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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 217 records · Page 12

Method for sequentially processing a multi-level interconnect circuit in a vacuum chamber

The processing of wafer devices to form multilevel interconnects for microelectronic circuits is described. The method is directed to performing the sequential steps of etching the via, removing the photo resist pattern, back sputtering the entire wafer surface and depositing the next layer of interconnect material under common vacuum conditions without exposure to atmospheric conditions. Apparatus for performing the method includes a vacuum system having a vacuum chamber in which wafers are processed on rotating turntables. The vacuum chamber is provided with an RF sputtering system and a DC magnetron sputtering system. A gas inlet is provided in the chamber for the introduction of various gases to the vacuum chamber and the creation of various gas plasma during the sputtering steps.

Routh, D. E.↗

Experimental investigation of the scattering effects of a sphere in a cylindrical resonant chamber

Resonance frequency, acoustic pressure, and quality factor measurements for transverse and longitudinal modes of a cylindrical chamber are presented as a function of the position of a sphere along the chamber axis. The tests were performed over a wide range of sample-to-chamber ratios, and formulations were devised of the resonance frequency shift as a function of the components of the volume ratios. Departures from linearity were explored for intermediate ratios. The results are considered significant for acoustic levitation operations in space, where the acoustic radiation may alter the acoustic properties of the chamber.

Barmatz, M.↗

Method for sequentially processing a multi-level interconnect circuit in a vacuum chamber

An apparatus is disclosed which includes a vacuum system having a vacuum chamber in which wafers are processed on rotating turntables. The vacuum chamber is provided with an RF sputtering system and a dc magnetron sputtering system. A gas inlet introduces various gases to the vacuum chamber and creates various gas plasma during the sputtering steps. The rotating turntables insure that the respective wafers are present under the sputtering guns for an average amount of time such that consistency in sputtering and deposition is achieved. By continuous and sequential processing of the wafers in a common vacuum chamber without removal, the adverse affects of exposure to atmospheric conditions are eliminated providing higher quality circuit contacts and functional device.

Routh, D. E.↗

Fatigue induced cracking in aluminum LN-2 shroud of 39 foot vacuum chamber

Fourteen years after completion of Ford's 39-foot space simulation chamber, leaks began to appear in its LN2 shroud. Although the shroud had been tight since its acceptance, cracks appeared in 1983 in some of the field welds of the one inch tubes which interconnect the LN2 panels. The resulting leaks were large enough to prevent pump down to high vacuum and could be heard easily when the chamber was at ambient conditions. New cracks appeared during each thermal cycle making it impossible to utilize the chamber for thermal vacuum testing. The analysis presented here implies that many, if not all, of the aluminum LN2 shrouds now in use may be in various stages of fatigue failure. The probability is high that fatigue cracks are working through the aluminum tubing in heat-affected zones of some field welds. The cracks may not be apparent yet, but after the shroud has experienced a certain number of thermal cycles these cracks will work through the material and become serious leaks. Fortunately, appropriate planning, analysis, and checking can, with a relatively small expenditure of money, help to avoid large and unexpected shroud failures and keep the chamber operational as long as it is needed.

Edwards, A. A.↗

Theoretical prediction of stationary positions in the rectangular chamber during asymmetric electroosmotic flow

Most microscopic cell electrophoretic work depends on the theortical prediction of stationary positions by Smoluchowski and Komagata. Their theoretical solutions are based on the assumption that the electroosmotic flow in a chamber is symmetric. Because experiences with the rectangular chamber indicate that symmetric flow occurs during less than 8% of the experiments, the existing theory for stationary position determination is expanded to include the more general case of asymmetric flow. Smoluchowski's equation for symmetric electroosmotic flow in a rectangular chamber having a width much smaller than its height or length is examined. Smoluchowski's approach is used to approximate stationary positions in rectangular chambers with height/width ratios greater than 40. Support for the theoretical prediction of stationary positions using is given by three types of experimental evidence.

