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At least 307 records · Page 17

Preliminary Analysis for an Optimized Oil-Free Rotorcraft Engine Concept

Recent developments in gas foil bearing technology have led to numerous advanced high-speed rotating system concepts, many of which have become either commercial products or experimental test articles. Examples include Oil-Free microturbines, motors, generators and turbochargers. The driving forces for integrating gas foil bearings into these high-speed systems are the benefits promised by removing the oil lubrication system. Elimination of the oil system leads to reduced emissions, increased reliability, and decreased maintenance costs. Another benefit is reduced power plant weight. For rotorcraft applications, this would be a major advantage, as every pound removed from the propulsion system results in a payload benefit. Implementing foil gas bearings throughout a rotorcraft gas turbine engine is an important long-term goal that requires overcoming numerous technological hurdles. Adequate thrust bearing load capacity and potentially large gearbox applied radial loads are among them. However, by replacing the turbine end, or hot section, rolling element bearing with a gas foil bearing many of the above benefits can be realized. To this end, engine manufacturers are beginning to explore the possibilities of hot section gas foil bearings in propulsion engines. This paper presents a logical follow-on activity by analyzing a conceptual rotorcraft engine to determine the feasibility of a foil bearing supported core. Using a combination of rotordynamic analyses and a load capacity model, it is shown to be reasonable to consider a gas foil bearing core section.

Howard, Samuel A.↗

Doppler-shifted reflections of X rays in beamfoil spectroscopy

Carbon foils were positioned at roughly 10 deg to the conventional perpendicular position so that the spectrometer would view the beam on emergence from the foil, with no radiation shielded by a bowed or wrinkled foil or by the foil holder. Extraneous peaks due to reflected radiation were detected in the spectrum obtained with the tilted foil. A large satellite appears longward of the spectral line and is attributed to Doppler-shifted radiation reflected from the foil surface. Special tests arranged to validate the origin of the satellites are described. The relative intensity of the reflected radiation compared with the direct radiation observed is at variance with the relative intensities reported for longer wavelengths. The reasons for this, possible effects of spectrometer geometry, and applications in the investigation or generation of polarization remain to be investigated

Bernstein, E. M.↗

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimeter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, C. C.↗

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimenter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, Ching-Cheh↗

Analysis of LDEF experiment AO187-2 chemical and isotopic measurements of micrometeoroids by secondary ion mass spectrometry

#Experiment AO187-2, that was flown on board the Long Duration Exposure Facility(LDEF), was designed to measure the chemical and isotopic compositions of interplanetary dust impinging on the spacecraft from outer space. Information on the nature and composition of orbital debris was also anticipated. The spacecraft maintained a constant orientation with respect to its velocity vector thereby defining leading and trailing edges that faced respectively into and away from the direction of motion. Arrays of individual capture cells each 80.8 sq cm in size and totaling 237 in number were exposed on both the leading and trailing edges of LDEF. Each cell consisted of a pure Ge target surface slightly separated from a thin (2.5 micrometers) metallized plastic 'entrance foil.' The basic concept was that incoming projectiles would penetrate the foil, strike the Ge target plate at high velocity producing a vapor-liquid cloud that would re-deposit material on the underside of the plastic foil. This material would then be analyzed using the sensitive surface analysis technique of Secondary Ion Mass Spectrometry (SIMS). In practice, most of the plastic entrance foils failed during the extended period of orbital exposure probably due to a combination of UV embrittlement, large densities of impact events and (for the leading edge) the effects of atomic oxygen erosion in orbit. However the foils failed gradually and most remained in place on the capture cells for a significant fraction of the duration of the flight . Because most of the impactors were small (less than 10 micrometers) they were heated and dispersed in traversing the entrance foils producing clouds of molten droplets and vapor that produced easily identifiable 'extended impacts' on the Ge target plates. Fortunately, it proved possible to make ion probe measurements of projectile compositions from material deposited on the Ge in the extended impact structures.

Zinner, Ernst↗

Remaining Technical Challenges and Future Plans for Oil-Free Turbomachinery

The application of Oil-Free technologies (foil gas bearings, solid lubricants and advanced analysis and predictive modeling tools) to advanced turbomachinery has been underway for several decades. During that time, full commercialization has occurred in aircraft air cycle machines, turbocompressors and cryocoolers and ever-larger microturbines. Emerging products in the automotive sector (turbochargers and superchargers) indicate that high volume serial production of foil bearings is imminent. Demonstration of foil bearings in APU s and select locations in propulsion gas turbines illustrates that such technology also has a place in these future systems. Foil bearing designs, predictive tools and advanced solid lubricants have been reported that can satisfy anticipated requirements but a major question remains regarding the scalability of foil bearings to ever larger sizes to support heavier rotors. In this paper, the technological history, primary physics, engineering practicalities and existing experimental and experiential database for scaling foil bearings are reviewed and the major remaining technical challenges are identified.

