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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Feasibility Study for Casting of High Temperature Refractory Superalloy Composites

Abstract This study investigated the feasibility of using conventional casting technique to fabricate refractory wires reinforced superalloy composites. These composites were being developed for advanced rocket engine turbine blades and other high temperature applications operating up to 2000 F. Several types of refractory metal wires such as W- Th, W-Re, Mo-Hf-C and W-HF-C reinforced waspaloy were experimentally cast and heat treated at 2000 F up to 48 hrs. Scanning electron microscope analysis was conducted in regions adjacent to the wire-matrix interface to determine the reaction zone and chemical compatibility resulting from material interdiffusion. It was concluded that fabrication using conventional casting may be feasible because the wire-matrix reaction zone thickness was comparable to similar composites produced by arc-sprayed monotape with hot isostatic pressing technique, Moreover, it was also found that the chemical compatibility could be improved significantly through a slight modification of the superalloy matrix compositions.

Lee, Jonathan A.↗
DOE OSTI2023

Report on FY 2023 Welding R&D at ORNL in support of ASME Alloy 709 Code Case Development

As part of the Alloy 709 (A709) ASME Code Case development effort under the Advanced Reactor Technologies (ART) Program, this work covers the development of the technical basis for weld fabrication and weld qualification of A709. This report summarizes the A709 welding research conducted at Oak Ridge National Laboratory (ORNL) in FY 2023. One of the focuses of the A709 welding research at ORNL is to relax the restriction of the P content in the A709 filler metal weld wire. In this report, we show the success in welding of high phosphorus (P) commercial A709 plates using A709 weld wires with relaxed P content of 80 wppm. A test weld was fabricated with the 80 wppm weld wire on the first commercial heat A709 base metal with 140 wppm P content using gas tungsten arc welding (GTAW). The test weld passed all weld qualification tests without issues. This study concludes that A709 matching filler metal with moderate amount of P of less than 80 wppm could be used to produce code qualified A709 welds with standard welding process without special treatment. It is recommended that the P level in the weld wire to be kept low to avoid hot cracking. Cross-weld specimens were machined from the two A709 production welds.. Cross welding creep rupture Code Case testing on these two production welds was initiated . The preliminary cross-weld creep tests results continue to show little or no creep strength reduction relative to the base metal.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Multiple Synchrotron Light Monitors for Transverse Matching and Monitoring at CEBAF

Beam setup at the Continuous Electron Beam Accelerator Facility (CEBAF) involves threading beam through the machine and monitoring global transfer functions to identify and address cumulative lattice errors. Transverse beam emittance may grow by as much as two orders of magnitude, mediated by synchrotron radiation. Re-matching the enlarged beam phase space into successive re-circulation arcs minimizes this emittance growth but requires knowledge of the actual beam distribution. This is now accomplished through quadrupole scans using wire profile monitors, the most time-consuming activity in our setup process. We propose to use Synchrotron Light Monitors (SLMs) to image the beam at homologous points in the four super-period recirculation arc lattices. Benefits include real-time monitoring of beam parameters and reduced elapsed time for initial setup.These SLMs will be installed in Arc 7 of the CEBAF machine, where Synchrotron Radiation contributes moderately to emittance growth. One of four required SLMs will be installed and commissioned this year, with the rest being installed next year.

Freeman, B.↗
NASA NTRSDate not supplied

Wire-break Ignition Testing of Materials for Spacesuit Fire Hazard Control

The input design constraints applied to the extravehicular activity (EVA) spacesuit pose a significant challenge for mitigation of fire hazards. To minimize fatigue and increase comfort of the crewmember operating the suit, the suit pressure is lowered below sea level conditions with typical EVA suit designs operating with 4.3 psia (29.7 kPa). With the lowered operating pressures and the use of closed-loop life support, the suit requires elevated concentrations of oxygen, typically >95%. At these oxygen concentrations, nearly the entirety of the suit internal materials are flammable. This leaves one remaining possible control leg of the fire triangle: ignition sources. Since the Gemini and Apollo programs, this has been a risk that has undergone constant reassessment, with a focus on improved mitigation. After the Apollo I fire, an arc ignition method was developed and used to quantify ignition thresholds for in-suit materials resulting in a current limit for powered in-suit devices applied to all subsequent suit designs. After the discovery of a frayed spacesuit biomed cable on STS-113 during the Shuttle Program, the previous arcing method was repeated with additional methods developed to extend the testing further. One of those methods was wire-break ignition testing, in which the current in a single strand of wire was progressively increased, preheating the material in proximity with a resultant break and the application of a reasonably repeatable arc to ignite the material, all while exposed in the selected environment. This method was used to test a suite of spacesuit materials providing relative performance with respect to ignition with this configuration for application of energy. This paper discusses extension of the current data set to address recent material additions, lowering of energy test levels for quantification of materials too low to measure in previous testing, as well as future plans to improve this method.