Source record↗

Multifunction Vacuum Chamber for IC Metallization

Vacuum system chamber processing multilayer metallization on integrated circuits (IC's) performs four operations ordinarily done in separated equipment. Chamber etches holes, removes photoresist, cleans by sputter etching, and deposits final layer of metal. Combinedfunction chamber costs less than separate equipment. Chamber avoids exposing integrated circuits to room air and, to oxidation and dust, between steps. Eliminates time spent in transferring circuits from one apparatus to next.

Routh, D. E.↗

Design, construction, activation, and operation of a high intensity acoustic test chamber

The design philosophy, construction, integration, and activation of the high intensity acoustic test chamber for production acceptance testing of satellites are discussed. The 32,000 cubic-foot acoustic test cell consists of a steel reinforced concrete chamber with six electropneumatic noise generators. One of the innovative features of the chamber is a unique quarter horn assembly that acoustically couples the noise generators to the chamber. Design concepts, model testing, and evaluation results are presented. Considerations such as nitrogen versus compressed air source, digital closed loop spectrum control versus manual equalizers, and microprocessor based interlock systems are included. Construction difficulties, anomalies encountered, and their resolution are also discussed. Results of the readiness testing are highlighted.

Kamel, L. T.↗

Thrust chamber thermal barrier coating techniques

Methods for applying thermal barrier coatings to the hot-gas side wall of rocket thrust chambers in order to significantly reduce the heat transfer in high heat flux regions was the focus of technology efforts for many years. This paper describes a successful technique developed by the Lewis Research Center that starts with the coating of a mandrel and then builds the thrust chamber around it by electroforming appropriate materials. This results in a smooth coating with exceptional adherence, demonstrated in hot fire rig tests. The low cycle fatigue life of chambers with coatings applied in this manner was increased dramatically compared to uncoated chambers.

Quentmeyer, Richard J.↗

High-pressure calorimeter chamber tests for liquid oxygen/kerosene (LOX/RP-1) rocket combustion

An experimental program was conducted to investigate the rocket combustion and heat transfer characteristics of liquid oxygen/kerosene (LOX/RP-1) mixtures at high chamber pressures. Two water-cooled calorimeter chambers of different combustion lengths were tested using 37- and 61-element oxidizer-fuel-oxidizer triplet injectors. The tests were conducted at nominal chamber pressures of 4.1, 8.3, and 13.8 MPa abs (600, 1200, and 2000 psia). Heat flux Q/A data were obtained for the entire calorimeter length for oxygen/fuel mixture ratios of 1.8 to 3.3. Test data at 4.1 MPa abs compared favorably with previous test data from another source. Using an injector with a fuel-rich outer zone reduced the throat heat flux by 47 percent with only a 4.5 percent reduction in the characteristic exhaust velocity efficiency C* sub eff. The throat heat transfer coefficient was reduced approximately 40 percent because of carbon deposits on the chamber wall.

Masters, Philip A.↗

Thrust chamber thermal barrier coating techniques

Methods for applying thermal barrier coatings to the hot-gas side wall of rocket thrust chambers in order to significantly reduce the heat transfer in high heat flux regions has been the focus of technology efforts for many years. A successful technique developed by NASA-Lewis that starts with the coating on a mandrel and then builds the thrust chamber around it by electroforming appropriate materials is described. This results in a smooth coating with exceptional adherence, as was demonstrated in hot fire rig tests. The low cycle fatigue life of chambers with coatings applied in this manner was increased dramatically compared to uncoated chambers.

Quentmeyer, Richard J.↗

Ring cusp/hollow cathode discharge chamber performance studies

An experimental study was performed to determine the effects of hollow cathode position, anode position, and ring cusp magnetic field configuration and strength on discharge chamber performance. The results are presented in terms of comparative plasma ion energy cost, extracted ion fraction, and beam profile data. Such comparisons are used to demonstrate whether changes in performance are caused by changes in the loss rate of primary electrons to the anode or the loss rate of ions to discharge chamber walls or cathode and anode surfaces. Results show: (1) the rate of primary electron loss to the anode decreases as the anode is moved downstream of the ring cusp toward the screen grid; (2) the loss rate of ions to hollow cathode surfaces are excessive if the cathode is located upstream of a point of peak magnetic flux density at the discharge chamber centerline; and (3) the fraction of the ions produced that are lost to discharge chamber walls and ring magnet surfaces is reduced by positioning of the magnet rings so the plasma density is uniform over the grid surface, and adjusting their strength to a level where it is sufficient to prevent excessive ion losses by Bohm diffusion.