DellaCorte, Christopher↗

The measurement of radiation exposure of astronauts by radiochemical techniques

Gamma analyses of the neutron-activated fecal samples from the Apollo 12 and 13 missions were completed, and the data are being evaluated. Samples of the exposed Apollo 12 solar wind composition foil and blank foils were obtained for analysis of the Po-2/0 (Pb-210, Rn-222) content. It is expected that the determination of the Po-210 content of these foils will yield the concentration of radon atoms incident on the foil while exposed to the lunar atmosphere, and this indirectly will permit an estimate of the average uranium concentration of the lunar surface. Proposals to measure the cosmic-ray intensity and energy spectra inside and outside of late Apollo and Project Skylab spacecraft by exposing and subsequently analyzing pure metal foils, and to measure the elemental mass balance in Project Skylab astronauts by instrumental neutron activation analysis of the intake and excreta are summarized.

Brodzinski, R. L.↗

Method of making porous conductive supports for electrodes

Porous conductive supports for electrochemical cell electrodes are made by electroforming thin corrugated nickel foil, and by stacking pieces of the corrugated foil alternatively with pieces of thin flat nickel foil. Corrugations in successive corrugated pieces are oriented at different angles. Adjacent pieces of foil are bonded by heating in a hydrogen atmosphere and then cutting the stack in planes perpendicular to the foils.

Schaer, G. R.↗

Magnetospheric particle composition experiment

Thin foils of aluminum and platinum were mounted on the exterior of the Skylab spacecraft where they were bombarded by particles that penetrate to the 400-km spacecraft altitude, including auroral particles precipitating from the earth magnetosphere. These foils have a high trapping efficiency for both charged and neutral particles above 1 keV and a decreasing but appreciable efficiency below that energy. Some sections of the foils were double layered to obtain an estimate of the energy of the entrapped particles. The foils were retrieved and returned for analysis in an ultrahigh-vacuum mass spectrometer. So far, the noble gas components of the entrapped particles have been analyzed in selected sections of two foils. Helium-4, helium-3, neon-20, and neon-22 have been detected.

Geiss, J.↗

Analytical study of graphite-epoxy tube response to thermal loads

The thermally-induced stresses and deformations in graphite-epoxy tubes with aluminum foil bonded to both inner and outer surfaces, and to the outer surface only are computed. Tubes fabricated from three material systems, T300/934, P75s/934, and P75s/BP907, and having a 1 inch inner radius and a lamination sequence of (+15/0 + or - 10/0)sub s are studied. Radial, axial, and circumferential stresses in the various layers of the tube, in the foil, and in the adhesive bonding the foil to the tubes are computed using an elasticity solution. The results indicate that the coatings have no detrimental effect on the stress state in the tube, particularly those stresses that lead to microcracking. The addition of the aluminum foil does, however, significantly influence the axial expansion of the T300/934 tube, the tube with the softer graphite fibers. The addition of foil can change the sign of the axial coefficient of thermal expansion. Twist tendencies of the tubes are only slightly affected by the addition of the coatings, but are of second order compared to the axial response.

Knott, Tamara W.↗

Automated Composites Processing Technology: Film Module

NASA's Marshall Space Flight Center (MSFC) has developed a technology that combines a film/adhesive laydown module with fiber placement technology to enable the processing of composite prepreg tow/tape and films, foils or adhesives on the same placement machine. The development of this technology grew out of NASA's need for lightweight, permeation-resistant cryogenic propellant tanks. Autoclave processing of high performance composites results in thermally-induced stresses due to differences in the coefficients of thermal expansion of the fiber and matrix resin components. These stresses, together with the reduction in temperature due to cryogen storage, tend to initiate microcracking within the composite tank wall. One way in which to mitigate this problem is to introduce a thin, crack-resistant polymer film or foil into the tank wall. Investigation into methods to automate the processing of thin film or foil materials into composites led to the development of this technology. The concept employs an automated film supply and feed module that may be designed to fit existing fiber placement machines, or may be designed as integral equipment to new machines. This patent-pending technology can be designed such that both film and foil materials may be processed simultaneously, leading to a decrease in part build cycle time. The module may be designed having a compaction device independent of the host machine, or may utilize the host machine's compactor. The film module functions are controlled by a dedicated system independent of the fiber placement machine controls. The film, foil, or adhesive is processed via pre-existing placement machine run programs, further reducing operational expense.

