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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
All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Fabrication of GRCop-84 Rocket Thrust Chambers

GRCop-84, a copper alloy, Cu-8 at% Cr-4 at% Nb developed at NASA Glenn Research Center for regenerative1y cooled rocket engine liners has excellent combinations of elevated temperature strength, creep resistance, thermal conductivity and low cycle fatigue. GRCop-84 is produced from pre-alloyed atomized powder and has been fabricated into plate, sheet and tube forms as well as near net shapes. Fabrication processes to produce demonstration rocket combustion chambers will be presented and includes powder production, extruding, rolling, forming, friction stir welding, and metal spinning. GRCop-84 has excellent workability and can be readily fabricated into complex components using conventional powder and wrought metallurgy processes. Rolling was examined in detail for process sensitivity at various levels of total reduction, rolling speed and rolling temperature representing extremes of commercial processing conditions. Results indicate that process conditions can range over reasonable levels without any negative impact to properties.

Loewenthal, William↗
NASA NTRS1972

Welding and brazing of nickel and nickel-base alloys

The joining of four types of nickel-base materials is described: (1) high-nickel, nonheat-treatable alloys, (2) solid-solution-hardening nickel-base alloys, (3) precipitation-hardening nickel-base alloys, and (4) dispersion-hardening nickel-base alloys. The high-nickel and solid-solution-hardening alloys are widely used in chemical containers and piping. These materials have excellent resistance to corrosion and oxidation, and retain useful strength at elevated temperatures. The precipitation-hardening alloys have good properties at elevated temperature. They are important in many aerospace applications. Dispersion-hardening nickel also is used for elevated-temperature service.

Mortland, J. E.↗
NASA NTRS2004

NASA Tech Briefs, December 2004

opics include: High-Rate Digital Receiver Board; Signal Design for Improved Ranging Among Multiple Transceivers; Automated Analysis, Classification, and Display of Waveforms; Fast-Acquisition/Weak-Signal-Tracking GPS Receiver for HEO; Format for Interchange and Display of 3D Terrain Data; Program Analyzes Radar Altimeter Data; Indoor Navigation using Direction Sensor and Beacons; Software Assists in Responding to Anomalous Conditions; Software for Autonomous Spacecraft Maneuvers; WinPlot; Software for Automated Testing of Mission-Control Displays; Nanocarpets for Trapping Microscopic Particles; Precious-Metal Salt Coatings for Detecting Hydrazines; Amplifying Electrochemical Indicators; Better End-Cap Processing for Oxidation-Resistant Polyimides; Carbon-Fiber Brush Heat Exchangers; Solar-Powered Airplane with Cameras and WLAN; A Resonator for Low-Threshold Frequency Conversion; Masked Proportional Routing; Algorithm Determines Wind Speed and Direction from Venturi-Sensor Data; Feature-Identification and Data-Compression Software; Alternative Attitude Commanding and Control for Precise Spacecraft Landing; Inspecting Friction Stir Welding using Electromagnetic Probes; and Helicity in Supercritical O2/H2 and C7H16/N2 Mixing Layers.

Source record↗
NASA NTRS1985

Explosive Welding in the 1990's

Explosive bonding is a unique joining process with the serious potential to produce composite materials capable of fulfilling many of the high performance materials capable of fulfilling many of the high performance materials needs of the 1990's. The process has the technological versatility to provide a true high quality metallurgical compatible and incompatible systems. Metals routinely explosively bonded include a wide variety of combinations of reactive and refractory metals, low and high density metals and their alloys, corrosion resistant and high strength alloys, and common steels. The major advantage of the process is its ability to custom design and engineer composites with physical and/or mechanical properties that meet a specific or unusual performance requirement. Explosive bonding offers the designer unique opportunities in materials selection with unique combinations of properties and high integrity bonds that cannot be achieved by any other metal joining process. The process and some applications are discussed.

Lalwaney, N. S.↗
NASA NTRS1985

Foam Insulation for Cryogenic Flowlines

Welded stainless-steel vacuum jackets on cryogenic ducts replaced by plastic foam-insulation jackets that weigh 12 percent less. Foam insulation has 85 percent of insulating ability of stainless-steel jacketing enclosing vacuum of 10 microns of mercury. Foam insulation easier to install than vacuum jacket. Moreover, foam less sensitive to damage and requires minimal maintenance. Resists vibration and expected to have service life of at least 10 years.

