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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

RP-1 Thermal Stability and Copper Based Materials Compatibility Study

A series of electrically heated tube tests was performed at the NASA Glenn Research Center s Heated Tube Facility to investigate the effect that sulfur content, test duration, and tube material play in the overall thermal stability and materials compatibility characteristics of RP-1. Scanning-electron microscopic (SEM) analysis in conjunction with energy dispersive spectroscopy (EDS) were used to characterize the condition of the tube inner wall surface and any carbon deposition or corrosion formed during these runs. Results of the parametric study indicate that tests with standard RP-1 (total sulfur -23 ppm) and pure copper tubing are characterized by a depostion/deposit shedding process producing local wall temperature swings as high as 500 F. The effect of this shedding is to keep total carbon deposition levels relatively constant for run times from 20 minutes up to 5 hours, though increasing tube pressure drops were observed in all runs. Reduction in the total sulfur content of the fuel from 23 ppm to less than 0.1 ppm resulted in the elimination of deposit shedding, local wall temperature variation, and the tube pressure drop increases that were observed in standard sulfur level RP-1 tests. The copper alloy GRCop-84, a copper alloy developed specifically for high heat flux applications, was found to exhibit higher carbon deposition levels compared to identical tests performed in pure copper tubes. Results of the study are consistent with previously published heated tube data which indicates that small changes in fuel total sulfur content can lead to significant differences in the thermal stability of kerosene type fuels and their compatibility with copper based materials. In conjunction with the existing thermal stability database, these findings give insight into the feasibility of cooling a long life, high performance, high-pressure liquid rocket combustor and nozzle with RP-1.

Stiegemeier, B. R.↗
NASA NTRS1973

Detection of lack of fusion using opaque additives

Reliable nondestructive inspection for incomplete weldment penetration and rapid oxidation of aluminum surfaces when exposed to the atmosphere are currently two major problems in welded aluminum spacecraft structure. Incomplete-penetration defects are extremely difficult to detect and can lead to catastrophic failure of the structure. The moisture absorbed by aluminum oxide on the surface can cause weldment porosity if the surface is not cleaned before welding. The approach employed in this program to solve both problems was to employ copper as a coating to prevent oxidation of the aluminum. Also, copper was used as an opaque additive in the weldment to enhance X-ray detection in the event of incomplete penetration.

Cook, J. L.↗
NASA NTRS1974

Metallized polymeric foam material

Open-celled polyurethane foams can be coated uniformly with thin film of metal by vapor deposition of aluminum or by sensitization of foam followed by electroless deposition of nickel or copper. Foam can be further processed to increase thickness of metal overcoat to impart rigidity or to provide inert surface with only modest increase in weight.

Birnbaum, B. A.↗
NASA NTRS1983

A helium-3 refrigerator employing capillary confinement of liquid cryogen

A condensation refrigerator suitable for operation in a zero gravity space environment was constructed. The condensed liquid refrigerant is confined by surface tension inside a porous metal matrix. Helium-4 and helium-3 gases were condensed and held in a copper matrix. Evaporative cooling of confined liquid helium-4 resulted in a temperature of 1.4K. Using a zeolite adsorption pump external to the cryostat, a temperature of 0.6 K was achieved through evaporative cooling of liquid helium-3. The amount of time required for complete evaporation of a controlled mass of liquid helium-4 contained in the copper matrix was measured as a function of the applied background power. For heating powers below 18 mW the measured times are consistent with the normal boiling of the confined volume of liquid refrigerant. At background powers above 18 mW the rapid rise in the temperature of the copper matrix the signature of the absence of confined liquid occurs in a time a factor of two shorter than that expected on the basis of an extrapolation of the low power data.

Ennis, D. J.↗
NASA NTRS1992

Supercooling effects in Cu-10 wt pct Co alloys solidified at different cooling rates

Electromagnetic levitation and electron beam surface melting were employed to study the effects of supercooling and cooling rate on the solidification of Cu-10 wt pct Co alloys. Two major effects were observed in the supercooled alloys: the nucleation of a metastable copper-rich phase which contains 13 wt pct to 20 wt pct Co in samples supercooled between 105 and 150 K and liquid phase separation which occurs in samples supercooled 150 K or more. The microstructure of the electron beam melted surfaces consisted of very fine spheres which were similar to those of the sample supercooled more than 150 K but with a refined microstructure. The results indicate that a dynamic bulk supercooling of 150 K may exist in the molten pool during the solidification of electron beam melted surfaces.

