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At least 289 records · Page 16

Erosion and the gas turbine engine, part 2

Procedures for protecting aircraft engines from impact damage due to sand and dust particles are discussed. One system is to develop a filtration system to remove most of the solid particles. Another method is to design blade materials and blade protection coatings. The concepts of erosion within aircraft engines are explained. Curves are presented to show the effect of impingement angle on ductile and elastic modes of erosion. Engine sand and dust ingestion tests were conducted on T63-A-5A engines and the results are produced in graph form. The results of tests conducted in a dynamic erosion facility are analyzed.

Newhart, J. E.↗

Some practical examples of cavitation erosion and their prevention

The problem of failures caused by cavitation erosion are discussed. The concepts of intensity of erosion, erosion strength, and the time dependence of erosion rate are analyzed. The relation of these parameters to system variables such as pressure and velocity, and to the properties of materials are investigated. Using several examples of actual cavitation erosion, methods of prevention and their limitations are examined.

Conn, A. F.↗

Structural materials for space applications

The long-term performance of structural materials in the space environment is a key research activity within NASA. The primary concerns for materials in low Earth orbit (LEO) are atomic oxygen erosion and space debris impact. Atomic oxygen studies have included both laboratory exposures in atomic oxygen facilities and flight exposures using the Shuttle. Characterization of atomic oxygen interaction with materials has included surface recession rates, residual mechanical properties, optical property measurements, and surface analyses to establish chemical changes. The Long Duration Exposure Facility (LDEF) is scheduled to be retrieved in 1989 and is expected to provide a wealth of data on atomic oxygen erosion in space. Hypervelocity impact studies have been conducted to establish damage mechanisms and changes in mechanical properties. Samples from LDEF will be analyzed to determine the severity of space debris impact on coatings, films, and composites. Spacecraft placed in geosynchronous Earth orbit (GEO) will be subjected to high doses of ionizing radiation which for long term exposures will exceed the damage threshold of many polymeric materials. Radiation interaction with polymers can result in chain scission and/or cross-linking. The formation of low molecular weight products in the epoxy plasticize the matrix at elevated temperatures and embrittle the matrix at low temperatures. This affects both the matrix-dominated mechanical properties and the dimensional stability of the composite. Embrittlement of the matrix at low temperatures results in enhanced matrix microcracking during thermal cycling. Matrix microcracking changes the coefficient of thermal expansion (CTE) of composite laminates and produces permanent length changes. Residual stress calculations were performed to estimate the conditions necessary for microcrack development in unirradiated and irradiated composites. The effects of UV and electron exposure on the optical properties of transparent polymer films were also examined to establish the optimum chemical structure for good radiation resistance. Thoughts on approaches to establishing accelerated testing procedures are discussed.

Tenney, Darrel R.↗

The Electric Propulsion Interactions Code (EPIC)

Science Applications International Corporation is currently developing the Electric Propulsion Interactions Code, EPIC, as part of a project sponsored by the Space Environments and Effects Program at the NASA Marshall Space Flight Center. Now in its second year of development, EPIC is an interactive computer tool that allows the construction of a 3-D spacecraft model, and the assessment of a variety of interactions between its subsystems and the plume from an electric thruster. These interactions may include erosion of surfaces due to sputtering and re-deposition of sputtered materials, surface heating, torque on the spacecraft, and changes in surface properties due to erosion and deposition. This paper describes the overall capability of EPIC and provides an outline of the physics and algorithms that comprise many of its computational modules.

Mikellides, I. G.↗

Performance of thermal control tape in the protection of composite materials

The selection of materials for construction of long duration mission spacecraft has presented many challenges to the aerospace design community. After nearly six years in low earth orbit, NASA's Long duration Exposure Facility (LDEF), retrieved in January of 1990, has provided valuable information on both the nature of the space environment as well as the effects of the space environment on potential spacecraft materials. Composites, long a favorite of the design community because of a high strength-to-weight ratio, were flown in various configurations on LDEF in order to evaluate the effects of radiation, atomic oxygen, vacuum, micrometeoroid debris, and thermal variation on their performance. Fiberglass composite samples covered with an aluminum thermal control tape were flown as part of the flight experiment A0171, the Solar Array Materials Passive LDEF Experiment (SAMPLE). Visual observations and test results indicate that the thermal control tape suffered little degradation from the space exposure and proved to be a reliable source of protection from atomic oxygen erosion and UV radiation for the underlying composite material.

