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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Improved fracture toughness corrosion-resistant bearing material

A development program was performed to establish whether a corrosion-resistant bearing material, such as a 14Cr steel, could be modified to allow carburization, thereby providing the excellent fracture toughness characteristics feasible with this process. The alloy selected for investigation was AMS 5749. Several modifications were made including the addition of a small amount of nickel for austenite stabilization. While some promising results were achieved, the primary objective of an acceptable combination of case hardness and microstructure was not attained. Because the high chromium content presents a serious problem in achieving a viable carburizing cycle, a number of experimental steels having lower chromium contents (8 to 12%) were produced in laboratory quantities and evaluated. The results were basically the same as those initially obtained with the modified AMS 5749. Corrosion tests were performed on AMS 5749, AISI M50, and 52100 bearing steels as well as some of the lower chromium steels. These tests showed that a reduced chromium level (10 to 12%) provided essentially the same corrosion protection as the 14Cr steels.

Bamberger, E. N.↗
NASA NTRS2016

Cyclic Oxidation and Hot Corrosion of NiCrY-Coated Disk Superalloys

Powder metallurgy disk superalloys have been designed for higher engine operating temperatures through improvement of their strength and creep resistance. Yet, increasing disk application temperatures to 704 degrees Centigrade and higher could enhance oxidation and activate hot corrosion in harmful environments. Protective coatings could be necessary to mitigate such attack. Cylindrical coated specimens of disk superalloys LSHR and ME3 were subjected to thermal cycling to produce cyclic oxidation in air at a maximum temperature of 760 degrees Centigrade. The effects of substrate roughness and coating thickness on coating integrity after cyclic oxidation were considered. Selected coated samples that had cyclic oxidation were then subjected to accelerated hot corrosion tests. This cyclic oxidation did not impair the coating's resistance to subsequent hot corrosion pitting attack.

protective coating↗
NASA NTRS2002

Corrosion Activities at the NASA Kennedy Space Center

This report documents summer faculty fellow efforts in the corrosion test bed at the NASA Kennedy Space Center. During the summer of 2002 efforts were concentrated on three activities: a short course on corrosion control for KSC personnel, evaluation of commercial wash additives used for corrosion control on Army aircraft, and improvements in the testing of a new cathodic protection system under development at KSC.

Heidersbach, Robert H.↗
NASA NTRS1981

Effects of environmental variables on the crack initiation stages of corrosion fatigue of high strength aluminum alloys

Fatigue initiation in six aluminum alloys used in the aircraft industry was investigated. Cyclic loading superimposed on a constant stress was alternated with atmospheric corrosion. Tests made at different stress levels revealed that a residual stress as low as 39% of the yield strength caused stress corrosion cracking in some of the alloys. An atmospheric corrosion rate meter developed to measure the corrosivity of the atmosphere is described. An easily duplicated hole in the square test specimen with a self-induced residual stress was developed.

Poteat, L. E.↗
DOE OSTI2021

Environmental degradation of electroplated nickel and copper coated SS316H in molten FLiNaK salt

Corrosion of nickel and copper electroplated coatings on SS316H in molten FLiNaK salt was studied. 500- and 1000-hour static corrosion tests were performed in molten FLiNaK at 700 degrees Celsius. Characterization of the coatings following corrosion indicated that they did not degrade in the molten salt during the corrosion experiment and fully protected the underlying SS316H from chromium dissolution. Interdiffusion between the copper coating and SS316H was extremely limited, interdiffusion between the nickel coating and SS316H. Diffusion modelling revealed that the nickel coatings still significantly reduced chromium dissolution over 60 years despite the interdiffusion.

36 MATERIALS SCIENCE↗
NASA NTRS1977

The 737 graphite composite flight spoiler flight service evaluation

The flight service experience of 110 graphite epoxy spoilers on 737 transport aircraft was reviewed as well as ground based environmental exposure of graphite epoxy material specimens for the period from April 1976 through April 1977. Several spoilers were installed on each of 27 aircraft representing seven major airlines operating throughout the world. A flight service evaluation program of at least 5 years is under way. As of April 30, 1977, a total of 766,938 spoiler flight hours and 1,168,090 spoiler landings were accumulated by the fleet. Based on visual ultrasonic, and destructive testing, there was no evidence of moisture migration into the honeycomb core and no core corrosion. Tests of removed spoilers and of ground based exposure specimens after the third year of service continue to indicate modest changes in composite strength properties.

