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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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NASA NTRS2004

Erosion Coatings Developed to Increase the Life and Durability of Composites

Both the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) have worked to develop and demonstrate erosion-resistant coatings that would increase the life and durability of composite materials used in commercial aircraft engines. These composite materials reduce component weight by 20 to 30 percent and result in less fuel burn and emissions and more fuel savings. Previously, however, their use was limited because of poor erosion resistance, which causes concerns about safety and leads to high maintenance costs. The coatings were tested by the University of Cincinnati, and the composites were manufactured by Texas Composites and coated by Engelhard and NASA Glenn. Rolls-Royce Corporation uses composite materials, which are stronger and less dense than steel or titanium, to make bypass vanes for their AE3007 engines. These engines are widely used in regional jet aircraft (Embraer) and unmanned air vehicles such as the Northrop Grumman Global Hawk. Coatings developed by NASA/Rolls-Royce can reduce erosion from abrasive materials and from impurities in the air that pass over these vanes, allowing Rolls-Royce to take advantage of the benefits of composite materials over titanium without the added costs of increased maintenance and/or engine failure. The Higher Operating Temperature Propulsion Components (HOTPC) Project developed cost-effective, durable coatings as part of NASA's goal to increase aviation system capacity growth. These erosion coatings will reduce the number of special inspections or instances of discontinued service due to erosion, allowing aircraft capacity to be maintained without inconveniencing the traveling public. A specific example of extending component life showed that these coatings increased the life of graphite fiber and polymer composite bypass vanes up to 8 times over that of the uncoated vanes. This increased durability allows components to operate to full design life without the fear of wear or failure. Recently, Rolls-Royce completed over 2000 hr of engine testing with the coated fan exit bypass vanes. There was no loss of coating after nearly 5000 typical engine cycles. Midway through the engine tests, the coated vanes were removed from the engine during a scheduled maintenance and inspection period. The vanes were shipped back to Glenn, where they underwent further stress testing in the Structural Dynamics Lab, mimicking more extreme conditions than those typical of the AE3007 engine cycle. These vanes were then replaced in the AE3007 and subjected to another 1000 hr of engine tests. Once again, there was no loss of coating and only a minimal appearance of cracking.

Sutter, James K.↗
NASA NTRS1995

Space environmental effects on polymer matrix composites as a function of sample location on LDEF

This paper presents results on the effect of circumferential location on the variation in solar absorptance (alpha(sub S)) and infrared emittance (epsilon) for five different polymer matrix composites (PMC), and variations in erosion depth due to atomic oxygen (AO) for fourteen different PMC materials. In addition, a chemical content design parameter (gamma) has been found that correlates well with the erosion yield obtained from space flight data and hyperthermal AO tests for hydrocarbon polymeric materials. This parameter defines the ratio of the total number of atoms in a repeat monomer unit to the difference between the total carbon content and the total number of intermolecular oxygen atoms in the same repeat unit.

Tennyson, R. C.↗
NASA NTRS1974

High reliability sheathed, beryllia insulated, tungsten-rhenium alloy thermocouple assemblies; their fabrication and EMF stability

Tantalum sheathed, BeO insulated, W-3% Re/W-25% Re thermocouple assemblies were fabricated and their emf drift determined during 2059 hours of exposure at 2073 K in a gaseous helium environment. The sheathed thermocouple assemblies were constructed from aged thermoelements, specially heat-treated BeO insulators, and specially cleaned and etched tantalum sheaths. Their thermal emf drifts ranged from the equivalent of only -0.3 to -0.8 K drift per 1000 hours of exposure at 2073 K. No evidence of any gross chemical attack or degradation of the component materials was found. The emf drift and material behavior of some unsheathed, BeO insulated, W-3% Re/W-25% Re thermocouples at 2250 and 2400 K were also determined. Unsheathed thermocouples tested in an argon environment at 2250 K for 1100 hours and at 2400 K for 307 hours exhibited changes in thermal emf that typically ranged from the equivalent of a few degrees K to as much as +11 K. Post-test examinations of these thermocouples revealed some undesirable material degradation and interaction which included erosion of the BeO insulators and contamination of the thermoelements by tantalum from the tantalum blackbody enclosure in which the thermocouples were contained.