Kamenetzky, Rachel R.↗

Erosion, Transportation, and Deposition on Outer Solar System Satellites: Landform Evolution Modeling Studies

Mass movement and landform degradation reduces topographic relief by moving surface materials to a lower gravitational potential. In addition to the obvious role of gravity, abrasive mechanical erosion plays a role, often in combination with the lowering of cohesion, which allows disaggregation of the relief-forming material. The identification of specific landform types associated with mass movement and landform degradation provides information about local sediment particle size and abundance and transportation processes. Generally, mass movements can be classified in terms of the particle sizes of the transported material and the speed the material moved during transport. Most degradation on outer planet satellites appears consistent with sliding or slumping, impact erosion, and regolith evolution. Some satellites, such as Callisto and perhaps Hyperion and Iapetus, have an appearance that implies that some additional process is at work, most likely sublimation-driven landform modification and mass wasting. A variant on this process is thermally driven frost segregation as seen on all three icy Galilean satellites and perhaps elsewhere. Titan is unique among outer planet satellites in that Aeolian and fluvial processes also operate to erode, transport, and deposit material. We will evaluate the sequence and extent of various landform-modifying erosional and volatile redistribution processes that have shaped these icy satellites using a 3-D model that simulates the following surface and subsurface processes: 1) sublimation and re-condensation of volatiles; 2) development of refractory lag deposits; 3) disaggregation and downward sloughing of surficial material; 4) radiative heating/cooling of the surface (including reflection, emission, and shadowing by other surface elements); 5) thermal diffusion; and 6) vapor diffusion. The model will provide explicit simulations of landform development and thusly predicts the topographic and volatile evolution of the surface and final landscape form as constrained by DEMs. We have also simulated fluvial and lacustrine modification of icy satellites landscapes to evaluate the degree to which fluvial erosion of representative initial landscapes can replicate the present Titan landscape.

erosion↗

Overview of Results from the MISSE 9-15 Polymers and Composites Experiment 1-4 (PCE 1-4)

Spacecraft in low Earth orbit (LEO) and other planetary orbits are subjected to harsh environmental conditions that can result in erosion, embrittlement and optical property degradation of susceptible materials threatening spacecraft performance and durability. To increase our understanding of space environmental effects on spacecraft materials, NASA Glenn Research Center has developed a series of experiments flown as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). Four Glenn experiments with 365 flight samples were flown on ISS’s MISSE-Flight Facility (MISSE-FF). These experiments are the Polymers and Composites Experiment-1 (PCE-1) flown as part of the MISSE-9 mission, the PCE-2 flown as part of the MISSE-10 mission, the PCE-3 flown as part of the MISSE-12 and MISSE-15 missions, and the PCE-4 flown as part of the MISSE-13 mission. The PCE 1-4 flight samples were flown in either ram, wake, zenith or nadir flight orientations. The primary objectives of the PCE 1-4 experiments are to determine the LEO atomic oxygen (AO) erosion yield, Ey (volume loss per incident oxygen atom) and radiation durability of spacecraft polymers, composites and coatings. In addition, each experiment has a wide variety of materials with numerous sample objectives. This presentation provides an overview of the PCE 1-4 experiments, the numerous sample collaborators, the space environmental exposure of the flight samples, and an overview of the post-flight observations and results. The results include AO fluence and contamination analyses for each mission flight orientation, erosion data for the PCE 1-4 AO Ey samples, optical property data, and tensile results for the MISSE-9 and MISSE-13 tensile samples. In addition, an introduction of results from other unique samples such as indium tin oxide (ITO) coated thermal control samples, shape memory polymer composites, melanin based composites, and specialty coatings, will be provided.

Atomic oxygen↗

NASA Glenn/AADC Collaboration Optimized Erosion Coatings for Inlet Guide Vanes

There is a need for lightweight, durable materials and structures to reduce the weight of propulsion systems. Polymer matrix composites (PMC's) are promising materials for aerospace applications because of their high strength-to-weight ratio relative to metals. Unfortunately, they are limited to applications where they are not exposed to hightemperature oxidizing atmospheres and/or particulates from ingested air. This is because oxidation and erosion occur on the surface, leading to weight loss, nodulation, and/or cracking on the surface, and a consequent decline of mechanical properties over time. Although prior research has shown that oxidation can be slowed when metallic or ceramic coatings are applied onto PMC's, there remains a need for erosion-resistant coatings that protect PMC's from high-velocity particulates in the engine flow path. These erosionresistant coatings could extend the life of polymer composites. Polymer composites are heavily damaged without an erosion-resistant coating because they are not as hard as metallic engine structures. The effectiveness and life of the coatings depends on their inherent properties as well as on the interaction between the coating and the PMC. Since polymers, in general, have high thermal expansion coefficients in comparison to metals and ceramics, failure of the coatings often occurs at this interface. The objective of this research is to develop strategies to improve this interface and tailor overlays for erosion resistance. The bondcoat, which was developed at the NASA Glenn Research Center, is composed of zinc blended with polyimides to improve the compatibility between the PMC and the overlay material. Initial coating trials at AADC produced vanes that had poor bonding between the overlay and bondcoats. Subsequently, Glenn successfully demonstrated that high-quality plasma-sprayed erosion coating systems could be applied to these guide vanes. Inlet guide vanes from AE 3007 engines fiber composites were coated using a coating system composed of a bondcoat and a hard topcoat. Optimization of the plasma spray process has led to plans for future erosion testing in gas turbine engine environments.