Sonju, T. R.↗
NASA NTRS1990

Combination Light

The Rayovac TANDEM is an advanced technology combination work light and general purpose flashlight that incorporates several NASA technologies. The TANDEM functions as two lights in one. It features a long range spotlight and wide angle floodlight; simple one-hand electrical switching changes the beam from spot to flood. TANDEM developers made particular use of NASA's extensive research in ergonomics in the TANDEM's angled handle, convenient shape and different orientations. The shatterproof, water resistant plastic casing also draws on NASA technology, as does the shape and beam distance of the square diffused flood. TANDEM's heavy duty magnet that permits the light to be affixed to any metal object borrows from NASA research on rare earth magnets that combine strong magnetic capability with low cost. Developers used a NASA-developed ultrasonic welding technique in the light's interior.

Source record↗
NASA NTRS1995

Progress in HTS trapped field magnets: J(sub c), area, and applications

Progress in trapped field magnets is reported. Single YBCO grains with diameters of 2 cm are made in production quantities, while 3 cm, 4 1/2 cm and 6 cm diameters are being explored. For single grain tiles: J(sub c) is approximately 10,000 A/cm(exp 2) for melt textured grains; J(sub c) is approximately 40,000 A/cm2 for light ion irradiation; and J(sub c) is approximately 85,000 A/cm(exp 2) for heavy ion irradiation. Using 2 cm diameter tiles bombarded by light ions, we have fabricated a mini-magnet which trapped 2.25 Tesla at 77K, and 5.3 Tesla at 65K. A previous generation of tiles, 1 cm x 1 cm, was used to trap 7.0 Tesla at 55K. Unirradiated 2.0 cm tiles were used to provide 8 magnets for an axial gap generator, in a collaborative experiment with Emerson Electric Co. This generator delivered 100 Watts to a resistive load, at 2265 rpm. In this experiment activation of the TFMs was accomplished by a current pulse of 15 ms duration. Tiles have also been studied for application as a bumper-tether system for the soft docking of spacecraft. A method for optimizing tether forces, and mechanisms of energy dissipation are discussed. A bus bar was constructed by welding three crystals while melt-texturing, such that their a,b planes were parallel and interleaved. The bus bar, an area of approximately 2 cm(exp 2), carried a transport current of 1000 amps, the limit of the testing equipment available.

Weinstein, Roy↗
NASA NTRS1995

Progress in HTS Trapped Field Magnets: J(sub c), Area, and Applications

Progress in trapped field magnets is reported. Single YBCO grains with diameters of 2 cm are made in production quantities, while 3 cm, 4 1/2 cm and 6 cm diameters are being explored. For single grain tiles: J(sub c) - 10,000 A/sq cm for melt textured grains; J(sub c) - 40,000 A/sq cm for light ion irradiation; and J(sub c) - 85,000 A/J(sub c) for heavy ion irradiation. Using 2 cm diameter tiles bombarded by light ions, we have fabricated a mini-magnet which trapped 2.25 Tesla at 77K, and 5.3 Tesla at 65K. A previous generation of tiles, 1 cm x 1 cm, was used to trap 7.0 Tesla at 55K. Unirradiated 2.0 cm tiles were used to provide 8 magnets for an axial gap generator, in a collaborative experiment with Emerson Electric Co. This generator delivered 100 Watts to a resistive load, at 2265 rpm. In this experiment, activation of the TFMs was accomplished by a current pulse of 15 ms duration. Tiles have also been studied for application as a bumper-tether system for the soft docking of spacecraft. A method for optimizing tether forces, and mechanisms of energy dissipation are discussed. A bus bar was constructed by welding three crystals while melt-texturing, such that their a,b planes were parallel and interleaved. The bus bar, of area approx. 2 sq cm, carried a transport current of 1000 amps, the limit of the testing equipment available.

