanta sites. A case-study at the San Francisco site confirmed that accounting for cloud-cover and associated meteorological conditions could substantially alter the spatial distribution of monthly ground-level PM2.5 concentrations.
The project was initially funded for one year (for $100,764) to investigate the potential of particulate reinforced metals for aeropropulsion applications and to generate fatigue results that quantify the mean stress effect for a titanium alloy matrix material (TIMETAL 21S). The project was continued for a second year (for $85,000) to more closely investigate cyclic deformation, especially ratcheting, of the titanium alloy matrix at elevated temperature. Equipment was purchased (for $19,000) to make the experimental program feasible; this equipment included an extensometer calibrator and a multi-channel signal conditioning amplifier. The project was continued for a third year ($50,000) to conduct cyclic relaxation experiments aimed at validating the elastic-viscoelastic-viscoplastic model that NASA GRC had developed for the titanium alloy. Finally, a one-year no cost extension was granted to enable continued analysis of the experimental results and model comparisons.