Stoecklin, R. L.↗
NASA NTRS1976

The 737 graphite composite flight spoiler flight service evaluation

The flight-service experience of 110 graphite-epoxy spoilers on 737 transport aircraft and related ground-based environmental exposure of graphite-epoxy material specimens is reported. Spoilers were installed on each of 27 aircraft representing seven major airlines operating throughout the world. Based on visual, ultrasonic, and destructive testing, there is no evidence of moisture migration into the honeycomb core and no core corrosion. Tests of removed spoilers and of ground-based exposure specimens after the second year of service indicate modest changes in composite strength.

Stoecklin, R. L.↗
DOE OSTI2024

Wire arc additive manufactured A36 steel performance for marine renewable energy systems

Additive manufacturing has established itself to be advantageous beyond small-scale prototyping, now supporting full-scale production of components for a variety of applications. Despite its integration across industries, marine renewable energy technology is one largely untapped application with potential to bolster clean energy production on the global scale. Wave energy converters (WEC) are one specific facet within this realm that could benefit from AM. As such, wire arc additive manufacturing (WAAM) has been identified as a practical method to produce larger scale marine energy components by leveraging cost-effective and readily available A36 steel feedstock material. The flexibility associated with WAAM can benefit production of WEC by producing more complex structural geometries that are challenging to produce traditionally. Additionally, for large components where fine details are less critical, the high deposition rate of WAAM in comparison to traditional wrought techniques could reduce build times by an order of magnitude. In this context of building and supporting WEC, which experience harsh marine environments, an understanding of performance under large loads and corrosive environments must be understood. Hence, WAAM and wrought A36 steel tensile samples were manufactured, and mechanical properties compared under both dry and corroded conditions. Here, the unique microstructure created via the WAAM process was found to directly correlate to the increased ultimate tensile and yield strength compared to the wrought condition. Static corrosion testing in a simulated saltwater environment in parallel with electrochemical testing highlighted an outperformance of corroded WAAM A36 steel than wrought, despite having a slighter higher corrosion rate. Ultimately, this study shows how marine energy systems may benefit from additive manufacturing components and provides a foundation for future applications of WAAM A36 steel.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Corrosion of metal particle and metal evaporated tapes

Very high coercivity metal particle (MP) and metal evaporated (ME) tapes are being used in 8mm video and digital audio tape applications, and more recently in digital data recording applications. In view of the inherent susceptibility of such media to environmental corrosion, a number of recent studies have addressed their long term stability and archivability. These studies have used an accelerated corrosion test based either on elevated temperature-humidity or polluting gas atmospheres known as Battelle tests. A comparison of the Battelle test results performed at different laboratories reveals a large variation from one location to another, presumably due to incorrect replication of the Battelle condition. Furthermore, when the Battelle tests are performed on enclosed cartridges, it is quite possible that diffusion limits the penetration of the extremely low concentration polluting gaseous species to the inner layers of the tapes during the short time of the accelerated test, whereas in real life these diffusion limitations may not apply. To avoid this uncertainty, the corrosion behavior of commercial 8mm MP and ME tapes when cassettes without their external plastic cases were exposed to 50 deg C and 80 percent RH for 7.5 weeks is investigated.

Speliotis, Dennis E.↗
NASA NTRS2003

Life-Prediction Parameters of Sapphire Determined for the Design of a Space Station Combustion Facility Window

To characterize the stress corrosion parameters and predict the life of a sapphire window being considered for use in the International Space Station's Fluids and Combustion Facility, researchers at the NASA Glenn Research Center conducted stress corrosion tests, fracture toughness tests, and reliability analyses, as shown in the figures. Standardized test methods, developed and updated by the author under the auspices of American Society for Testing and Materials, were employed. One interesting finding is that sapphire exhibits a susceptibility to stress corrosion in water similar to that of glass. In addition to generating the stress corrosion parameters and fracture toughness data, closed-form expressions for the variances of the crack growth parameters were derived. The expressions allow confidence bands to be easily placed on life predictions of ceramic components. Brittle materials such as sapphire and quartz are required for windows in a variety of applications such as the Fluids and Combustion Facility. To minimize the launch weight of such facilities, researchers must design the windows to be as lightweight as possible. The safe use of lightweight, brittle windows in structural applications is limited by two factors: low fracture toughness and slow crack growth, or stress corrosion. Stress corrosion of these and other optical materials can occur in relatively common environments, such as humid air. Access to the data has been requested by designers for use in the life prediction of a Northrop Grumman F16 instrument window and a Jet Propulsion Laboratory instrument window. One Space Act Agreement has been formed. Future work includes the measurement of the life of subscale windows.