Weinstein, Roy↗
NASA NTRS2008

Miniature High-Force, Long-Stroke SMA Linear Actuators

Improved long-stroke shape-memory-alloy (SMA) linear actuators are being developed to exert significantly higher forces and operate at higher activation temperatures than do prior SMA actuators. In these actuators, long linear strokes are achieved through the principle of displacement multiplication, according to which there are multiple stages, each intermediate stage being connected by straight SMA wire segments to the next stage so that relative motions of stages are additive toward the final stage, which is the output stage. Prior SMA actuators typically include polymer housings or shells, steel or aluminum stages, and polymer pads between successive stages of displacement-multiplication assemblies. Typical output forces of prior SMA actuators range from 10 to 20 N, and typical strokes range from 0.5 to 1.5 cm. An important disadvantage of prior SMA wire actuators is relatively low cycle speed, which is related to actuation temperature as follows: The SMA wires in prior SMA actuators are typically made of a durable nickel/titanium alloy that has a shape-memory activation temperature of 80 C. An SMA wire can be heated quickly from below to above its activation temperature to obtain a stroke in one direction, but must then be allowed to cool to somewhat below its activation temperature (typically, less than or equal to 60 C in the case of an activation temperature of 80 C) to obtain a stroke in the opposite direction (return stroke). At typical ambient temperatures, cooling times are of the order of several seconds. Cooling times thus limit cycle speeds. Wires made of SMA alloys having significantly higher activation temperatures [denoted ultra-high-temperature (UHT) SMA alloys] cool to the required lower return-stroke temperatures more rapidly, making it possible to increase cycle speeds. The present development is motivated by a need, in some applications (especially aeronautical and space-flight applications) for SMA actuators that exert higher forces, operate at greater cycle speeds, and have stronger housings that can withstand greater externally applied forces and impacts. The main novel features of the improved SMA actuators are the following: 1) The ends of the wires are anchored in compact crimps made from short steel tubes. Each wire end is inserted in a tube, the tube is flattened between planar jaws to make the tube grip the wire, the tube is compressed to a slight U-cross-section deformation to strengthen the grip, then the crimp is welded onto one of the actuator stages. The pull strength of a typical crimp is about 125 N -- comparable to the strength of the SMA wire and greater than the typical pull strengths of wire-end anchors in prior SMA actuators. Greater pull strength is one of the keys to achievement of higher actuation force; 2) For greater strength and resistance to impacts, housings are milled from aluminum instead of being made from polymers. Each housing is made from two pieces in a clamshell configuration. The pieces are anodized to reduce sliding friction; 3) Stages are made stronger (to bear greater compression loads without excessive flexing) by making them from steel sheets thicker than those used in prior SMA actuators. The stages contain recessed pockets to accommodate the crimps. Recessing the pockets helps to keep overall dimensions as small as possible; and, 4) UHT SMA wires are used to satisfy the higher-speed/higher-temperature requirement.

Cummin, Mark A.↗
NASA NTRS1975

Sinter of uniform, predictable, blemish-free nickel plaque for large aerospace nickel cadmium cells

A series of nickel slurry compositions were tested. Important slurry parameters were found to be the nature of the binder, a pore former and the method of mixing. A slow roll mixing which is non-turbulent successfully eliminated entrapped air so that bubbles and pockets were avoided in the sinter. A slurry applicator was developed which enabled an equal quantity of slurry to be applied to both sides of the grid. Sintering in a furnace having a graded atmosphere characteristic, ranging from oxidizing to strongly reducing, improved adhesion of porous sinter to grid and resulted in a uniform welding of nickel particles to each other throughout the plaque. Sintering was carried out in a horizontal furnace having three heating zones and 16 heating control circuits. Tests used for plaque evaluation include (1) appearance, (2) grid location and adhesion, (3) mechanical strength, (4) thickness, (5) weight per unit area, (6) void volume per unit area, (7) surface area and (8) electrical resistance. Plaque material was impregnated using Heliotek proprietary processes and 100 AH cells were fabricated.

Seiger, H. N.↗
NASA NTRS2001

Cryogenic Treatment of Al-Li Alloys for Improved Weldability, Repairability, and Reduction of Residual Stresses

Service performance has shown that cryogenic treatment of some metals provides improved strength, fatigue life, and wear resistance to the processed material. Effects such as these were initially discovered by NASA engineers while evaluating spacecraft that had returned from the cold vacuum of space. Factors such as high cost, poor repairability, and poor machinability are currently prohibitive for wide range use of some aerospace aluminum alloys. Application of a cryogenic treatment process to these alloys is expected provide improvements in weldability and weld properties coupled with a reduction in repairs resulting in a significant reduction in the cost to manufacture and life cycle cost of aerospace hardware. The primary purpose of this effort was to evaluate the effects of deep cryogenic treatment of some aluminum alloy plate products, welds, and weld repairs, and optimize a process for the treatment of these materials. The optimized process is being evaluated for improvements in properties of plate and welds, improvements in weldability and repairability of treated materials, and as an alternative technique for the reduction of residual stresses in repaired welds. This paper will present the results of testing and evaluation conducted in this effort. These results will include assessments of changes in strength, toughness, stress corrosion susceptability, weldability, repairability, and reduction in residual stresses of repaired welds.