Burns, G. W.↗
NASA NTRS1978

Wear of seal materials used in aircraft propulsion systems

The various types of seal locations in a gas turbine engine are described, and the significance of wear to each type is reviewed. Starting with positive contact shaft seals, existing material selection guidelines are reviewed, and the existing PV (contact pressure X sliding velocity) criteria for selecting seal materials are discussed, along with the theoretical background for these criteria. Examples of wear mechanisms observed to operate in positive contact seals are shown. Design features that can extend the operating capabilities of positive contact seals, including pressure balancing and incorporation of hydrodynamic lift are briefly discussed. It is concluded that, despite the benefits arising from these design features, improved positive contact seal materials from the standpoint of wear, erosion and oxidation resistance will be necessary for further improvements in seal performance and durability, and to meet stringent future challenges.

Bill, R. C.↗
NASA NTRS1983

A comprehensive analysis of cavitation and liquid impingement erosion data

Cavitation-erosion experimental data previously covering several materials tested in a rotating disk device and a magnetostriction apparatus were analyzed using new normalization and curve-fitting techniques. From this process a universal approach is derived which can include data from cavitation and liquid impingement studies for specific materials from different test devices.

Rao, P. V.↗
NASA NTRS1985

A Statistical Treatment of the Regional Slope Characteristics of Venus and Earth

Regional slope is a scale dependent parameter that describes the planar gradient over some (relative broad) area of topography. As such, it has a fundamental relevance to the geological evolution of a planetary surface. It is controlled by the interaction of those processes which tend to increase or reduce surface relief (e.g., tectonism, volcanism, impact cratering, weathering, viscous relaxation) and in turn, exerts control on the erosion, transportation and deposition of surface materials. The regional slope values, measured over 3 by 3 regions for Venus and Earth are calculated. The regional slope frequency distribution information was analyzed for Venus and Earth. The effects on terrestrial regional slope resulting from the removal of the ocean load from sea floor topography were examined.

Shapiro, V. I.↗
NASA NTRS1986

Solar concentrator materials development

Materials with potential applications in reflective and refractive solar dynamic concentrators are tested for resistance to atomic oxygen degradation. It is found that inorganic coatings such as MgF2, SiO(x), and ITO provide excellent protection for reflective surfaces while organic materials are much more susceptible to erosion and mass loss. Of the organic polymers tested, the silicones have the highest intrinsic resistance to atomic oxygen degradation.

Morel, D. E.↗
NASA NTRS1989

Aeolian processes on Venus

This review assesses the potential aeolian regime on Venus as derived from spacecraft observations, laboratory simulations, and theoretical considerations. The two requirements for aeolian processes (a supply of small, loose particles and winds of sufficient strength to move them) appear to be met on Venus. Venera 9, 10, 13, and 14 images show particles considered to be sand and silt size on the surface. In addition, dust spurts (grains 5 to 50 microns in diameter) observed via lander images and inferred from the Pioneer-Venus nephalometer experiments suggest that the particles are loose and subject to movement. Although data on near surface winds are limited, measurements of 0.3 to 1.2 m/sec from the Venera lander and Pioneer-Venus probes appear to be well within the range required for sand and dust entrainment. Aeolian activity involves the interaction of the atmosphere, lithosphere, and loose particles. Thus, there is the potential for various physical and chemical weathering processes that can effect not only rates of erosion, but changes in the composition of all three components. The Venus Simulator is an apparatus used to simulate weathering under venusian conditions at full pressure (to 112 bars) and temperature (to 800 K). In one series of tests, the physical modifications of windblown particles and rock targets were assessed and it was shown that particles become abraded even when moved by gentle winds. However, little abrasion occurs on the target faces. Thus, compositional signatures for target rocks may be more indicative of the windblown particles than of the bedrock. From these and other considerations, aeolian modifications of the venusian surface may be expected to occur as weathering, erosion, transportation, and deposition of surficial materials. Depending upon global and local wind regimes, there may be distinctive sources and sinks of windblown materials. Radar imaging, especially as potentially supplied via the Magellan mission, may enable the identification of such areas on Venus.

Greeley, Ronald↗
NASA NTRS1992

Long-Lived Electrode For Arc Welding In Vacuum

Improved electrode for gas/tungsten arc welding in vacuum essentially hollow cylinder along which inert gas flows. Interior of cylinder provides large surface area for emission of electrons to form welding arc. Flow of pressurized inert gas inhibits vaporization of hot electrode material. Both features combine to reduce erosion of electrode. Electrode lasts considerably longer in vacuum than conventional electrode.