Munitz, A.↗
NASA NTRS1986

Improvements in MDC and TWT overall efficiency through the application of carbon electrode surfaces

The effects of secondary electron emission losses on TWT efficiency are investigated and techniques for minimizing these losses are described. The TWT-multistage depressed collector performance was optimized and measured over a wide range of operating conditions using geometrically identical collectors that utilized copper, pyrolytic graphite, and isotropic graphite electrodes. The data reveal that carbon rather than copper electrodes improve the TWT efficiency, and the ion-textured graphite is most effective in minimizing the secondary electron emission losses. It is noted that degradation of the collector efficiency can be limited to a small percentage with the proper MDC design and the use of low secondary electron yield carbon electrode surfaces.

Ramins, Peter↗
NASA NTRS1977

Graphical method for predicting life of a rocket thrust chamber with half-hard zirconium-copper liner and electroformed nickel closeout

A method for estimating the life of a regeneratively cooled rocket thrust chamber was developed and is based on the hot-gas wall temperature and the temperature difference between the hot-gas wall and the outside surface of the closeout. This method permits a quick estimate of the life of a thrust chamber when design changes or test-cycle variations are considered. Strain range and life are presented graphically as functions of these temperature parameters for a typical high-performance rocket thrust chamber with a half-hard zirconium-copper liner and an electroformed nickel closeout.

Kasper, H. J.↗
NASA NTRS1994

Results from LDEF experiment A0114: The interaction of atomic oxygen with materials surfaces at orbital altitudes

In 1975 the University of Alabama in Huntsville proposed an experiment for the Long Duration Exposure Facility (LDEF) designed to investigate the effects of the collision of the ambient orbital atmosphere, mainly consisting of atomic oxygen, with satellite surfaces travelling at about 8 km per second. In 1989, the potential for recovery of significant data from A0114 on a wide variety of materials was recognized and funding for three years of data analysis was appropriated. Some significant or unique findings from the experiment A0114 include: numerous measurements of oxidation rates of surfaces under fast O atom bombardment, including Si, Ge, GaAs, SiC, and optical quality metal films; measurement of the stable attitude of the LDEF spacecraft in orbit using the gas dynamics pinhole camera; description of the formation of thick oxide films on copper at 20 C with fast oxygen; measurement of erosion rates of Kapton and other polymers at space station lifetime atomic oxygen fluences (10(exp 22) atoms/sq cm); and measurement of the cosmogenic isotopes Be-7 on spacecraft surfaces.

Gregory, John C.↗
NASA NTRS1979

Ion-beam-textured graphite

Results of evaluation of seven different materials (copper, tantalum, titanium carbide, soot, smooth pyrolytic graphite, and ion-beam-textured graphite) for low secondary-electron emitting surface for depressed collects in microwave amplifiers indicate that ion-beam-textured graphite shows greatest potential for use.

Curren, A. N.↗
NASA NTRS1978

Morphology of gold and copper ion-plated coatings

Copper and gold films (0.2 to 2 microns thick) were ion plated onto polished 304-stainless-steel, glass, mica surfaces. These coatings were examined by SEM for defects in their morphological growth. Three types of defects were distinguished: nodular growth, abnormal or runaway growth, and spits. The cause for each type of defect was investigated. Nodular growth is due to inherent substrate microdefects, abnormal or runaway growth is due to external surface inclusions, and spits are due to nonuniform evaporation (ejection of droplets). All these defects induce stresses and produce porosity in the coatings and thus weaken their mechanical properties. During surface rubbing, large nodules are pulled out, leaving vacancies in the coatings.

