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At least 235 records · Page 13

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NASA NTRS1994

A Theoretical Evaluation of Secondary Atomization Effects on Engine Performance for Aluminum Gel Propellants

A one-dimensional model of a gel-fueled rocket combustion chamber has been developed. This model includes the processes of liquid hydrocarbon burnout, secondary atomization. aluminum ignition, and aluminum combustion. Also included is a model of radiative heat transfer from the solid combustion products to the chamber walls. Calculations indicate that only modest secondary atomization is required to significantly reduce propellant burnout distances, aluminum oxide residual size and radiation heat wall losses. Radiation losses equal to approximately 2-13 percent of the energy released during combustion were estimated. A two-dimensional, two-phase nozzle code was employed to estimate radiation and nozzle two-phase flow effects on overall engine performance. Radiation losses yielded a 1 percent decrease in engine I(sub sp). Results also indicate that secondary atomization may have less effect on two-phase losses than it does on propellant burnout distance and no effect if oxide particle coagulation and shear induced droplet breakup govern oxide particle size. Engine I(sub sp) was found to decrease from 337.4 to 293.7 seconds as gel aluminum mass loading was varied from 0-70 wt percent. Engine I(sub sp) efficiencies, accounting for radiation and two-phase flow effects, on the order of 0.946 were calculated for a 60 wt percent gel, assuming a fragmentation ratio of 5.

Mueller, D. C.↗

NASA NTRS1997

Degradation of Perfluorinated Ether Lubricants on Pure Aluminum Surfaces: Semiempirical Quantum Chemical Modeling

The AM1 semiempirical quantum chemical method was used to model the interaction of perfluoroethers with aluminum surfaces. Perfluorodimethoxymethane and perfluorodimethyl ether were studied interacting with aluminum surfaces, which were modeled by a five-atom cluster and a nine-atom cluster. Interactions were studied for edge (high index) sites and top (low index) sites of the clusters. Both dissociative binding and nondissociative binding were found, with dissociative binding being stronger. The two different ethers bound and dissociated on the clusters in different ways: perfluorodimethoxymethane through its oxygen atoms, but perfluorodimethyl ether through its fluorine atoms. The acetal linkage of perfluorodimeth-oxymethane was the key structural feature of this molecule in its binding and dissociation on the aluminum surface models. The high-index sites of the clusters caused the dissociation of both ethers. These results are consistent with the experimental observation that perfluorinated ethers decompose in contact with sputtered aluminum surfaces.

Slaby, Scott M.↗

NASA NTRS1996

Effective Thermal Conductivity of an Aluminum Foam + Water Two Phase System

This study examined the effect of volume fraction and pore size on the effective thermal conductivity of an aluminum foam and water system. Nine specimens of aluminum foam representing a matrix of three volume fractions (4-8% by vol.) and three pore sizes (2-4 mm) were tested with water to determine relationships to the effective thermal conductivity. It was determined that increases in volume fraction of the aluminum phase were correlated to increases in the effective thermal conductivity. It was not statistically possible to prove that changes in pore size of the aluminum foam correlated to changes in the effective thermal conductivity. However, interaction effects between the volume fraction and pore size of the foam were statistically significant. Ten theoretical models were selected from the published literature to compare against the experimental data. Models by Asaad, Hadley, and de Vries provided effective thermal conductivity predictions within a 95% confidence interval.

Moskito, John↗

NASA NTRS1997

NASA-UVA Light Aerospace Alloy and Structure Technology Program Supplement: Aluminum-Based Materials for High Speed Aircraft

This is the final report of the study "Aluminum-Based Materials for High Speed Aircraft" which had the objectives (1) to identify the most promising aluminum-based materials with respect to major structural use on the HSCT and to further develop those materials and (2) to assess the materials through detailed trade and evaluation studies with respect to their structural efficiency on the HSCT. The research team consisted of ALCOA, Allied-Signal, Boeing, McDonnell Douglas, Reynolds Metals and the University of Virginia. Four classes of aluminum alloys were investigated: (1) I/M 2XXX containing Li and I/M 2XXX without Li, (2) I/M 6XXX, (3) two P/M 2XXX alloys, and (4) two different aluminum-based metal matrix composites (MMC). The I/M alloys were targeted for a Mach 2.0 aircraft and the P/M and MMC alloys were targeted for a Mach 2.4 aircraft. Design studies were conducted using several different concepts including skin/stiffener (baseline), honeycomb sandwich, integrally stiffened and hybrid adaptations (conventionally stiffened thin-sandwich skins). Alloy development included fundamental studies of coarsening behavior, the effect of stress on nucleation and growth of precipitates, and fracture toughness as a function of temperature were an integral part of this program. The details of all phases of the research are described in this final report.