Colin Campbell↗
NASA NTRS1974

Development of strain gages for use to 1311 K (1900 F)

A high temperature electric resistance strain gage system was developed and evaluated to 1366 K (2000 F) for periods of at least one hour. Wire fabricated from a special high temperature strain gage alloy (BCL-3), was used to fabricate the gages. Various joining techniques (NASA butt welding, pulse arc, plasma needle arc, and dc parallel gap welding) were investigated for joining gage filaments to each other, gage filaments to lead-tab ribbons, and lead-tab ribbons to lead wires. The effectiveness of a clad-wire concept as a means of minimizing apparent strain of BCL-3 strain gages was investigated by sputtering platinum coatings of varying thicknesses on wire samples and establishing the optimum coating thickness--in terms of minimum resistivity changes with temperature. Finally, the moisture-proofing effectiveness of barrier coatings subjected to elevated temperatures was studied, and one commercial barrier coating (BLH Barrier H Waterproofing) was evaluated.

Lemcoe, M. M.↗
NASA NTRS2016

Deep Charging Evaluation of Satellite Power and Communication System Components

Deep charging, in contrast to surface charging, focuses on electron penetration deep into insulating materials applied over conductors. A classic example of this scenario is an insulated wire. Deep charging can pose a threat to material integrity, and to sensitive electronics, when it gives rise to an electrostatic discharge or arc. With the advent of Electric Orbit Raising, which requires spiraling through Earth's radiation belts, satellites are subjected to high energy electron environments which they normally would not encounter. Beyond Earth orbit, missions to Jupiter and Saturn face deep charging concerns due to the high energy radiation environments. While predictions can be made about charging in insulating materials, it is difficult to extend those predictions to complicated geometries, such as the case of an insulating coating around a small wire, or a non-uniform silicone grouting on a bus bar. Therefore, to conclusively determine the susceptibility of a system to arcs from deep charging, experimental investigations must be carried out. This paper will describe the evaluation carried out by NASA's Marshall Space Flight Center on subscale flight-like samples developed by Space Systems/Loral, LLC. Specifically, deep charging evaluations of solar array wire coupons, a photovoltaic cell coupon, and a coaxial microwave transmission cable, will be discussed. The results of each evaluation will be benchmarked against control sample tests, as well as typical power system levels, to show no significant deep charging threat existed for this set of samples under the conditions tested.

Schneider, T. A.↗
DOE OSTI2025

Time-Dependent 600 °C Post-Weld Heat Treatment Response of Laser-Wire-Directed Energy Deposited Austenitic Stainless Steel Claddings on Carbon Steel

Austenitic stainless steel overlay claddings are often used to protect nuclear reactor pressure vessels from corrosion. Arc welding processes are traditionally employed, which require a high heat input to bond the dissimilar metals, creating a large heat-affected zone and high residual stress that demands a lengthy stress-relieving post-weld heat treatment, up to 48 hours. High energy beam (e.g., laser, electron beam) directed energy deposition-based overlay cladding processes show promise for fabricating claddings with superior performance compared to arc welded ones because of their localized heat input; however, their necessity and time of post-weld heat treatment are currently unclear. In this research, we investigate the time dependence of a 600 C stress-relieving post-weld heat treatment of austenitic stainless steel clad on low carbon steel by laser-wire-directed energy deposition, comparing the microstructure and mechanical properties of the as-fabricated condition to 2-, 10-, and 48-hour heat treatment times. Diffusion simulations and microscopy show a gradual carburization of the stainless steel cladding and decarburization of the heat-affected zone/base metal. Nanoindentation testing shows up to a 1.8–2.69 embrittlement in the cladding and a 0.33 to 0.69 softening in the heat-affected zone after the 48-hour post-weld heat treatment. Tensile testing of the cladding composites reveals that increasing post-weld heat treatment time raises clad cracking susceptibility due to intergranular carbide formation and shows that laser-wire-directed energy deposition claddings may not require post-weld heat treatment.