Hulcher, A. Bruce↗

Liquid Oxygen Rotating Friction Ignition Testing of Aluminum and Titanium with Monel and Inconel for Rocket Engine Propulsion System Contamination Investigation

Metallic contaminant was found in the liquid oxygen (LOX) pre-valve screen of the shuttle main engine propulsion system on two orbiter vehicles. To investigate the potential for an ignition, NASA Johnson Space Center White Sands Test Facility performed (modified) rotating friction ignition testing in LOX. This testing simulated a contaminant particle in the low-pressure oxygen turbo pump (LPOTP) and the high-pressure oxygen turbo pump (HPOTP) of the shuttle main propulsion system. Monel(R) K-500 and Inconel(R) 718 samples represented the LPOTP and HPOTP materials. Aluminum foil tape and titanium foil represented the contaminant particles. In both the Monel(R) and Inconel(R) material configurations, the aluminum foil tape samples did not ignite after 30 s of rubbing. In contrast, all of the titanium foil samples ignited regardless of the rubbing duration or material configuration. However, the titanium foil ignitions did not propagate to the Monel and Inconel materials.

Peralta, S.↗

Method of Suppressing Sublimation in Advanced Thermoelectric Devices

A method of applying a physical barrier to suppress thermal decomposition near a surface of a thermoelectric material including applying a continuous metal foil to a predetermined portion of the surface of the thermoelectric material, physically binding the continuous metal foil to the surface of the thermoelectric material using a binding member, and heating in a predetermined atmosphere the applied and physically bound continuous metal foil and the thermoelectric material to a sufficient temperature in order to promote bonding between the continuous metal foil and the surface of the thermoelectric material. The continuous metal foil forms a physical barrier to enclose a predetermined portion of the surface. Thermal decomposition is suppressed at the surface of the thermoelectric material enclosed by the physical barrier when the thermoelectric element is in operation.

Sakamoto, Jeffrey S.↗

Advancements Toward Oil-Free Rotorcraft Propulsion

NASA and the Army have been working for over a decade to advance the state-of-the-art (SOA) in Oil-Free Turbomachinery with an eye toward reduced emissions and maintenance, and increased performance and efficiency among other benefits. Oil-Free Turbomachinery is enabled by oil-free gas foil bearing technology and relatively new high-temperature tribological coatings. Rotorcraft propulsion is a likely candidate to apply oil-free bearing technology because the engine size class matches current SOA for foil bearings and because foil bearings offer the opportunity for higher speeds and temperatures and lower weight, all critical issues for rotorcraft engines. This paper describes an effort to demonstrate gas foil journal bearing use in the hot section of a full-scale helicopter engine core. A production engine hot-core location is selected as the candidate foil bearing application. Rotordynamic feasibility, bearing sizing, and load capability are assessed. The results of the program will help guide future analysis and design in this area by documenting the steps required and the process utilized for successful application of oil-free technology to a full-scale engine.

Howard, Samuel A.↗

Composite Aerogel Multifoil Protective Shielding

New technologies are needed to survive the temperatures, radiation, and hypervelocity particles that exploration spacecraft encounter. Multilayer insulations (MLIs) have been used on many spacecraft as thermal insulation. Other materials and composites have been used as micrometeorite shielding or radiation shielding. However, no material composite has been developed and employed as a combined thermal insulation, micrometeorite, and radiation shielding. By replacing the scrims that have been used to separate the foil layers in MLIs with various aerogels, and by using a variety of different metal foils, the overall protective performance of MLIs can be greatly expanded to act as thermal insulation, radiation shielding, and hypervelocity particle shielding. Aerogels are highly porous, low-density solids that are produced by the gelation of metal alkoxides and supercritical drying. Aerogels have been flown in NASA missions as a hypervelocity particle capture medium (Stardust) and as thermal insulation (2003 MER). Composite aerogel multifoil protective shielding would be used to provide thermal insulation, while also shielding spacecraft or components from radiation and hypervelocity particle impacts. Multiple layers of foil separated by aerogel would act as a thermal barrier by preventing the transport of heat energy through the composite. The silica aerogel would act as a convective and conductive thermal barrier, while the titania powder and metal foils would absorb and reflect the radiative heat. It would also capture small hypervelocity particles, such as micrometeorites, since it would be a stuffed, multi-shock Whipple shield. The metal foil layers would slow and break up the impacting particles, while the aerogel layers would convert the kinetic energy of the particles to thermal and mechanical energy and stop the particles.