Vaughn, J. A.↗

Rocket combustion chamber life-enhancing design concepts

NASA continues to pursue technologies which can lead to an increase in life and reduce the costs of fabrication of the Space Shuttle Main Engine. The joint NASA/Air Force Advanced Launch System Program has set its prime objectives to be high reliability and low cost for their new advanced booster engine. In order to meet these objectives, NASA will utilize the results of several ongoing programs to provide the required technologies. An overview is presented of those programs which address life enhancing design concepts for the combustion chamber. Seven different design concepts, which reduce the thermal strain and/or increase the material strength of the combustion chamber liner wall are discussed. Subscale rocket test results are presented, where available, for life enhancing design concepts. Two techniques for reducing chamber fabrication costs are discussed, as well as issues relating to hydrocarbon fuels/combustion chamber liner materials compatibility.

Quentmeyer, Richard J.↗

System development and early biological tests in NASA's biomass production chamber

The Biomass Production Chamber at Kennedy Space Center was constructed to conduct large scale plant growth studies for NASA's CELSS program. Over the past four years, physical systems and computer control software have been continually upgraded and the degree of atmospheric leakage from the chamber has decreased from about 40 to 5 percent of the total volume per day. Early tests conducted with a limited degree of closure showed that total crop (wheat) growth from the best trays was within 80 percent of reported optimal yields for similar light levels. Yields from subsequent tests under more tightly closed conditions have not been as good--up to only 65 percent of optimal yields. Yields appear to have decreased with increasing closure, yet potential problems exist in cultural techniques and further studies are warranted. With the ability to tightly seal the chamber, quantitative data were gathered on CO2 and water exchange rates. Results showed that stand photosynthesis and transpiration reached a peak near 25 days after planting, soon after full vegetative ground cover was established. In the final phase of testing when atmospheric closure was the highest, ethylene gas levels in the chamber rose from about 10 to nearly 120 ppb. Evidence suggests that the ethylene originated from the wheat plants themselves and may have caused an epinastic rolling of the leaves, but no apparent detrimental effects on whole plant function.

Wheeler, R. M.↗

Measuring tropospheric HNO3 - Problems and prospects for Nylon filter and mist chamber techniques

A series of laboratory and field measurements was performed to evaluate the mist chamber technique for determining tropospheric HNO3 concentrations. Both the mist chamber and standard Nylon filter techniques exhibit high collection efficiency and excellent agreement measuring HNO3 vapors from a permeation source. When simultaneously sampling ambient air in eastern Virginia, the Nylon filter measured an average of 70 percent higher HNO3 concentration than the mist chamber technique. The results indicate that O3 causes a low-level positive artifact interference in HNO3 measurements performed with the filter technique. This O3-induced error is small, however, compared to the large difference between atmospheric HNO3 concentrations determined with the two techniques. It is hypothesized that unidentified (organic?) nitrogen species in the atmosphere react for form NO3(-) on the filter and this phenomenon may interfere with Nylon filter measurements of HNO3 vapor. These potential interferences did not appear to affect measurements of HNO3 with the mist chamber method.

Talbot, R. W.↗

Test chamber for low-background IR focal plane testing

A unique and versatile vacuum chamber has been designed for JPL's IR Focal Plane Technology Group. This chamber is equipped with multiple ports for cryogen and electrical vacuum feedthroughs, pumping units, vacuum gages, sources, and detector camera heads. The design incorporates a liquid-nitrogen-cooled optical table and radiation shield for low-background IR detector testing. Focal planes can be tested at temperatures ranging from 300 K to that of liquid helium. This paper describes the design and construction of this low-background IR focal plane test chamber and discusses some of its distinctive features. An analysis of the test chamber's performance is also presented.