Sutter, James K.↗

High Temperature Solid Particle Erosion in a Melt-Infiltrated SiC/SiC Ceramic Matrix Composite

Ceramic matrix composites (CMCs) are an enabling propulsion material system that offer weight benefits over current Ni-based superalloys, and have higher temperature capabilities that can reduce cooling requirements. Incorporating CMCs into the hot section of gas-turbine engines therefore leads to an increase in engine efficiency. While significant advancements have been made, challenges still remain for current and next-generation gas-turbines; particularly when operating in dust-laden or erosive environments. Solid particles entrained in the gas flow can impact engine hardware resulting in localized damage and material removal due to repeated, cumulative impacts. In this study, the erosion behavior of a melt-infiltrated (MI) silicon carbide fiber-reinforced silicon carbide (SiC/SiC) CMC is investigated at high temperature (1,200 °C) in a simulated combustion environment using 150 µm alumina particles as erodent. Particle impact velocities ranged from 100 to 200 m/s and the angle of impingement varied from 30° to 90°. Erosion testing was also performed on α-SiC to elucidate similarities and differences in the erosion response of the composite compared to that of a monolithic ceramic. Scanning electron microscopy (SEM) was used to study the post-erosion damage morphology and the governing mechanisms of material removal.

Ceramic matrix composites (CMCs), solid particle e↗

Heatshield Erosion Due to Dust Particle Impacts on the Schiaparelli Capsule During Martian Entry

One of the unique features of spacecraft entering the atmosphere of Mars is the possibility of a major dust storm occurring during the entry. Design of the thermal protection system (TPS) for Mars missions have to account for the possibility of dust erosion when estimating the thickness of the TPS. Because weight is always a critical factor in designing entry vehicles, accurate assessment of dust erosion is necessary to avoid over-design of the TPS.This study will present computational results of heatshield erosion due to dust particle impacts on the ExoMars Schiaparelli capsule if it had encountered a dust storm during its October 2016 entry. A one-way coupling approach is used where particle trajectories are computed based on an underlying CFD flow solution. Based on a distribution of particle sizes ranging from 1 to 18 microns in diameter, the Icarus material response solver predicted approximately 1 mm of TPS heatshield erosion due to particle impacts, which was 40% of the value due to material charring.

thermal protection system↗

New Active Optical Technique Developed for Measuring Low-Earth-Orbit Atomic Oxygen Erosion of Polymers

