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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Advances in Solid State Joining of Haynes 230 High Temperature Alloy

The J-2X engine is being designed for NASA s new class of crew and launch vehicles, the Ares I and Ares V. The J-2X is a LOX/Hydrogen upper stage engine with 294,000 lbs of thrust and a minimum Isp of 448 seconds. As part of the design criteria to meet the performance requirements a large film-cooled nozzle extension is being designed to further expand the hot gases and increases the specific impulse. The nozzle extension is designed using Haynes 230, a nickel-chromium-tungsten-molybdenum superalloy. The alloy was selected for its high strength at elevated temperatures and resistance to hydrogen embrittlement. The nozzle extension is manufactured from Haynes 230 plate spun-forged to form the contour and chemically-milled pockets for weight reduction. Currently fusion welding is being evaluated for joining the panels which are then mechanically etched and thinned to required dimensions for the nozzle extension blank. This blank is then spun formed into the parabolic geometry required for the nozzle. After forming the nozzle extension, weight reduction pockets are chemically milled into the nozzle. Fusion welding of Haynes results in columnar grains which are prone to hot cracking during forming processes. This restricts the ability to use spin forging to produce the nozzle contour. Solid state joining processes are being pursued as an alternative process to produce a structure more amenable to spin forming. Solid state processes have been shown to produce a refined grain structure within the joint regions as illustrated in Figure 1. Solid state joining processes include friction stir welding (FSW) and a patented modification termed thermal stir welding (TSW). The configuration of TSWing utilizes an induction coil to preheat the material minimizing the burden on the weld tool extending its life. This provides the ability to precisely select and control the temperature. The work presented in this presentation investigates the feasibility of joining the Haynes 230 alloy using the solid state welding processes of FSW and TSW. Process descriptions and attributes of each weld process will be presented. Weld process set-up and welding techniques will be discussed leading to the challenges experienced in joining the superalloy. Mechanical property data will also be presented.

Ding, R. Jeffrey↗
NASA NTRS1987

Advanced nickel-cadmium batteries for geosynchronous spacecraft

A nickel cadmium battery was developed that can be operated at 80 percent depth of discharge in excess of 10 years in a geosynchronous orbit application, and has about a 30 percent weight savings per spacecraft over present nickel cadmium batteries when used with a 1000 watts eclipse load. The approach used in the development was to replace nylon separators with inert polymer impregnated zirconia, use electrochemically deposited plates in place of conventional chemically precipitated ones, and use an additive to extend negative plate lifetime. The design has undergone extensive testing using both engineering and protoflight cell configurations.

Pickett, David F.↗
NASA NTRS2002

Generalized Reliability Methodology Applied to Brittle Anisotropic Single Crystals

A generalized reliability model was developed for use in the design of structural components made from brittle, homogeneous anisotropic materials such as single crystals. The model is based on the Weibull distribution and incorporates a variable strength distribution and any equivalent stress failure criteria. In addition to the reliability model, an energy based failure criterion for elastically anisotropic materials was formulated. The model is different from typical Weibull-based models in that it accounts for strength anisotropy arising from fracture toughness anisotropy and thereby allows for strength and reliability predictions of brittle, anisotropic single crystals subjected to multiaxial stresses. The model is also applicable to elastically isotropic materials exhibiting strength anisotropy due to an anisotropic distribution of flaws. In order to develop and experimentally verify the model, the uniaxial and biaxial strengths of a single crystal nickel aluminide were measured. The uniaxial strengths of the <100> and <110> crystal directions were measured in three and four-point flexure. The biaxial strength was measured by subjecting <100> plates to a uniform pressure in a test apparatus that was developed and experimentally verified. The biaxial strengths of the single crystal plates were estimated by extending and verifying the displacement solution for a circular, anisotropic plate to the case of a variable radius and thickness. The best correlation between the experimental strength data and the model predictions occurred when an anisotropic stress analysis was combined with the normal stress criterion and the strength parameters associated with the <110> crystal direction.

Salem, Jonathan A.↗
NASA NTRS1972

NiCd battery electrodes

The objective of this research program was to develop and evaluate electrodes for a negative limited nickel-cadmium cell and to prove its feasibility. The program consisted of three phases: (1) the development of cadmium electrodes with high hydrogen overvoltage characteristics, (2) the testing of positive and negative plates, and (3) the fabrication and testing of complete negative limited NiCd cells. The following electrode structures were manufactured and their physical and electrochemical characteristics were evaluated: (1) silver sinter-based Cd electrodes, (2) Teflon-bonded Cd electrodes, (3) electrodeposited Cd sponge, and (4) Cd-sinter structures. All cadmium electrode structures showed a sharp increase in potential at the end of charge, with the advent of hydrogen evolution occurring at approximately -1.3 V versus Hg/HgO. The hydrogen advent potentials on pure cadmium structures were 50 to 70 mV more cathodic than those of their silver-containing counterparts.