Starke, E. A., Jr.↗

NASA NTRS2001

Burning Velocity Measurements in Aluminum-Air Suspensions using Bunsen Type Dust Flames

Laminar burning velocity (sometimes also referred in literature as fundamental or normal flame propagation speed) is probably the most important combustion characteristic of the premixed combustible mixture. The majority of experimental data on burning velocities in gaseous mixtures was obtained with the help of the Bunsen conical flame. The Bunsen cone method was found to be sufficiently accurate for gaseous mixtures with burning velocities higher than 10-15 cm/s at normal pressure. Hans Cassel was the first to demonstrate that suspensions of micron-size solid fuel particles in a gaseous oxidizer can also form self-sustained Bunsen flames. He was able to stabilize Bunsen flames in a number of suspensions of different nonvolatile solid fuels (aluminum, carbon, and boron). Using the Bunsen cone method he estimated burning velocities in the premixed aluminum-air mixtures (particle size less than 10 microns) to be in the range of 30-40 cm/s. Cassel also found, that the burning velocity in dust clouds is a function of the burner diameter. In our recent work, we have used the Bunsen cone method to investigate dependence of burning velocity on dust concentration in fuel-rich aluminum dust clouds. Burning velocities in stoichiometric and fuel-rich aluminum dust suspensions with average particle sizes of about 5 microns were found to be in the range of 20-25 cm/s and largely independent on dust concentration. These results raise the question to what degree burning velocities derived from Bunsen flame specifically and other dust flame configurations in general, are indeed fundamental characteristics of the mixture and to what degree are they apparatus dependent. Dust flames in comparison to gas combustion, are thicker, may be influenced by radiation heat transfer in the flame front, respond differently to heat losses, and are fundamentally influenced by the particular flow configuration due to the particles inertia. Since characteristic spatial scales of dust flames are larger, one can expect that they will also be more sensitive than homogeneous combustion to a particular experimental geometric configuration of the flame and the flow. With such sensitivity the introduction of the very concept of the fundamental flame speed may be problematic for dust combustion. With this in mind, the objective of the present work is to further investigate Bunsen dust flames and evaluate to what degree burning velocities derived from Bunsen cone depend on experimental conditions (i.e. flow rate and nozzle diameter).

Lee, John↗

NASA NTRS2002

Friction-Stir Welding of Aluminum For the Space Program

The Marshall Space Flight Center is developing and characterizing the friction stir welding process for the Space Shuttle and other space programs. This revolutionary process, invented and patented by The Weld Institute in England, offers tremendous advantages for joining aluminum for high performance applications. It is particularly suited for advanced aluminum-lithium alloys, such as 2195, the primary structural alloy used in the External Tank. The friction stir welding process joins metals with minimal heat input, resulting in high-strength joints with high ductility. It is a simple process to demonstrate using a common milling machine for sample parts, but relatively expensive to implement on large-scale hardware, due to the high cost of tooling needed to handle the high forging pressures characteristic of the process. Recent developments at the Marshall Space Flight Center have demonstrated friction stir welding on linear joints up to 5 meters (15 ft.), with material thickness ranging between 2.5 mm and 16.5 mm (0.100" to 0.650"). High efficiency weld joints have been produced in aluminum from the 2000, 5000, and 6000 series alloy systems. A "retractable pin tool" system was patented by MSFC that allows use of friction stir welding for joints with changing material thickness, and with less rigid tooling than previously considered. This presentation will describe the details of alloys welded to-date and technical advances under development at MSFC. These developments could have substantial benefit to industrial applications for welding aluminum.

Jones, Clyde S.↗

NASA NTRS2002

High Strength and Wear Resistant Aluminum Alloy for High Temperature Applications

In this paper, a new high strength and wear resistant aluminum cast alloy invented by NASA-MSFC for high temperature applications will be presented. Developed to meet U.S. automotive legislation requiring low-exhaust emission, the novel NASA 398 aluminum-silicon alloy offers dramatic improvement in tensile and fatigue strengths at elevated temperatures (500 F-800 F), enabling new pistons to utilize less material, which can lead to reducing part weight and cost as well as improving performance. NASA 398 alloy also offers greater wear resistance, surface hardness, dimensional stability, and lower thermal expansion compared to conventional aluminum alloys for several commercial and automotive applications. The new alloy can be produced economically using permanent steel molds from conventional gravity casting or sand casting. The technology was developed to stimulate the development of commercial aluminum casting products from NASA-developed technology by offering companies the opportunity to license this technology.