Polymers such as polyimide Kapton (DuPont) and Teflon FEP (DuPont, fluorinated ethylene propylene) are commonly used spacecraft materials because of desirable properties such as flexibility, low density, and in the case of FEP, a low solar absorptance and high thermal emittance. Polymers on the exterior of spacecraft in the low-Earth-orbit (LEO) environment are exposed to energetic atomic oxygen. Atomic oxygen reaction with polymers causes erosion, which is a threat to spacecraft performance and durability. It is, therefore, important to understand the atomic oxygen erosion yield E (the volume loss per incident oxygen atom) of polymers being considered in spacecraft design. The most common technique for determining E is a passive technique based on mass-loss measurements of samples exposed to LEO atomic oxygen during a space flight experiment. There are certain disadvantages to this technique. First, because it is passive, data are not obtained until after the flight is completed. Also, obtaining the preflight and postflight mass measurements is complicated by the fact that many polymers absorb water and, therefore, the mass change due to water absorption can affect the E data. This is particularly true for experiments that receive low atomic oxygen exposures or for samples that have a very low E. An active atomic oxygen erosion technique based on optical measurements has been developed that has certain advantages over the mass-loss technique. This in situ technique can simultaneously provide the erosion yield data on orbit and the atomic oxygen exposure fluence, which is needed for erosion yield determination. In the optical technique, either sunlight or artificial light can be used to measure the erosion of semitransparent or opaque polymers as a result of atomic oxygen attack. The technique is simple and adaptable to a rather wide range of polymers, providing that they have a sufficiently high optical absorption coefficient. If one covers a photodiode with a uniformly thick sheet of semitransparent polymer such as Kapton H polyimide, then as atomic oxygen erodes the polymer, the short-circuit current from the photodiode will increase in an exponential manner with fluence. This nonlinear response with fluence results in a lack of sensitivity for measuring low atomic oxygen fluences. However, if one uses a variable-thickness polymer or carbon sample, which is configured as shown in the preceding figure, then a linear response can be achieved for opaque materials using a parabolic well for a circular geometry detector or a V-shaped well for a rectangular-geometry detector. Variable-thickness samples can be fabricated using many thin polymer layers. For semitransparent polymers such as Kapton H polyimide, there is an initial short-circuit current that is greater than zero. This current has a slightly nonlinear dependence on atomic oxygen fluence in comparison to opaque materials such as black Kapton as shown in the graph. For this graph figure, the total thickness of Kapton H was assumed to be 0.03 cm. The photodiode short-circuit current shown in the graph was generated on the basis of preliminary measurements-a total reflectance rho of 0.0424 and an optical absorption coefficient a of 146.5 cm(sup -1). In addition to obtaining on-orbit data, the advantage of this active erosion and erosion yield measurement technique is its simplicity and reliance upon well-characterized fluence witness materials as well as a nearly linear photodiode short-circuit current dependence upon atomic oxygen fluence. The optical technique is useful for measuring either atomic oxygen fluence or erosion, depending on the information desired. To measure the atomic oxygen erosion yield of a test material, one would need to have two photodiode sensors, one for the test material and one that uses a known erosion yield material (such as Kapton) to measure the atomic oxygen fluence.

Banks, Bruce A.↗

Reusable Solid Rocket Motor Nozzle Joint-4 Thermal Analysis

This study provides for development and test verification of a thermal model used for prediction of joint heating environments, structural temperatures and seal erosions in the Space Shuttle Reusable Solid Rocket Motor (RSRM) Nozzle Joint-4. The heating environments are a result of rapid pressurization of the joint free volume assuming a leak path has occurred in the filler material used for assembly gap close out. Combustion gases flow along the leak path from nozzle environment to joint O-ring gland resulting in local heating to the metal housing and erosion of seal materials. Analysis of this condition was based on usage of the NASA Joint Pressurization Routine (JPR) for environment determination and the Systems Improved Numerical Differencing Analyzer (SINDA) for structural temperature prediction. Model generated temperatures, pressures and seal erosions are compared to hot fire test data for several different leak path situations. Investigated in the hot fire test program were nozzle joint-4 O-ring erosion sensitivities to leak path width in both open and confined joint geometries. Model predictions were in generally good agreement with the test data for the confined leak path cases. Worst case flight predictions are provided using the test-calibrated model. Analysis issues are discussed based on model calibration procedures.

Clayton, J. Louie↗

Studies of erosion of solar max samples of Kapton and Teflon

Several samples of Kapton and Teflon which was exposed to solar radiation were examined. The samples represent material behavior in near Earth space. Clues to the identity of erosive processes and the responsible species were searched for. Interest centered around oxygen atoms which are ubiquitous at these altitudes and are known to erode some metal surfaces. Three diagnostic methods were employed: optical microscopy, scanning electron microscopy, and fourier transform infrared spectroscopy. Two types of simulation were used: a flow containing low energy oxygen atoms and bombardment with 3000 volt Ar ions. Results and conclusions are presented.

Fristrom, R. M.↗

The NASA atomic oxygen effects test program

The NASA Atomic Oxygen Effects Test Program was established to compare the low earth orbital simulation characteristics of existing atomic oxygen test facilities and utilize the collective data from a multitude of simulation facilities to promote understanding of mechanisms and erosion yield dependence upon energy, flux, metastables, charge, and environmental species. Four materials chosen for this evaluation include Kapton HN polyimide, FEP Teflon, polyethylene, and graphite single crystals. The conditions and results of atomic oxygen exposure of these materials is reported by the participating organizations and then assembled to identify degrees of dependency of erosion yields that may not be observable from any single atomic oxygen low earth orbital simulation facility. To date, the program includes 30 test facilities. Characteristics of the participating test facilities and results to date are reported.