Spalvins, T.↗
NASA NTRS1991

Development of a Rayleigh scattering system for temperature measurements in combustor flows

A dual line laser induced Rayleigh scattering system has been developed to be used in high temperature gas flows such as in combustors, and preliminary tests have been performed in a hot air jet. The qualification measurements included the collection and analysis of Rayleigh signal for time-resolved gas temperature over the two lines of a copper-vapor laser. The dual line signal collection technique is a feature to be used in detecting and discriminating the surface scattered laser light in the Rayleigh signal. Optical fibers are used to transmit the laser beam to the optical probe bench and to carry the collected signal from the bench to the housing of the signal sensors. Incident laser intensity at the probe volume is measured for both lines at each pulse of the laser. This information is used to normalize the signal. Good agreement has been obtained between the two line Rayleigh scattering and thermocouple results in the particle free co-flowing air jet.

Otugen, M. V.↗
NASA NTRS1997

Using Superconducting Thin Films in Microwave Lines

High temperature superconductors(HTS) and microwaves devices form the ideal partnership. The application of superconductors in microwave devices, components and systems allows the reduction in size, power consumption and insertion loss. The surface resistance of high-Tc superconductors has been found to be two orders of magnitude lower than normal conducting copper materials. The reduction in size and power requirements, which together both lead to a reduction in system mass, coupled with reasonably accessible operating temperatures, suggest that HTS microwave components should find ready application in satellite communications systems. At present, multi- channeling communication networks demand filters with narrow bandwidth in order to allow the available RF frequency spectrum to be partitioned into small frequency bands, -and possible variation of dielectric constant from substrate to substrate is undesirable. Microwave multiplexers demand the fabrication of two identical filters in each channel. Thus, the filter with tuning function is preferable. Tunable filters are the critical component for phased array antennas in order to electronically steer the radiated beam. To fabricate a tunable filter that uses an electric field for operation, one would like a material that provides a large change on dielectric constant for a given electric field, yet has a relatively low tangent in order to minimize the insertion loss of the device. Ferroelectrics have been the materials of choice. Their large dielectric constant sufficiently increases the coupling between microwave resonators and its dependence on electric field provides timability. Development of technology promises to diminish tangent loss. The use of thin ferroelectric films sufficiently decreases insertion losses keeping considerable potential for applications. NASA Lewis Research Center is the one of the leading centers in investigation of superconductors/ferroelectric tunable components for microwave devices. A large number of possible microwave devices were fabricated and tested on the basis of thin film multilayer superconductor-ferroelectric structures. In major cases the systems with edge-coupling scheme were investigated. Dr. Genkin has recently focused on the new potentialities which implements the using of thin ferroelectric films in filters fabricated with end-coupled microstrip lines. Numerical modeling shows that these systems have large potential for application in tunable narrow- and wide-bandpass filters in the frequency range 10-20 GHz. The phase shifter with end-coupled resonant sections was fabricated and tested. Experimental results show large tunability, particular in low voltages. The possible optimization of this structure promises to improve the obtained result and to reach the low level of insertion losses.

Genkin, Varery↗
NASA NTRS1996

Method of forming multi-element thin hot film sensors on polyimide film

The invention comprises a method of forming a multi-element, thin hot film sensor on a polyimide film. The sensor is formed by first cleaning one surface of the polyimide. Then, under a continuous vacuum, the surface is simultaneously cleaned by ion bombardment while nickel is deposited by evaporation. The ion beam cleaning is discontinued and copper is then deposited to an initial thickness by evaporation without a break in the vacuum. The vacuum is then removed and a final thickness of copper is deposited by plating. Sensor patterns are then defined in the nickel and copper layers using conventional photolithography and etching techniques.

Hopson, Jr., Purnell↗
NASA NTRS1983

The XPS depth profiling and tribological characterization of ion-plated gold on various metals

Friction properties were measured with a gold film; the graded interface between gold and nickel substrate; and the nickel substrate. All sliding was conducted against hard silicon carbide pins in two processes. In the adhesive process, friction arises primarily from adhesion between sliding surfaces. In the abrasion process, friction occurs as a result of the hard pin sliding against the film, indenting into it, and plowing a series of grooves. Copper and 440 C stainless steel substrates were also used. Results indicate that the friction related to both adhesion and abrasion is influenced by coating depth. The trends in friction behavior as a function of film depth are, however, just the opposite. The graded interface exhibited the highest adhesion and friction, while the graded interface resulted in the lowest abrasion and friction. The coefficient of friction due to abrasion is inversely related to the hardness. The greater the hardness of the surface, the lower is the abrasion and friction. The microhardness in the graded interface exhibited the highest hardness due to an alloy hardening effect. Almost no graded interface between the vapor-deposited gold film and the substrates was detected.