Coating↗
NASA NTRS1969

Testing the flammability of materials exposed to arcs

Apparatus tests flammability and ignition characteristics of materials in close proximity to incandescent metal fragments or spalls ejected from intermittent short circuit arcs in air or oxygen rich atmospheres. It simulates a situation where an exposed live wire makes contact with a grounded member in areas containing organic matter.

Hamlett, B. J.↗
NASA NTRS2006

Evaluation of Risk and Possible Mitigation Schemes for Previously Unidentified Hazards

In April 2004, the NASA Engineering and Safety Center (NESC) was commissioned by NASA's Chief Safety and Mission Assurance (S&MA) Officer to review and render a technical opinion on the probability of a catastrophic failure related to this scenario: The Space Shuttle Program (SSP) recognized a zero-fault-tolerant design related to an inadvertent firing of the primary reaction control system (RCS) jets on the Orbiter during mated operations with the International Space Station (ISS). It was determined that an un-commanded firing of an RCS jet could cause serious damage or loss of both the SSP Orbiter and the ISS. Several scenarios were suggested in which an un-commanded firing of the RCS jet is possible. These scenarios include an arc track event in the 28-volt heater circuits that could result in a wire-to-wire short to the adjacent reaction control jet wire. In this worst-case scenario, enough current and power could be applied to activate the reaction control jet valves and fire a thruster. The following report summarizes the work that was sponsored by the NESC as part of their assessment of the Orbiter inadvertent firing of a RCS thruster while attached to the ISS.

Linzey, William↗
NASA NTRS2010

Foil Gas Thrust Bearings for High-Speed Turbomachinery

A methodology has been developed for the design and construction of simple foil thrust bearings intended for parametric performance testing and low marginal costs, supporting continued development of oil-free turbomachinery. A bearing backing plate is first machined and surface-ground to produce flat and parallel faces. Partial-arc slots needed to retain the foil components are then machined into the plate by wire electrical discharge machining. Slot thicknesses achievable by a single wire pass are appropriate to accommodate the practical range of foil thicknesses, leaving a small clearance in this hinged joint to permit limited motion. The backing plate is constructed from a nickel-based superalloy (Inconel 718) to allow heat treatment of the entire assembled bearing, as well as to permit hightemperature operation. However, other dimensionally stable materials, such as precipitation-hardened stainless steel, can also be used for this component depending on application. The top and bump foil blanks are cut from stacks of annealed Inconel X-750 foil by the same EDM process. The bump foil has several azimuthal slits separating it into five individual bump strips. This configuration allows for variable bump spacing, which helps to accommodate the effects of the varying surface velocity, thermal crowning, centrifugal dishing, and misalignment. Rectangular tabs on the foil blanks fit into the backing plate slots. For this application, a rather traditional set of conventionally machined dies is selected, and bump foil blanks are pressed into the dies for forming. This arrangement produces a set of bump foil dies for foil thrust bearings that provide for relatively inexpensive fabrication of various bump configurations, and employing methods and features from the public domain.

Edmonds, Brian↗
NASA NTRS1994

Program Supports Scientific Visualization

Primary purpose of General Visualization System (GVS) computer program is to support scientific visualization of data generated by panel-method computer program PMARC_12 (inventory number ARC-13362) on Silicon Graphics Iris workstation. Enables user to view PMARC geometries and wakes as wire frames or as light shaded objects. GVS is written in C language.

Keith, Stephan↗
NASA NTRS1992

Thin film thermocouples for high temperature measurement on ceramic materials

Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high-heating-rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.

Holanda, Raymond↗
NASA NTRS1993

Development of thin film thermocouples on ceramic materials for advanced propulsion system applications

Thin film thermocouples were developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hr or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.

Holanda, Raymond↗
NASA NTRS1992

Development of Thin Film Thermocouples on Ceramic Materials for Advanced Propulsion System Applications

Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 c. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperature of 1500 C depending on the stability of the particular ceramic substrate.

Holanda, R.↗
NASA NTRS1985

Electrical safety requirements: Implications for the module designer

Commercial photovoltaic array installations, which include residential and intermediate applications, are subject to building and electrical codes and to product safety standards. The National Electrical Code (NEC) Article 690, titled Solar Photovoltaic Systems, contains provisions defining acceptable levels of system safety and emphasizes the system design and its installation. The Underwriters Laboratories, Inc. (UL), document titled: Proposed First Edition of the Standard for Flat Plate Photovoltaic Modules and Panels, UL-1703, identifies module and panel construction requirements that ensure product safety. Together these documents describe requirements intended to minimize hazards such as shock and fire. Although initial focus of these requirements is on single crystal silicon modules, they are generic in nature, and are equally applicable to high voltage ( 30 Vdc), multikilowatt, thin film systems. A major safety concern is insulation breakdown within the module or array wiring system, or discontinuities within the electrical conductors. These failures can result in ground faults, in circuit arcs, or exposure to hazardous electrical parts. Safeguards are discussed.