Banks, Bruce A.↗

Assessment of tbe Performance of Ablative Insulators Under Realistic Solid Rocket Motor Operating Conditions (a Doctoral Dissertation)

Ablative insulators are used in the interior surfaces of solid rocket motors to prevent the mechanical structure of the rocket from failing due to intense heating by the high-temperature solid-propellant combustion products. The complexity of the ablation process underscores the need for ablative material response data procured from a realistic solid rocket motor environment, where all of the potential contributions to material degradation are present and in their appropriate proportions. For this purpose, the present study examines ablative material behavior in a laboratory-scale solid rocket motor. The test apparatus includes a planar, two-dimensional flow channel in which flat ablative material samples are installed downstream of an aluminized solid propellant grain and imaged via real-time X-ray radiography. In this way, the in-situ transient thermal response of an ablator to all of the thermal, chemical, and mechanical erosion mechanisms present in a solid rocket environment can be observed and recorded. The ablative material is instrumented with multiple micro-thermocouples, so that in-depth temperature histories are known. Both total heat flux and thermal radiation flux gauges have been designed, fabricated, and tested to characterize the thermal environment to which the ablative material samples are exposed. These tests not only allow different ablative materials to be compared in a realistic solid rocket motor environment but also improve the understanding of the mechanisms that influence the erosion behavior of a given ablative material.

Martin, Heath Thomas↗

Erosion Results of the MISSE 9-15 Polymers and Composites Experiment 1-4 (PCE 1-4)

Polymers and other oxidizable materials on the exterior of spacecraft in the low Earth orbit (LEO) space environment can be eroded from reaction with atomic oxygen (AO). Therefore, in order to design durable spacecraft it is important to know the extent of erosion that will occur during a mission. This can be determined by knowing the LEO AO erosion yield, E y (volume loss per incident oxygen atom), of materials susceptible to AO reaction. In addition, recent flight experiments have shown that the AO E y can vary with the AO fluence and/or solar exposure. Therefore, obtaining AO E y data for materials flown on various spaceflight missions is important. NASA Glenn Research Center has flown numerous experiments as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS) to characterize the LEO E y of polymers, composites, protective coatings, and other spacecraft materials. Recently, four Glenn experiments with 365 flight (F) samples were flown on ISS’s MISSE-Flight Facility (MISSE-FF). These experiments are the Polymers and Composites Experiment-1 (PCE-1) flown as part of the MISSE-9 mission, the PCE-2 flown as part of the MISSE-10 mission, the PCE-3 flown as part of the MISSE-12 and MISSE-15 missions, and the PCE-4 flown as part of the MISSE-13 mission. Although each experiment had numerous sample objectives, the primary objective was to determine the LEO AO E y of various spacecraft materials as a function of solar irradiation and AO fluence. This paper provides a summary of the erosion data for the PCE 1-4 AO E y samples. The AO E y for 150 samples flown in either the LEO ram, wake, zenith or nadir directions are provided. The AO ram fluence varied from 2.97×10 20 atoms/cm 2 after 0.89 years of direct space exposure (with relatively high levels of Si contamination) on MISSE 12 to 3.93×10 20 atoms/cm 2 after 1.17 years of direct space exposure on MISSE-10. The ram AO E y values for uncoated polymers range from 3.81×10 –25 cm 3 /atom for polytetrafluoroethylene (M9R-C20 F) exposed to an AO fluence of 3.44×10 20 atoms/cm 2 on MISSE-9 to 4.43×10 –23 cm 3 /atom for AO etched low density polyimide aerogel (M12R-C21 F) exposed to an AO fluence of 2.97×10 21 atoms/cm 2 on MISSE-12. Because of the low AO fluence and relatively high Si contamination, a number of PCE-3 wake samples experienced mass gain. Thus, AO E y values are not provided for these samples. Although there are calculated AO E y values for the zenith, wake and nadir samples, the ram AO E y for a particular material is a more reliable value in terms of AO exposure because the zenith, wake and nadir directions were exposed to either no or very little AO fluence and thus other space environmental factors (i.e. vacuum, thermal extremes and thermal cycling, and/or various types of radiation) are responsible for the mass loss.

Erosion yield↗

Rocketdyne's advanced coal slurry pumping program

The Rocketdyne Division of Rockwell International Corporation is conducting a program for the engineering, fabrication, and testing of an experimental/prototype high-capacity, high-pressure centrifugal slurry feed pump for coal liquefaction purposes. The abrasion problems in a centrifugal slurry pump are primarily due to the manner in which the hard, solid particles contained in the slurry are transported through the hydraulic flow passages within the pump. The abrasive particles can create scraping, grinding, cutting, and sandblasting effects on the various exposed parts of the pump. These critical areas involving abrasion and impact erosion wear problems in a centrifugal pump are being addressed by Rocketdyne. The mechanisms of abrasion and erosion are being studied through hydrodynamic analysis, materials evaluation, and advanced design concepts.

Davis, D. E.↗