Miyoshi, K.↗
NASA NTRS2005

VPS Process for Copper Components in Thrust Chamber Assemblies

For several years, NASA's Marshall Space Flight Center (MSFC) has been working with Plasma Processes, Inc., (PPI) to fabricate thrust chamber liners with GRCop-84. Using the vacuum plasma spray (VPS) process, chamber liners of a variety of shapes and sizes have been created. Each has been formed as a functional gradient material (FGM) that creates a unique protective layer of NiCrAlY on the GRCop-84 liner s hot wall surface. Hot-fire testing was successfully conducted on a subscale unit to demonstrate the liner's durability and performance. Similar VPS technology has also been applied to create functional gradient coatings (FGC) on copper injector faceplates. Protective layers of NiCrAlY and zirconia were applied to both coaxial and impinging faceplate designs. Hot-fire testing is planned for these coated injectors in April 2005. The resulting material systems for both copper alloy components allows them to operate at higher temperatures with improved durability and operating margins.

Elam, Sandra↗
NASA NTRS2000

Effects of Conformal Coat on Tin Whisker Growth

A whisker from a tin plated part was blamed for the loss of a commercial spacecraft in 1998. Although pure tin finishes are prohibited by NASA, tin plated parts, such as hybrids, relays and commercial off the shelf (COTS) parts, are something discovered to have been installed in NASA spacecraft. Invariably, the assumption is that a conformal coat will prevent the growth of, or short circuits caused by, tin whiskers. This study measures the effect a Uralane coating has on the initiation and growth of tin whiskers, on the ability of this coating to prevent a tin whisker from emerging from the coating, and on the ability to prevent shorting. A sample of fourteen brass substrates (1 inch by 4 inches by 1/16 inch) were plated by two separate processes: half of the specimens were 'bright' tin plated directly over the brass substrate and half received a copper flash over the brass substrate prior to 'bright' tin plating. Each specimen was coated on one half of the substrate with three bi-directional sprays of Uralane 5750 to a nominal thickness of 25 to 75 micrometers (1 to 3 mils). Several specimens of both types, Cu and non-Cu flashed, were placed in an oven maintained at 50 C as others' work suggests that this is the optimal temperature for whisker formation. The remaining specimens were maintained at room ambient conditions. The surfaces of each specimen have been regularly inspected using both optical (15 to 400x power) and Scanning Electronic Microscopy (SEM). Many types of growths, including needle-like whiskers, first appeared approximately three months after plating on the non-conformally coated sides of all specimens. At four months, 4 to 5 times more growth sites were observed on the coated side; however, the density of growth sites on the non-conformally coated side has since increased rapidly, and now, at one year, is about the same for both sides. The density of growth sites is estimated at 90/sq mm with 30 percent of the sites growing whiskers (needle-like forms) with the potential to cause short circuit bridging. The average growth rate of the needle-like whiskers on the non-conformally coated areas is about 130 micrometers per year with some outliers reaching 800 micrometers after one year. It is more difficult to make growth measurements under the conformal coat. As yet no whiskers have been observed to penetrate through the coating surface, however, a number of tin nodules appear on the verge of breaking through the thinner regions of the coating surface. These domes are developing sharper and sharper tips, as if a growing whisker is about to push its way through a tough skin. Our observations are that the specimens with copper flash show a much lower density of nucleation sites and significantly slower whisker growth compared to the specimens that have only bright tin plating over brass. The specimens kept at room temperature have a higher whisker density than those stored at 50 C. This is an unexpected result and does not agree with the published findings of others. All of the whiskers originate from small surface defects (thin, tiny scratches) that appear over the entire surface of each specimen.

Kadesch, Jong S.↗