Sugimura, R. S.↗
DOE OSTI2024

Influence of Nb alloying on Nb recrystallization and the upper critical field of Nb 3 ⁢Sn

Nb 3 Sn conductors are important candidates for high-field magnets for particle accelerators, and they continue to be widely used for many laboratory and NMR magnets. However, the critical current density, J c , of present Nb 3 Sn conductors declines swiftly above 12-15 T. State-of-the-art Ta- and Ti-doped strands exhibit upper critical field, H c2 , values of ~ 24-26.5 T (4.2 K) and do not reach the FCC target J c , which serves as the present stretch target for Nb 3 Sn development. As recently demonstrated, to meet this goal requires enhanced vortex pinning but an independent and supplementary approach is to significantly enhance H c2 . In this study, we have arc-melted multiple Nb alloys with added Hf, Zr, Ta and Ti and drawn them successfully into monofilament wires to investigate the possibilities of H c2 enhancement through alloying. H c2 (T) was measured for all samples in fields up to 16 T and some up to 31 T. We have found that all alloys show good agreement with the standard Werthamer, Helfand, and Hohenberg (WHH) fitting procedure without the need to adjust the paramagnetic limitation parameter (α) and spin-orbit scattering parameter (λ so ). The evaluation of dH c2 /dT near T c , which is proportional to the electronic specific heat coefficient γ and the normal state resistivity ρn, allows a better understanding of the induced disorder introduced by alloying in the A15 phase. So far, we have observed that Hf alloying of pure Nb can enhance H c2 (0) by 3-4 T to ~28 T, while adding just 1 at. %Hf or Zr into a Nb4Ta base alloy can raise H c2 (0) to ~31 T. Very importantly we find that Hf and Zr raise the alloy recrystallization temperature above the usual A15 reaction temperature range of 650°C – 750°C, thus ensuring denser A15 phase nucleation in the Nb alloy grain boundaries, possibly leading to a more homogeneous A15 phase Sn content and refined A15 grain size. Furthermore, the potential for further advancements in Nb 3 Sn properties is explored in relation to the recrystallization of the Nb alloy and the factors controlling the upper critical field.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRSDate not supplied

Weldability Investigation of Crack Resistant Aluminum Filler Metals Developed for Large Scale Additive Manufacturing and Industrial Welding Applications

In this study the NASA MSFC welding and manufacturing team investigated a new-age aluminum filler wire designed for welding and additive manufacturing (AM) of high strength aluminum alloys. High strength aluminum alloys are known to exhibit hot cracking and hot tearing issues during fusion welding operations. The goal of this investigation was to determine whether this new-age family of alloys can suppress the hot cracking and hot tearing issues exhibited during welding of high strength aluminum alloys and to do an initial characterization of the mechanical performance of welds created using these filler wires. This study focuses on fusion welding of aluminum alloy 6061 and compares the weldability characteristics of five aluminum filler metals and two forms of 6061 base material. The MSFC team utilized manual gas tungsten arc welding (GTAW) to conduct all welding operations and carried out metallographic analysis accompanied with mechanical testing to evaluate the performance of the welds created during this study. During the study it was observed that the new-age filler wires facilitated grain refinement in the weld fusion zone and were capable of creating crack free welds in aluminum alloy 6061 while exhibiting properties that met or exceeded conventional off the shelf aluminum filler metals.

Welding↗
NASA NTRS1989

Identification Of Anomalies In Welds

Advanced techniques combined with conventional analytical methods. Combination of real-time radiography, scanning electron microscopy, and energy-dispersive spectrometry identify enigmatic features in radiographs of welds where standard tensile, hardness, and electrical-conductivity tests and visible-light microscopic and macroscopic examinations insufficient. New combination of techniques applied successfully to variable-polarity-plasma-arc welds of 2219 aluminum alloy. Joints subjected to penetration, fill, and weld-repair passes with 2319 aluminum weld wire.

Knichen, David G.↗