Weeks, Jack L.↗
NASA NTRS2002

HOTPC PMC Project Overview

A review of NASA GRCs Higher Operating Temperature Propulsion Components Project (HOTPC) on polymer matrix composites (PMCs) will be described. The summary includes research from NASA GRC in-house, university and industry's cooperative programs. Current research emphasis focuses on developing high temperature PMCs used in rapidly heated structures, erosion coatings for PMCs, nano-materials compatible with polyimide resins, and development of more durable high temperature PMCs.

Sutter, Jim↗
NASA NTRS1990

NASA GRC HOTPC PMC Project Overview

A review of NASA GRCs Higher Operating Temperature Propulsion Components Project (HOTPC) on polymer matrix composites (PMCs) will be described. The summary includes research from NASA GRC in-house, university and industry's cooperative programs. Current research emphasis focuses' on developing high temperature PMCs used in rapidly heated structures, erosion coatings for PMCs, nano-materials compatible with polyimide resins, and development of more durable high temperature PMCs.

Source record↗
NASA NTRS1985

Characterization of solid particle erosion resistance of ductile metals based on their properties

This paper presents experimental results pertaining to spherical glass bead and angular crushed glass particle impingement. A concept of energy absorption to explain the failure of material is proposed and is correlated with the erosion characteristics of several pure metals. Analyses of extensive erosion data indicate that the properties - surface energy, specific melting energy, strain energy, melting point, bulk modulus, hardness, atomic volume - and the product of the parameters - linear coefficient of thermal expansion x bulk modulus x temperature rise required for melting, and ultimate resilience x hardness - exhibit the best correlations. The properties of surface energy and atomic volume are suggested for the first time for correlation purposes and are found to correlate well with erosion rates at different angles of impingement. It further appears that both energy and thermal properties contribute to the total erosion.

Rao, P. V.↗
NASA NTRS1993

Space environmental effects on LDEF composites: A leading edge coated graphite epoxy panel

The electronics module cover for the leading edge (Row D 9) experiment M0003-8 was fabricated from T300 graphite/934 epoxy unidirectional prepreg tape in a (O(sub 2), +/- 45, O(sub 2), +/- 45, 90, 0)(sub s) layup. This 11.75 in x 16.75 in panel was covered with thermal control coatings in three of the four quadrants with the fourth quadrant uncoated. The composite panel experienced different thermal cycling extremes in each quadrant due to the different optical properties of the coatings and bare composite. The panel also experienced ultraviolet (UV) and atomic oxygen (AO) attack as well as micrometeoroid and space debris impacts. An AO reactivity of 0.99 x 10(exp -24) cm(sup 3)/atom was calculated for the bare composite based on thickness loss. The white urethane thermal control coatings (A276 and BMS 1060) prevented AO attack of the composite substrate. However, the black urethane thermal control coating (Z306) was severely eroded by AO, allowing some AO attack of the composite substrate. An interesting banding pattern on the AO eroded bare composite surface was investigated and found to match the dimensions of the graphite fiber tow widths as prepregged. Also, erosion depths were greater in the darker bands. Five micrometeoroid/space debris impacts were cross sectioned to investigate possible structural damage as well as impact/AO interactions. Local crushing and delaminations were found to some extent in all of the impacts. No signs of coating undercutting were observed despite the extensive AO erosion patterns seen in the exposed composite material at the impact sites. An extensive microcrack study was performed on the panel along with modeling of the thermal environment to estimate temperature extremes and thermal shock. The white coated composite substrate displayed almost no microcracking while the black coated and bare composite showed extensive microcracking. Significant AO erosion was seen in many of the cracks in the bare composite.

George, Pete E.↗
NASA NTRS2020

Toward an In-Depth Material Model for Cermet Nuclear Thermal Rocket Fuel Elements

The development and qualification of nuclear thermal propulsion (NTP) fuel element technologies would be aided by an in-depth model of material response and failure modes at operating conditions. Integrated computational materials engineering techniques have the potential to provide such a model, as demonstrated here through three case studies focused on a tungsten-uranium mononitride cermet fuel. The first case focuses on the erosion of tungsten (W, also named wolfram), a nominal coating/cladding material, in hot hydrogen. Ab initio techniques are used to calculate erosion rates and thermal expansion at NTP operating conditions. The second focuses on the stability of uranium mononitride (UN) fuels at high temperature and in the presence of hydrogen. Phase diagram techniques reveal potential instabilities and decomposition pathways at high hydrogen concentrations. The third focuses on using microstructure information to predict high temperature mechanical response and failure of tungsten, used in refractory cermet materials. Combined finite element and discrete dislocation dynamics techniques provide mechanical properties in agreement with experimental methods. The integration of these techniques for an all-encompassing material model is discussed.