Malone, Tina W.↗
NASA NTRS2014

Manufacturing Challenges Associated with the Use of Metal Matrix Composites in Aerospace Structures

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as NASA's Orion Crew Exploration Vehicle and Space Launch System. A current focus of FSW research is to extend the process to new materials, such as MMCs, which are difficult to weld using conventional fusion techniques. Since Friction Stir Welding occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This chapter summarizes the challenges encountered when joining MMCs to themselves or to other materials in structures. Specific attention is paid to the influence of process variables in Friction Stir Welding on the wear process characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. A phenomenological model of the wear process was constructed based on the rotating plug model of Friction Stir Welding. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is also explored. In-process force, torque, and vibration signals are analyzed to assess the feasibility of in situ monitoring of tool shape changes as a result of wear (an advancement which would eliminate the need for off-line evaluation of tool condition during joining). Monitoring, controlling, and reducing tool wear in FSW of MMCs is essential to implementation of these materials in structures (such as launch vehicles) where they would be of maximum benefit. The work presented here is extendable to machining of MMCs, where wear of the tool is also a limiting factor.

Prater, Tracie↗
NASA NTRS1992

Test experience, 490 N high performance (321 sec Isp) engine

Engines with area ratios of 44:1 and 286:1 are tested by means of hot fire tests using the NTO/MMH bipropellant to maximize the performance of the combined technologies. The low-thrust engine systems are designed with oxidation resistant materials that can operate at temperatures of more than 2204 C for tens of hours. The chamber is attached to the injector in a configuration that prevents overheating of the injector, valve, and the spacecraft interface. Three injectors with 44:1 area ratios are capable of nominal specific impulse values of 309 sec, and a performance of 321 lbf-sec/lbm is noted for an all-welded engine assembly with area ratio of 286:1. The all-welded engine is shown to have an acceptable design margin for thermal characteristics. High-performance liquid apogee engines are shown to perform optimally when based on iridium/rhenium chamber technology, use of a special platelet injector, and the minimization of losses due to fuel-film cooling.

Schoenman, L.↗
NASA NTRS1973

Development of modified poly(perfluoropropyleneoxide) urethane systems for use in liquid oxygen and in enriched 100 percent oxygen atmosphere

This program consisted of two separate though related phases. The initial phase was directed toward improving the mechanical and adhesive properties of the very highly fluorinated-polyurethane resin system derived from the hydroxyl-terminated polyperfluoropropylene oxide and 6-chloro-2,4,5-trifluoro-m-phenylene diisocyanate. Various new curing agents for this system were investigated, with the goal of providing a more thermally stable crosslink (cure) mechanism to provide wider applicability and fuller utilization of the outstanding oxygen resistance of the PFPO system. Complete resistance to liquid- and gaseous-oxygen impact at presures as high as 1035 N/sq cm were attained with the use of the PFPO resin castings. The second corollary phase was directed toward investigating the feasibility and optimization of the allophanate cured, urethane extended polymer derived from hydroxyl-terminated polyperfluoropropyleneoxide and 6-chloro-2,4,5-trifluoro-m-phenylene diisocyanate, as the adhesive system for use in a weld-bond configuration for liquid oxygen tankage. The synthesis and application procedures of the adhesive system to insure liquid oxygen compatibility (under 10 kg-m loading), and the development of procedures and techniques to provide high quality weld-bonded joint configurations were studied.

Harrison, E. S.↗
NASA NTRS2003

Development of a Thin Film Solar Cell Interconnect for the Powersphere Concept

Progressive development of microsatellite technologies has resulted in increased demand for lightweight electrical power subsystems including solar arrays. The use of thin film photovoltaics has been recognized as a key solution to meet the power needs. The lightweight cells can generate sufficient power and still meet critical mass requirements. Commercially available solar cells produced on lightweight substrates are being studied as an option to fulfill the power needs. The commercially available solar cells are relatively inexpensive and have a high payoff potential. Commercially available thin film solar cells are primarily being produced for terrestrial applications. The need to convert the solar cell from a terrestrial to a space compatible application is the primary challenge. Solar cell contacts, grids and interconnects need to be designed to be atomic oxygen resistant and withstand rapid thermal cycling environments. A mechanically robust solar cell interconnect is also required in order to withstand handling during fabrication and survive during launch. The need to produce the solar cell interconnects has been identified as a primary goal of the Powersphere program and is the topic of this paper. Details of the trade study leading to the final design involving the solar cell wrap around contact, flex blanket, welding process, and frame will be presented at the conference.