Holleck, G.↗
NASA NTRS1984

Special Test Methods for Batteries

Various methods are described for measuring heat generation in primary and secondary batteries as well as the specific heat of batteries and cell thermal conductance. Problems associated with determining heat generation in large batteries are examined. Special attention is given to monitoring temperature gradients in nickel cadmium cells, the use of auxiliary electrodes for conducting tests on battery charge control, evaluating the linear sweep of current from charge to discharge, and determining zero current voltage. The fast transient behavior of batteries in the microsecond range, and the electrical conductance of nickel sinters in the thickness direction are also considered. Mechanical problems experienced in the vibration of Ni-Cd batteries and tests to simulate cyclic fatigue of the steel table connecting the plates to the comb are considered. Methods of defining the distribution of forces when cells are compressed during battery packaging are also explored.

Gross, S.↗
NASA NTRS1987

Punching Holes in Thin Metals

Simple punching tool used to make holes in thin metal sheets, without burrs and edge deformations. Tool used on such materials as stainless steel, nickel alloys, beryllium, copper, and aluminum, in thicknesses of 0.002 to 0.010 in. With new punch, hole size held to tolerance of 0.025 mm. Includes rubber punch extruding into hole in top plate, pushing out exposed portion of clamped metal sheet.

Garcia, Richard↗
NASA NTRS1979

Electrodeposition applications for the Space Shuttle Main Engine

Electrodeposition processes play a key role in the fabrication and in-service performance of the Space Shuttle Main Engine. Applications range from the electroforming of the main combustion chamber to the deposition of high-purity copper or gold for hydrogen embrittlement protection of susceptible materials of construction, or nickel for mechanical protection of foam insulated propellant ducts. Techniques for controlling electrolyte purity, verification of deposit integrity, and deposit profile and thickness are reported. The use of in-situ techniques (cell-plating) for localized plating and repair of damaged substrate materials are summarized.

Otousa, J. E.↗
NASA NTRS1975

Flat-plate solar-collector performance evaluation with a solar simulator as a basis for collector selection and performance prediction

This paper reports the measured thermal efficiency and evaluation of 23 collectors which differ according to absorber material (copper, aluminum, steel), absorber coating (nonselective black paint, selective copper oxide, selective black nickel, selective black chrome), type of glazing material (glass, Tedlar, Lexan, anti-reflection glass), the use of honeycomb material and the use of vacuum to prevent thermal convection losses. The collectors are given performance rankings based on noon-hour solar conditions and all-day solar conditions. The determination with the simulator of an all-day collector performance is made possible by tests at different incident angles. The solar performance rankings are made based on whether the collector is to be used for pool heating, hot water, absorption air conditioning, heating, or for a solar Rankine machine.

Simon, F. F.↗
NASA NTRS1981

Initial capacity conditioning on electrochemical nickel hydroxide electrodes

Conditioning is the initial cycling where cell capacity is usually unstable. The causes of the initial capacity build were examined. Gridless electrodes were fabricated to ensure mechanical homogeneity, so that a strain measured in one direction would be typical of a strain measured in the other directions. Plate hardness was also determined. These two parameters stabilize together.

Fritts, D. H.↗
NASA NTRS2001

Effect of Handling, Storage and Cycling on Ni-H2 Cells: Second Plateau Phenomenon

Proper handling of Ni-H2 cells/batteries in storage, during I&T, and at launch site is very important to preserve the useful energy and to extend the mission life. Cell reversal test is not a prudent test to verify or quantify the nickel pre-charge in Ni-H2 cells/batteries. The second plateau is due to the formation of Ni(+3) that is electrochemically inactive. Gas analysis of the cell, and chemical analysis of the positive plate are confirmatory tests to determine the nature of pre-charge in Ni-H2 cells.

Vaidyanathan, Hari↗
NASA NTRS1973

Large area focusing collector for the observation of cosmic X rays.

A large area focusing X-ray collector constructed for a sounding rocket is described. The instrument consists of nested reflecting plates that are curved slightly in one dimension to form a set of parabolas with a common focus. An array of plates such as the one in the sounding rocket focuses a parallel beam of X-rays to a line. The reflecting surfaces are commercial float glass with an evaporated metallic coating such as gold or nickel. With a gold coating, the effective area of the rocket collector is about 250 sq cm for 0.3 keV X rays and about 150 sq cm at 1.2 keV. Its angular resolution is a few arc minutes and field of view is about plus or minus .75 deg (full width at half maximum). The collector performed successfully during a sounding rocket flight.