Staller, Craig↗

Corrosion Prevention in Copper Combustion Chamber Liners of Liquid Oxygen/Methane Booster Engines

Prior research conducted by United Technologies Research Center and Rockwell International Rocketdyne Division encountered severe copper corrosion while flowing hydrocarbon fuels through copper cooling tubes. These experimental results have very important implications for the development of low-cost, regeneratively cooled, oxygen/hydrocarbon bipropellant booster engines. Aerojet TechSystems undertook a program sponsored by NASA/Lewis Research Center in 1986 with two objectives: (1) to define the corrosive interaction process that occurs between hydrocarbon fuels and copper combustion chamber liner materials, using both static and dynamic test methods, and (2) to identify and demonstrate protective measures against this corrosive process. The results of the first program task demonstrated that the most damaging corrosive process was caused by trace amounts of sulfur-containing impurities in the hydrocarbon fuel which react with the copper chamber liner material to form cuprous sulfide (Cu2S), as reported in Paper No. AlAA 88-3215. Experiments were conducted which demonstrated this corrosive process with Mil-Spec RP-1, propane, and methane fuels in contact with OFHC, NASA-Z, and ZrCu coppers. The preliminary results of the second program task demonstrated that electrodeposited gold and platinum coatings held promise of preventing corrosion of copper chamber liners by methane contaminated with sulfur-containing impurities, as reported in Paper No. AIAA 89-2738. Experiments were conducted which demonstrated greatly reduced corrosion of copper by hydrogen sulfide (H2S) and methyl mercaptan (CH3SH) as measured impurities in methane. This paper presents the concluding, confirmatory results from the second program task. The efficacy of a protective gold coating on NASA-Z copper cooling channel walls was conclusively demonstrated. Tests were conducted in the Aerojet Carbothermal Test Facility which provide realistic simulations of booster engine cooling channel conditions such as temperature, pressure, flow velocity, and heat flux. Dynamic test series were performed with methane containing 5 and 10 ppm (by volume) hydrogen sulfide. Gold-plated and unplated copper alloy specimens were evaluated. The tests demonstrated that gold coatings were effective in preventing corrosion of the copper. Posttest metallographic examinations of the unplated specimens showed severe corrosion as a result of reaction with the sulfur containing contaminant in the fuel. In contrast, posttest metallographic examination of the gold-coated specimens showed no corrosion under similar operating conditions. The findings from metallurgical and chemical analyses of the copper specimens, chemical analysis of the methane, and description of all test conditions are provided. Conclusions are reached as to the efficacy of the plating methods and the effectiveness of the metal coatings in the prevention of corrosion in hydrocarbon-fueled booster engine combustion chamber liners.

S D Rosenberg↗

Space Shuttle vernier thruster long-life chamber development

The Space Shuttle Reaction Control Subsystem (RCS) vernier thruster is a pressure fed engine that utilizes storable propellants to provide precise attitude control for the Orbiter. The current vernier thruster is life limited due to its chamber material. By developing an iridium-lined rhenium chamber for the vernier, substantial gains could be achieved in the operational life of the chamber. The present RCS vernier, its requirements, operating characteristics, and life limitations are described. The current technology status of iridium-lined rhenium is presented along with a description of the operational life capabilities to be gained from implementing this material into the design of a long life vernier chamber. Discussion of the proposed demonstration program to be performed by the NASA Lyndon B. Johnson Space Center to attain additional insight into the application of this technology to the RCS vernier, includes the technical objectives, approach, and program schedule. The plans for further development and integration with the Orbiter and the Shuttle system are also presented.

Krohn, Douglas D.↗

Rocket combustion chamber life-enhancing design concepts

NASA continues to pursue technologies which can lead to an increase in life and reduce the costs of fabrication of the Space Shuttle Main Engine. The joint NASA/Air Force Advanced Launch System Program has set its prime objectives to be high reliability and low cost for their new advanced booster engine. In order to meet these objectives, NASA will utilize the results of several ongoing programs to provide the required technologies. An overview is presented of those programs which address life enhancing design concepts for the combustion chamber. Seven different design concepts, which reduce the thermal strain and/or increase the material strength of the combustion chamber liner wall are discussed. Subscale rocket test results are presented, where available, for life enhancing design concepts. Two techniques for reducing chamber fabrication costs are discussed, as well as issues relating to hydrocarbon fuels/combustion chamber liner materials compatibility.

Quentmeyer, R. J.↗