Jones, Steven M.↗

Coordinated Microanalyses of Seven Particles of Probable Interstellar Origin from the Stardust Mission

Stardust, a NASA Discovery-class mission, was the first sample-return mission to return solid samples from beyond the Moon. Stardust was effectively two missions in one spacecraft: it returned the first materials from a known primitive solar system body, the Jupiter-family comet Wild 2; Stardust also returned a collector that was exposed to the contemporary interstellar dust stream for 200 days during the interplanetary cruise. Both collections present severe technical challenges in sample preparation and in analysis. By far the largest collection is the cometary one: approximately 300 micro g of material was returned from Wild 2, mostly consisting of approx. 1 ng particles embedded in aerogel or captured as residues in craters on aluminum foils. Because of their relatively large size, identification of the impacts of cometary particles in the collection media is straightforward. Reliable techniques have been developed for the extraction of these particles from aerogel. Coordinated analyses are also relatively straightforward, often beginning with synchrotron-based x-ray fluorescence (S-XRF), X-ray Absorption Near-Edge Spectoscopy (XANES) and x-ray diffraction (S-XRD) analyses of particles while still embedded in small extracted wedges of aerogel called ``keystones'', followed by ultramicrotomy and TEM, Scanning Transmission X-ray Microscopy (STXM) and ion microprobe analyses (e.g., Ogliore et al., 2010). Impacts in foils can be readily analyzed by SEM-EDX, and TEM analysis after FIB liftout sample preparation. In contrast, the interstellar dust collection is vastly more challenging. The sample size is approximately six orders of magnitude smaller in total mass. The largest particles are only a few pg in mass, of which there may be only approx.10 in the entire collection. The technical challenges, however, are matched by the scientific importance of the collection. We formed a consortium carry out the Stardust Interstellar Preliminary Examination (ISPE) to carry out an assessment of this collection, partly in order to characterize the collection in sufficient detail so that future investigators could make well-informed sample requests. The ISPE is the sixth PE on extraterrestrial collections carried out with NASA support. Some of the basic questions that we asked were: how many impacts are there in the collector, and what fraction of them have characteristics consistent with extraterrestrial materials? What is the elemental composition of the rock-forming elements? Is there crystalline material? Are there organics? Here we present coordinated microanalyses of particles captured in aerogel, using S-FTIR, S-XRF, STXM, S-XRD; and coordinated microanalyses of residues in aluminum foil, using SEMEDX, Auger spectroscopy, STEM, and ion microprobe. We discuss a novel approach that we employed for identification of tracks in aerogel, and new sample preparation techniques developed during the ISPE. We have identified seven particles - three in aerogel and four in foils - that are most consistent with an interstellar origin. The seven particles exhibit a large diversity in elemental composition. Dynamical evidence, supported supported by laboratory simulations of interstellar dust impacts in aerogel and foils, and numerical modeling of interstellar dust propagation in the heliosphere, suggests that at least some of the particles have high optical cross-section, perhaps due to an aggregate structure. However, the observations are most consistent with a variety of morphologies

Westphal, Andrew J.↗

Analysis of Thermal-Protection Systems for Space-Vehicle Cryogenic-Propellant Tanks

Analytical techniques are presented that permit the calculation of heat-transfer rates with various thermal-protection systems for liquid-cryogenic-propellant tanks subjected to on-board, solar, and planetary heat fluxes. The thermal-protection systems considered include using closely spaced reflective surfaces (foils) and widely spaced reflective surfaces (shadow shields), insulation, arrangement of vehicle components, orientation with respect to radiant heating sources, and coatings for the control of solar absorptivity. The effectiveness of these thermal-protection systems in reducing propellant heating is shown both for ideal heat-transfer models and for a simplified hydrogen-oxygen terminal stage on a Mars mission. The proper orientation of a space-vehicle cryogenic tank with respect to the Sun is one of the more beneficial methods of reducing the heating effect of solar flux. Shadow shields can be extremely effective in reducing the propellant heating due to both solar and on-board fluxes. However, low-altitude planet orbits can result in high propellant heating rates due to planetary radiation reflected from the shields. For low-altitude orbits of more than a few days, foils appear to be desirable for all cryogenic-tank surfaces. Foils are also effective in reducing the on-board heating. A choice of shadow shields or foils cannot be made until a particular vehicle and a particular mission are chosen. The thermal conductivity of insulation materials would have to be lower by about two orders of magnitude with no increase in density before insulation could compete with reflective surfaces for use in long-duration thermal protection of cryogenic tanks in space. To demonstrate the application of the methods devised, thermal-protection systems are developed for a hydrogen-oxygen terminal stage for typical Mars missions.

SPACE VEHICLE↗

Development of explosively bonded TZM wire reinforced Columbian sheet composites

Methods of producing TZM molybdenum wire reinforced C129Y columbium alloy composites by explosive welding were studied. Layers of TZM molybdenum wire were wound on frames with alternate layers of C129Y columbium alloy foil between the wire layers. The frames held both the wire and foils in place for the explosive bonding process. A goal of 33 volume percent molybdenum wire was achieved for some of the composites. Variables included wire diameter, foil thickness, wire separation, standoff distance between foils and types and amounts of explosive. The program was divided into two phases: (1) development of basic welding parameters using 5 x 10-inch composites, and (2) scaleup to 10 x 20-inch composites.

Otto, H. E.↗