Lee, Jonathan A.↗

NASA NTRS2003

Self-Reacting Friction Stir Welding for Aluminum Alloy Circumferential Weld Applications

Friction stir welding is an innovative weld process that continues to grow in use, in the commercial, defense, and space sectors. It produces high quality and high strength welds in aluminum alloys. The process consists of a rotating weld pin tool that plasticizes material through friction. The plasticized material is welded by applying a high weld forge force through the weld pin tool against the material during pin tool rotation. The high weld forge force is reacted against an anvil and a stout tool structure. A variation of friction stir welding currently being evaluated is self-reacting friction stir welding. Self-reacting friction stir welding incorporates two opposing shoulders on the crown and root sides of the weld joint. In self-reacting friction stir welding, the weld forge force is reacted against the crown shoulder portion of the weld pin tool by the root shoulder. This eliminates the need for a stout tooling structure to react the high weld forge force required in the typical friction stir weld process. Therefore, the self-reacting feature reduces tooling requirements and, therefore, process implementation costs. This makes the process attractive for aluminum alloy circumferential weld applications. To evaluate the application of self-reacting friction stir welding for aluminum alloy circumferential welding, a feasibility study was performed. The study consisted of performing a fourteen-foot diameter aluminum alloy circumferential demonstration weld using typical fusion weld tooling. To accomplish the demonstration weld, weld and tack weld development were performed and fourteen-foot diameter rings were fabricated. Weld development consisted of weld pin tool selection and the generation of a process map and envelope. Tack weld development evaluated gas tungsten arc welding and friction stir welding for tack welding rings together for circumferential welding. As a result of the study, a successful circumferential demonstration weld was produced leading the way for future circumferential weld implementation.

Bjorkman, Gerry↗

NASA NTRS2003

Aging Optimization of Aluminum-Lithium Alloy L277 for Application to Cryotank Structures

Compared with aluminum alloys such as 2219, which is widely used in space vehicle for cryogenic tanks and unpressurized structures, aluminum-lithium alloys possess attractive combinations of lower density and higher modulus along with comparable mechanical properties and improved damage tolerance. These characteristics have resulted in the successful use of the aluminum-lithium alloy 2195 for the Space Shuttle External Tank, and the consideration of newer U.S. aluminum-lithium alloys such as L277 and C458 for future space vehicles. A design of experiments aging study was conducted for plate and a limited study on extrusions. To achieve the T8 temper, Alloy L277 is typically aged at 290 F for 40 hours. In the study for plate, a two-step aging treatment was developed through a design of experiments study and the one step aging used as a control. Based on the earlier NASA studies on 2195, the first step aging temperature was varied between 220 F and 260 F. The second step aging temperatures was varied between 290 F and 310 F, which is in the range of the single-step aging temperature. For extrusions, two, single-step, and one two-step aging condition were evaluated. The results of the design of experiments used for the T8 temper as well as a smaller set of experiments for the T6 temper for plate and the results for extrusions will be presented.

Sova, B. J.↗

NASA NTRS2002

High quality optically polished aluminum mirror and process for producing

A new technical advancement in the field of precision aluminum optics permits high quality optical polishing of aluminum monolith, which, in the field of optics, offers numerous benefits because of its machinability, lightweight, and low cost. This invention combines diamond turning and conventional polishing along with india ink, a newly adopted material, for the polishing to accomplish a significant improvement in surface precision of aluminum monolith for optical purposes. This invention guarantees the precise optical polishing of typical bare aluminum monolith to surface roughness of less than about 30 angstroms rms and preferably about 5 angstroms rms while maintaining a surface figure accuracy in terms of surface figure error of not more than one-fifteenth of wave peak-to-valley.

Lyons, III, James J.↗

NASA NTRS2005

High quality optically polished aluminum mirror and process for producing

Lyons, III, James J.↗

NASA NTRS1986

Aluminum base alloy powder metallurgy process and product

A metallurgical method including cooling molten aluminum particles and consolidating resulting solidified particles into a multiparticle body, wherein the improvement comprises the provision of greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn. Aluminum containing greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn.