Salem, Jonathan A.↗
DOE OSTI2026

Comparative Study of Zinc Cold-Spray Coating and Pre-treatments for Magnesium Alloys

Magnesium (Mg) alloys are appealing for automotive lightweighting owing to their high specific strength. However, their susceptibility to corrosion in harsh environments remains a major challenge. Conventional industrial pre-treatment coatings, including zinc phosphate, chromate conversion, and non-chromate conversion, often exhibit discontinuities and microcracks, leading to localized corrosion near fasteners and parting lines. Here, this study investigates cold-sprayed zinc (Zn) coatings as a novel pre-treatment alternative for high-pressure die cast (HPDC) AZ91 Mg alloys, demonstrating significant improvements in wear and corrosion performance. Cold spray produces uniform and robust coatings, reducing wear rate by over 50% and reducing corrosion rate by over 99.3%, as measured by evolved hydrogen release, compared to traditional pre-treatments. Multimodal corrosion testing reveals that Zn cold-spray coatings form a protective layer during exposure, minimizing general and filiform corrosion, and exhibiting corrosion potential (E corr ) that is nobler by ~ 400 mV than the surfaces of both pre-treated and uncoated AZ91. Scalability of cold spray for selective application around multimaterial joints further strengthens their industrial viability. This work establishes Zn cold-spray coatings as highly effective pre-treatment solutions for the advancement of corrosion resistant Mg alloy components in automotive applications.

multimodal corrosion↗
NASA NTRS2011

Corrosion Protection of Launch Infrastructure and Hardware Through the Space Shuttle Program

Corrosion, the environmentally induced degradation of materials, has been a challenging and costly problem that has affected NASA's launch operations since the inception of the Space Program. Corrosion studies began at NASA's Kennedy Space Center (KSC) in 1966 during the Gemini/Apollo Programs with the evaluation of long-term protective coatings for the atmospheric protection of carbon steel. NASA's KSC Beachside Corrosion Test Site, which has been documented by the American Society of Materials (ASM) as one of the most corrosive, naturally occurring environments in the world, was established at that time. With the introduction of the Space Shuttle in 1981, the already highly corrosive natural conditions at the launch pad were rendered even more severe by the acidic exhaust from the solid rocket boosters. In the years that followed, numerous efforts at KSC identified materials, coatings, and maintenance procedures for launch hardware and equipment exposed to the highly corrosiye environment at the launch pads. Knowledge on materials degradation, obtained by facing the highly corrosive conditions of the Space Shuttle launch environment, as well as limitations imposed by the environmental impact of corrosion control, have led researchers at NASA's Corrosion Technology Laboratory to establish a new technology development capability in the area of corrosion prevention, detection, and mitigation at KSC that is included as one of the "highest priority" technologies identified by NASA's integrated technology roadmap. A historical perspective highlighting the challenges encountered in protecting launch infrastructure and hardware from corrosion during the life of the Space Shuttle program and the new technological advances that have resulted from facing the unique and highly corrosive conditions of the Space Shuttle launch environment will be presented.

Calle, L. M.↗
NASA NTRS1973

Performance characteristics of zinc-rich coatings applied to carbon steel

A program was conducted to evaluate the performance of topcoated and untopcoated zinc-rich coatings. Sacrificial coatings of this type are required for protecting carbon steel structures from the aggressive KSC sea coast environment. A total of 59 commercially available zinc-rich coatings and 47 topcoated materials were exposed for an 18-month period. Test panels were placed in special racks placed approximately 30.5 m (100 feet) above the high tide line at the KSC Corrosion Test Site. Laboratory tests to determine the temperature resistance, abrasion resistance, and adhesion of the untopcoated zinc-rich coatings were also performed. It has been concluded that: (1) The inorganic types of zinc-rich coatings are far superior to the organic types in the KSC environment. (2) Organic zinc-rich coatings applied at 0.1 - 0.15 mm (4-6 mils) film thickness provide better corrosion protection than when applied at the manufacturers' recommended nominal film thickness of .08 mm (3 mils). (3) Topcoats are not necessary, or even desirable, when used in conjunction with zinc-rich coatings in the KSC environment. (4) Some types of inorganic zinc-rich coatings require an extended outdoor weathering period in order to obtain adequate mechanical properties. and (5) A properly formulated inorganic zinc-rich coating is not affected by a 24-hour thermal exposure to 400 C (752 F).