cermet↗
NASA NTRS1993

Atomic oxygen interaction at defect sights in protective coatings on polymers flown on LDEF

Although the Long Duration Exposure Facility (LDEF) has exposed materials with a fixed orientation relative to the ambient low-Earth-orbital environment, arrival of atomic oxygen is angularly distributed as a result of the atomic oxygen's high temperature Maxwellian velocity distribution and the LDEF's orbital inclination. Thus, atomic oxygen entering defects in protective coatings on polymeric surfaces can cause wider undercut cavities than the size of the defect in the protective coating. Because only a small fraction of atomic oxygen reacts upon first impact with most polymeric materials, secondary reactions with lower energy thermally accommodated atomic oxygen can occur. The secondary reactions of scattered and/or thermally accommodated atomic oxygen also contribute to widening the undercut cavity beneath the protective coating defect. As the undercut cavity enlarges, exposing more polymer, the probability of atomic oxygen reacting with underlying polymeric material increases because of multiple opportunities for reaction. Thus, the effective atomic oxygen erosion yield for atoms entering defects increases above that of the unprotected material. Based on the results of analytical modeling and computational modeling, aluminized Kapton multilayer insulation exposed to atomic oxygen on row 9 lost the entire externally exposed layer of polyimide Kapton, yet based on the results of this investigation, the bottom surface aluminum film must have remained in place, but crazed. Atomic oxygen undercutting at defect sites in protective coatings on graphite epoxy composites indicates that between 40 to 100 percent of the atomic oxygen thermally accommodates upon impact, and that the reaction probability of thermally accommodated atomic oxygen may range from 7.7 x 10(exp -6) to 2.1 x 10(exp -3), depending upon the degree of thermal accommodation upon each impact.

Banks, Bruce A.↗
NASA NTRS1979

Evaluation of candidate metals in a simulated space shuttle main engine environment for application as turbine blade dampers

The high-pressure pumps for the space shuttle main engine are driven by combustion products which are 50 percent H2 and 50 percent H2O (by weight). The Haynes alloy 188, used in the dampers, experienced erosion. The erosion producing characteristics of wet H2 were evaluated using a controlled environment produced by a ballistic compressor. Four candidate materials were evaluated: H-188, A-286, Pt/Rh and Rh. Rh was clearly the most erosion resistant. Comparisons with AISI 4340 and Fe specimens of known uniformity indicate that metallurgical defects in the candidate materials are primary contributors to the higher than usual erosion.

Caveny, L. H.↗
NASA NTRS1999

Polymers Erosion and Contamination Experiment Being Developed

The Polymers Erosion and Contamination Experiment (PEACE) is currently being developed at the NASA Lewis Research Center by the Electro-Physics Branch in conjunction with students and faculty from Hathaway Brown School in Cleveland. The experiment is a Get Away Special Canister shuttle flight experiment sponsored by the American Chemical Society. The two goals of this experiment are (1) to measure ram atomic oxygen erosion rates of approximately 40 polymers that have potential use in space applications and (2) to validate a method for identifying sources of silicone contamination that occur in the shuttle bay. Equipment to be used in this flight experiment is shown in the schematic diagram. Spacecraft materials subjected to attack by atomic oxygen in the space environment experience significant degradation over the span of a typical mission. Therefore, learning the rates of atomic oxygen erosion of a wide variety of polymers would be of great benefit to future missions. PEACE will use two independent techniques to determine the atomic oxygen erosion rates of polymers. Large (1-in.-diameter) samples will be used for obtaining mass loss. Preflight and postflight dehydrated masses will be obtained, and the mass lost during flight will be determined. Small (0.5-in.-diameter) samples will be protected with isolated particles (such as NaCl crystals) and then exposed to the space environment. After flight, the protective particles will be removed (washed off) and atomic force microscopy (AFM) will be used to measure the erosion depth from protected mesas. Erosion depth measurements are more sensitive than traditional mass measurements and are very useful for materials with low erosion yields or with very low fluence missions.

deGroh, Kim K.↗