Paris, Henry G.↗

NASA NTRS2009

Aluminum is More Cytotoxic than Lunar Dust in Human Skin and Lung Fibroblasts

NASA plans to build a permanent space station on the moon to explore its surface. The surface of the moon is covered in lunar dust, which consists of fine particles that contain silicon, aluminum and titanium, among others. Because this will be a manned base, the potential toxicity of this dust has to be studied. Also, toxicity standards for potential exposure have to be set. To properly address the potential toxicity of lunar dust we need to understand the toxicity of its individual components, as well as their combined effects. In order to study this we compared NASA simulant JSC-1AVF (volcanic ash particles), that simulates the dust found on the moon, to aluminum, the 3rd most abundant component in lunar dust. We tested the cytotoxicity of both compounds on human lung and skin fibroblasts (WTHBF-6 and BJhTERT cell lines, respectively). Aluminum oxide was more cytotoxic than lunar dust to both cell lines. In human lung fibroblasts 5, 10 and 50 g/sq cm of aluminum oxide induced 85%, 61% and 30% relative survival, respectively. For human skin fibroblasts the same concentrations induced 58%, 41% and 58% relative survival. Lunar dust was also cytotoxic to both cell lines, but its effects were seen at higher concentrations: 50, 100, 200 and 400 g/sq cm of lunar dust induced a 69%, 46%, 35% and 30% relative survival in the skin cells and 53%, 16%, 8% and 2% on the lung cells. Overall, for both compounds, lung cells were more sensitive than skin cells. This work was supported by a NASA EPSCoR grant through the Maine Space Grant Consortium (JPW), the Maine Center for Toxicology and Environmental Health., a Fulbright Grant (JM) and a Delta Kappa Gamma Society International World Fellowship (JM).

Hammond, D.↗

NASA NTRS2011

Higher Magnification Imaging of the Polished Aluminum Collector Returned from the Genesis Mission

The polished aluminum collector (previously referred to as the polished aluminum kidney) was intended for noble gas analysis for the Gene-sis mission. The aluminum collector, fabricated from alloy 6061T, was polished for flight with alumina, then diamond paste. Final cleaning was performed by soak-ing and rinsing with hexane, then isopropanol, and last-ly megasonically energized ultrapure water prior to installation. It was mounted inside the collector canister on the thermal shield at JSC in 2000. The polished aluminum collector was not surveyed microscopically prior to flight.

Rodriquez, Melissa C.↗

NASA NTRS2006

Electrically Conductive Anodized Aluminum Surfaces

Anodized aluminum components can be treated to make them sufficiently electrically conductive to suppress discharges of static electricity. The treatment was conceived as a means of preventing static electric discharges on exterior satin-anodized aluminum (SAA) surfaces of spacecraft without adversely affecting the thermal-control/optical properties of the SAA and without need to apply electrically conductive paints, which eventually peel off in the harsh environment of outer space. The treatment can also be used to impart electrical conductivity to anodized housings of computers, medical electronic instruments, telephoneexchange equipment, and other terrestrial electronic equipment vulnerable to electrostatic discharge. The electrical resistivity of a typical anodized aluminum surface layer lies between 10(exp 11) and 10(exp 13) Omega-cm. To suppress electrostatic discharge, it is necessary to reduce the electrical resistivity significantly - preferably to < or = 10(exp 9) Omega-cm. The present treatment does this. The treatment is a direct electrodeposition process in which the outer anodized surface becomes covered and the pores in the surface filled with a transparent, electrically conductive metal oxide nanocomposite. Filling the pores with the nanocomposite reduces the transverse electrical resistivity and, in the original intended outer-space application, the exterior covering portion of the nanocomposite would afford the requisite electrical contact with the outer-space plasma. The electrical resistivity of the nanocomposite can be tailored to a value between 10(exp 7) and 10(exp 12) Omega-cm. Unlike electrically conductive paint, the nanocomposite becomes an integral part of the anodized aluminum substrate, without need for adhesive bonding material and without risk of subsequent peeling. The electrodeposition process is compatible with commercial anodizing production lines. At present, the electronics industry uses expensive, exotic, electrostaticdischarge- suppressing finishes: examples include silver impregnated anodized, black electroless nickel, black chrome, and black copper. In comparison with these competing finishes, the present nanocomposite finishes are expected to cost 50 to 20 percent less and to last longer.