Paton, W. J.↗
DOE OSTI2020

Long-Term Corrosion Studies Of Pine Derived Bio-Oil And Blends With Heavy Fuel Oil

Biomass derived liquid fuels offer a means to reduce greenhouse gas emissions compared to those produced by combustion of petroleum derived liquid fuels. However, the corrosivity of bio-oils toward the less expensive structural materials creates a material selection problem for designers of storage tanks and combustion systems. Samples of candidate structural materials are being exposed for thousands of hours in multiple fast pyrolysis bio-oils and conditions to evaluate the corrosion resistance of these materials. One method to mitigate the corrosivity of bio-oils and speed their adoption, while also decreasing the pollution issues associated with low quality petroleum derived fuels, is to utilize blends of bio-oil and heavy fuel oil in engines currently solely burning a petroleum-based fuel. In addition to the corrosion studies conducted in 100% bio-oil, studies were also conducted with blends of the fast pyrolysis bio-oil produced from pine tree components with a heavy fuel oil that is used in ocean-going ships. This bio-oil had a very high carboxylic acid content which made it very corrosive to carbon and 2¼ Cr-1 Mo steel and even 409 stainless steel. The heavy fuel oil was not corrosive to carbon steel, but its sulfur content makes it a significant pollution producer and particularly undesirable for use near coastlines. Corrosion tests were conducted with the individual components and with various blends of the two liquid fuels. Studies showed a significantly lower corrosivity of the blends than would be projected assuming linear mixing behavior. Adoption of such blends holds the potential to reduce production of sulfur-containing exhaust gases as well as carbon dioxide from non-renewable fuels.

Keiser, Jim↗
DOE OSTI2020

Long-Term Corrosion Studies of Pine Derived Bio-Oil and Blends with Heavy Fuel Oil

Biomass derived liquid fuels offer a means to reduce greenhouse gas emissions compared to those produced by combustion of petroleum derived liquid fuels. However, the corrosivity of bio-oils toward the less expensive structural materials creates a material selection problem for designers of storage tanks and combustion systems. Samples of candidate structural materials are being exposed for thousands of hours in multiple fast pyrolysis bio-oils and conditions to evaluate the corrosion resistance of these materials. One method to mitigate the corrosivity of bio-oils and speed their adoption, while also decreasing the pollution issues associated with low quality petroleum derived fuels, is to utilize blends of bio-oil and heavy fuel oil in engines currently solely burning a petroleum-based fuel. In addition to the corrosion studies conducted in 100% bio-oil, studies were also conducted with blends of the fast pyrolysis bio-oil produced from pine tree components with a heavy fuel oil that is used in ocean-going ships. This bio-oil had a very high carboxylic acid content which made it very corrosive to carbon and 2¼ Cr-1 Mo steel and even 409 stainless steel. The heavy fuel oil was not corrosive to carbon steel, but its sulfur content makes it a significant pollution producer and particularly undesirable for use near coastlines. Corrosion tests were conducted with the individual components and with various blends of the two liquid fuels. Studies showed a significantly lower corrosivity of the blends than would be projected assuming linear mixing behavior. Adoption of such blends holds the potential to reduce production of sulfur-containing exhaust gases as well as carbon dioxide from non-renewable fuels.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Corrosion of SS 316, Inconel 617, Inconel 625 in molten chloride salt with emphasis on the speciation of Cr, Ni, and Co in molten salt matrix by XAFS

Dr. Hartmann’ report summarizes the corrosion behavior of materials used in the construction and operation of molten salt reactors which is is of great interest to the molten salt reactor (MSR) community. In the present study we intent to decipher the very elemental phenomena on the corrosion of austenitic chromium-containing stainless steel SS316, as well as Inconel 625 and ASME-coded high temperature Alloy (Inconel) 617. We initiated and are in continuation of conducting ampoule type corrosion testing at 550 °C and 650 °C to determine chromium diffusivity and the related activation energy as well as the speciation of the corrosion products.

36 MATERIALS SCIENCE↗