Simburger, Edward J.↗
NASA NTRS1992

UPT scenarios: Implications for system reliability

The objective of this project was to examine the corrosion resistance of 316L stainless steel in several urine pre-treat solutions. Four solutions were examined: untreated urine (control); urine pretreated with oxone (potassium peroxymonosulfate sulfate); urine pretreated with sodium hypochlorite (NaOCl); and urine pretreated with ozone (O3). In accordance with current procedures, all solutions but the control were acidified to a pH of 2.5 using sulfuric acid--this suppresses the generation of ammonia in the solutions and is intended to limit microbial growth. Welded and unwelded coupons were exposed to each solution. In addition, Titanium coupons (welded and unwelded) were exposed to biologically active environmental control and life support system (ECLSS) water. Microbial attachment and biofilm growth were monitored. Ozone was examined as a biocide/oxidizer/corrosion preventative (simultaneous addition) and as a remediation method (added one week after exposure). In an unrelated effort, HP 9-4-30 coupons were exposed to biologically active solutions. Corrosion rates for welded and unwelded samples were determined--results were correlated to the ongoing HP 9-4-30 weldment stress corrosion study.

Walsh, Daniel W.↗
NASA NTRS2008

NASA Tech Briefs, January 2008

Topics covered include: Induction Charge Detector with Multiple Sensing Stages; Generic Helicopter-Based Testbed for Surface Terrain Imaging Sensors; Robot Electronics Architecture; Optimized Geometry for Superconducting Sensing Coils; Sensing a Changing Chemical Mixture Using an Electronic Nose; Inertial Orientation Trackers with Drift Compensation; Microstrip Yagi Antenna with Dual Aperture-Coupled Feed; Patterned Ferroelectric Films for Tunable Microwave Devices; Micron-Accurate Laser Fresnel-Diffraction Ranging System; Efficient G(sup 4)FET-Based Logic Circuits; Web-Enabled Optoelectronic Particle-Fallout Monitor; SiO2/TiO2 Composite for Removing Hg from Combustion Exhaust; Lightweight Tanks for Storing Liquefied Natural Gas; Hybrid Wound Filaments for Greater Resistance to Impacts; Making High-Tensile-Strength Amalgam Components; Bonding by Hydroxide-Catalyzed Hydration and Dehydration; Balanced Flow Meters without Moving Parts; Deflection-Compensating Beam for Use inside a Cylinder; Four-Point-Latching Microactuator; Curved Piezoelectric Actuators for Stretching Optical Fibers; Tunable Optical Assembly with Vibration Dampening; Passive Porous Treatment for Reducing Flap Side-Edge Noise; Cylindrical Piezoelectric Fiber Composite Actuators; Patterning of Indium Tin Oxide Films; Gimballed Shoulders for Friction Stir Welding; Improved Thermal Modulator for Gas Chromatography; Nuclear-Spin Gyroscope Based on an Atomic Co-Magnetometer; Utilizing Ion-Mobility Data to Estimate Molecular Masses; Optical Displacement Sensor for Sub-Hertz Applications; Polarization/Spatial Combining of Laser-Diode Pump Beams; Spatial Combining of Laser-Diode Beams for Pumping an NPRO; Algorithm Optimally Orders Forward-Chaining Inference Rules; Project Integration Architecture; High Power Amplifier and Power Supply; Estimating Mixing Heights Using Microwave Temperature Profiler; and Multiple-Cone Sunshade for a Spaceborne Telescope.

Source record↗
NASA NTRS1994

Copper Alloy For High-Temperature Uses

Alloy of Cu/8Cr/4Nb (numbers indicate parts by atom percent) improved over older high-temperature copper-based alloys in that it offers enhanced high temperature strength, resistance to creep, and ductility while retaining most of thermal conductivity of pure copper; in addition, alloy does not become embrittled upon exposure to hydrogen at temperatures as high as 705 degrees C. Designed for use in presence of high heat fluxes and active cooling; for example, in heat exchangers in advanced aircraft and spacecraft engines, and other high-temperature applications in which there is need for such material. High conductivity and hardness of alloy exploited in welding electrodes and in high-voltage and high-current switches and other applications in which wear poses design problem.

Dreshfield, Robert L.↗