Gorenstein, P.↗
NASA NTRS1975

Survey of coatings for solar collectors

Optimum solar selective properties of black chrome require some tailoring of current and time for plating solution being used. Black zinc is produced from high zinc electroplate by subsequent conversion with chromate dip. Measurements have also been made of reflectance of previously known solar selective coatings of black copper and electroplated black nickel.

Mcdonald, G. E.↗
NASA NTRS1983

Gamma prime shape changes during creep of a nickel-base superalloy

Changes in the shape of the gamma-prime phase in the single-crystal nickel base alloy NASAIR 100 during tensile and compressive creep have been investigated experimentally by Laue X-ray diffractometry. It is found that under tensile loading, gamma-prime changes from the initial cubic shape to plates perpendicular to the applied stress. This change occurs during primary creep at 1000 C, 148 MPa. Prolonged creep exposures result in a thickening of the gamma-prime plates that is similar to Ostwald ripening often observed in other superalloys during creep. Under compressive loading, two sets of gamma-prime plates parallel to the applied stress are formed.

Nathal, M. V.↗
NASA NTRS1987

Statistically determined nickel cadmium performance relationships

A statistical analysis was performed on sealed nickel cadmium cell manufacturing data and cell matching data. The cells subjected to the analysis were 30 Ah sealed Ni/Cd cells, made by General Electric. A total of 213 data parameters was investigated, including such information as plate thickness, amount of electrolyte added, weight of active material, positive and negative capacity, and charge-discharge behavior. Statistical analyses were made to determine possible correlations between test events. The data show many departures from normal distribution. Product consistency from one lot to another is an important attribute for aerospace applications. It is clear from these examples that there are some significant differences between lots. Statistical analyses are seen to be an excellent way to spot those differences. Also, it is now proven beyond doubt that battery testing is one of the leading causes of statistics.

Gross, Sidney↗
NASA NTRS1993

The influence of primary and secondary orientations on the elastic response of a nickel-base single-crystal superalloy

The influence of primary orientation on the elastic response of a (001)-oriented nickel-base single-crystal superalloy, PWA 1480, was investigated under mechanical, thermal, and combined thermal and mechanical loading conditions using finite element techniques. Elastic stress analyses were performed using the MARC finite element code on a square plate of PWA 1480 material. Primary orientation of the single crystal superalloy was varied in increments of 2 deg, from 0 to 10 deg, from the (001) direction. Two secondary orientations (0 and 45 deg) were considered, with respect to the global coordinate system, as the primary orientation angle was varied. The stresses developed within the single crystal plate were determined for each loading condition. In this paper, the influence of the angular offset between the primary crystal orientation and the loading direction on the elastic stress response of the PWA 1480 plate is presented for different loading conditions. The influence of primary orientation angle, when constrained between the bounds considered, was not found to be as significant as the influence of the secondary orientation angle, which is not typically controlled.

Abdul-Aziz, Ali↗
NASA NTRS1974

Status of the NASA-Lewis flat-plate collector tests with a solar simulator

Simulator test results of 15 collector types are presented. Collectors are given performance ratings according to their use for pool heating, hot water, absorption A/C or heating, and solar Rankine machines. Collectors found to be good performers in the above categories, except for pool heating, were a black nickel coated, 2 glass collector, and a black paint 2 glass collector containing a mylar honeycomb. For pool heating, a black paint, one glass collector was found to be the best performer. Collector performance parameters of 5 collector types were determined to aid in explaining the factors that govern performance. The two factors that had the greatest effect on collector performance were the collector heat loss and the coating absorptivity.

Simon, F. F.↗
NASA NTRS1974

Status of the NASA-Lewis flat-plate collector tests with a solar simulator

Simulator test results of 15 collector types are reported. Collectors are given performance ratings according to their use for pool heating, hot water, absorption A/C or heating and solar Rankine machines. Collectors found to be good performers in the above categories, except for pool heating, were a black nickel coated, 2 glass collector, and a black paint 2 glass collector containing a mylar honeycomb. For pool heating, a black paint, one glass collector was found to be the best performer. Collector performance parameters of 5 collector types were determined to aid in explaining the factors that govern performance. The two factors that had the greatest effect on collector performance were the collector heat loss and the coating absorptivity.

Simon, F. F.↗