Nguyen, Trung Hung↗

NASA NTRS2005

Molybdate Coatings for Protecting Aluminum Against Corrosion

Conversion coatings that comprise mixtures of molybdates and several additives have been subjected to a variety of tests to evaluate their effectiveness in protecting aluminum and alloys of aluminum against corrosion. Molybdate conversion coatings are under consideration as replacements for chromate conversion coatings, which have been used for more than 70 years. The chromate coatings are highly effective in protecting aluminum and its alloys against corrosion but are also toxic and carcinogenic. Hexavalent molybdenum and, hence, molybdates containing hexavalent molybdenum, have received attention recently as replacements for chromates because molybdates mimic chromates in a variety of applications but exhibit significantly lower toxicity. The tests were performed on six proprietary formulations of molybdate conversion coatings, denoted formulations A through F, on panels of aluminum alloy 2024-T3. A bare alloy panel was also included in the tests. The tests included electrochemical impedance spectroscopy (EIS), measurements of corrosion potentials, scanning electron microscopy (SEM) with energy-dispersive spectroscopy (EDS), and x-ray photoelectron spectroscopy (XPS).

Calle, Luz Marina↗

NASA NTRS2013

Net Shape Spin Formed Cryogenic Aluminum Lithium Cryogenic Tank Domes for Lower Cost Higher Performance Launch Vehicles

With the goal of lower cost (simplified manufacturing and lower part count) and higher performance (higher strength to weight alloys) the NASA Technical Maturation Program in 2006 funded a proposal to investigate spin forming of space launch vehicle cryogenic tank domes. The project funding continued under the NASA Exploration Technology Development Program through completion in FY12. The first phase of the project involved spin forming of eight, 1 meter diameter "path finder" domes. Half of these were processed using a concave spin form process (MT Aerospace, Augsburg Germany) and the other half using a convex process (Spincraft, Boston MA). The convex process has been used to produce the Ares Common Bulkhead and the concave process has been used to produce dome caps for the Space Shuttle light weight external tank and domes for the NASDA H2. Aluminum Lithium material was chosen because of its higher strength to weight ratio than the Aluminum 2219 baseline. Aluminum lithium, in order to obtain the desired temper (T8), requires a cold stretch after the solution heat treatment and quench. This requirement favors the concave spin form process which was selected for scale up. This paper describes the results of processing four, 5.5 meter diameter (upper stage scale) net shaped spin formed Aluminum Lithium domes. In order to allow scalability beyond the limits of foundry and rolling mills (about 12 foot width) the circular blank contained one friction stir weld (heavy lifter scales require a flat blank containing two welds). Mechanical properties data (tensile, fracture toughness, stress corrosion, and simulated service testing) for the parent metal and weld will also be discussed.

Curreri, Peter A.↗

NASA NTRS2011

Experimental Evaluation of Optically Polished Aluminum Panels on the Deep Space Network's 34 Meter Antenna

The potential development of large aperture ground?based "photon bucket" optical receivers for deep space communications has received considerable attention recently. One approach currently under investigation is to polish the aluminum reflector panels of 34?meter microwave antennas to high reflectance, and accept the relatively large spotsize generated by state of?the?art polished aluminum panels. Theoretical analyses of receiving antenna pointing, temporal synchronization and data detection have been addressed in previous papers. Here we describe the experimental effort currently underway at the Deep Space Network (DSN) Goldstone Communications Complex in California, to test and verify these concepts in a realistic operational environment. Two polished aluminum panels (a standard DSN panel polished to high reflectance, and a custom designed aluminum panel with much better surface quality) have been mounted on the 34 meter research antenna at Deep?Space Station 13 (DSS?13), and a remotely controlled CCD camera with a large CCD sensor in a weather?proof container has been installed next to the subreflector, pointed directly at the custom polished panel. The point?spread function (PSF) generated by the Vertex polished panel has been determined to be smaller than the sensor of the CCD camera, hence a detailed picture of the PSF can be obtained every few seconds, and the sensor array data processed to determine the center of the intensity distribution. In addition to estimating the center coordinates, expected communications performance can also been evaluated with the recorded data. The results of preliminary pointing experiments with the Vertex polished panel receiver using the planet Jupiter to simulate the PSF generated by a deep?space optical transmitter are presented and discussed in this paper.

optical receiver↗