Search NASA⌕ Search

SEARCH · Search NASA

Results for “Plasma materials processing”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 325 records · Page 18

Plasma Abatement of Volatile Organic Compounds for Treatment of Spacecraft Trash Combustion Gaseous Effluents.

One approach that has been investigated for trash management aboard long-duration crewed exploration space missions is the so-called Trash-to-Gas approach. This technology uses a thermal process (i.e., combustion, pyrolysis, etc.) to convert crew trash into relatively non-reactive gases (i.e., CO2, CO, etc.) that can be easily vented overboard. One difficulty with this approach is the potential for the contamination of the spacecraft habitable volume from the myriad volatile organic compounds (VOCs) that are concurrently produced from these thermal processes. One possible VOC abatement process is to apply a plasma to the effluent gases. Plasmas provide high energy electrons and ions that are capable of breaking down gaseous organic species generally into smaller compounds. To explore Plasma VOC abatement, the authors constructed a plasma gas system that recirculates a particular VOCladen gas mixture through a plasma torch. This allows the periodic collection of aliquots of gaseous samples for subsequent analyses via gas chromatography mass spectrometry, designed to quantify the remaining VOC materials. The VOCs evaluated included 100 ppm of acetone, benzene, ethanol, and pentane in a background of carbon dioxide. The plasma conversion of all analytes followed first order rate kinetics, and complete VOC elimination was observed after 10 min or less of treatment, for all analytes measured. Additionally, it was observed that the plasma caused the conversion of CO2 into oxygen and CO.

Joel A. Olson↗

Cosmic-ray picture of the heliosphere

The existing data base on the characteristics of the heliosphere is discussed. It is known that solar gravity is less than necessary to hold all the solar material, and therefore a supersonic solar wind exists. Skylab soft X-ray photographs revealed the existence of coronal holes, which evolve in an 11 yr cycle. It has been proposed that all but the highest energy cosmic rays detected on earth can be attributed to solar and heliospheric origins, a controversial view which requires further empirical and theoretical work on particle acceleration processes and regions of interaction of the solar wind with interplanetary plasma. It is possible that a warped solar current sheet stretches to interplanetary space and organizes the solar magnetic field and thereby guides cosmic rays. An inverse correlation has been identified between the sunspot cycle and cosmic ray intensity. The features and effects of solar flares, subsequent shock waves and high speed particle streams are also discussed.

Venkatesan, D.↗

Furnace Cyclic Oxidation Behavior of Multi-Component Low Conductivity Thermal Barrier Coatings

Ceramic thermal barrier coatings will play an increasingly important role in advanced gas turbine engines because of their ability to further increase engine operating temperatures and reduce cooling, thus helping achieve future engine low emission, high efficiency and improved reliability goals. Advanced multi-component zirconia-based thermal barrier coatings are being developed using an oxide defect clustering design approach to achieve the required coating low thermal conductivity and high temperature stability. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of the candidate coating materials was conducted using conventional furnace cyclic oxidation tests. In this paper, furnace cyclic oxidation behavior of plasma-sprayed zirconia-based defect cluster thermal barrier coatings was investigated at 1163 C using 45 min hot cycles. The ceramic coating failure mechanisms were studied using scanning electron microscopy (SEM) combined with X-ray diffraction (XRD) phase analysis after the furnace tests. The coating cyclic lifetime is also discussed in relation to coating processing, phase structures, dopant concentration, and other thermo-physical properties.

Zhu, Dong-Ming↗

Electrical Breakdown of Anodized Structures in a Low Earth Orbital Environmental

A comprehensive set of investigations involving arcing on a negatively biased anodized aluminum plate immersed in a low density argon plasma at low pressures (P(sub O), 7.5 x 10(exp -5) Torr) have been performed. These arcing experiments were designed to simulate electrical breakdown of anodized coatings in a Low Earth Orbital (LEO) environment. When electrical breakdown of an anodized layer occurs, an arc strikes, and there is a sudden flux of electrons accelerated into the ambient plasma. This event is directly followed by ejection of a quasi-neutral plasma cloud consisting of ejected material blown out of the anodized layer. Statistical analysis of plasma cloud expansion velocities have yielded a mean propagation velocity, v = (19.4 +/- 3.5) km/s. As the plasma cloud expands into the ambient plasma, energy in the form of electrical noise is generated. The radiated electromagnetic noise is detected by means of an insulated antenna immersed in the ambient plasma. The purpose of the investigations is (1) to observe and record the electromagnetic radiation spectrum resulting from the arcing process. (2) Make estimates of the travel time of the quasi-neutral plasma cloud based on fluctuations to several Langmuir probes mounted in the ambient plasma. (3) To study induced arcing between two anodized aluminum structures in close proximity.

Galofaro, J. T.↗

Plasma Abatement of Volatile Organic Compounds

One difficulty with crewed space operations is the potential for the contamination of the spacecraft habitable volume from volatile organic compounds (VOCs) that may be present. One possible VOC abatement process is to apply a plasma to the contaminated gases. Plasmas provide high energy electrons and ions that are capable of breaking down gaseous organic species generally into smaller compounds. To explore plasma VOC abatement, the authors constructed a plasma gas system that recirculates a particular VOC-laden gas mixture through a plasma torch. This allows for the periodic collection of aliquots of gaseous samples for subsequent analyses via gas chromatography mass spectrometry, designed to quantify the remaining VOC materials. The VOCs evaluated included 100 ppm of acetone, benzene, ethanol, and pentane in a background of carbon dioxide. The plasma conversion of all analytes followed first-order rate kinetics, and VOC elimination was observed after 10 min or less of treatment for all analytes measured. Additionally, it was observed that the plasma caused the conversion of CO 2 into oxygen and CO.

Joel A. Olson↗

Atomic oxygen effects on SiO(x) coated Kapton for photovoltaic arrays in low earth orbit

Commercially applied SiOx was evaluated as a protective coating for the polyimide Kapton solar array blankets for Space Station Freedom. Three different rolls of coated material were tested in a plasma asher to determine their durability to attack by atomic oxygen. Mass loss data indicated that all of the coatings tested would structurally survive for 15 years in LEO (low earth orbit), except for one which had several uncoated lines across the sample which were caused by ridgelanes in the Kapton. It appears that the size rather than number of defects alone effects the mass loss the most. Careful handling of the material after coating and during processing may be critical for array survival.

Rutledge, Sharon K.↗

Fast electrons in small solar flares

This review summarizes both the direct spacecraft observations of nonrelativistic solar electrons, and observations of the X-ray and radio emission generated by these particles at the sun and in the interplanetary medium. These observations bear on the basic astrophysical process of particle acceleration in tenuous plasmas. We find that in many small solar flares, the nearly 5-100 keV electrons accelerated during flash phase constitute the bulk of the total flare energy. Thus the basic flare mechanism in these flares essentially converts the available flare energy into fast electrons. These electrons may produce the other flare electromagnetic emissions through their interactions with the solar atmosphere. In large proton flares these electrons may provide the energy to eject material from the sun and to create a shock wave which could accelerate nuclei and electrons to much higher energies.

Lin, R. P.↗

High-Temperature Lubricants

In the early 1980's, Lewis Research Center began a program to develop high-temperature lubricants for use on future aircraft flying at three or more times the speed of sound, which can result in vehicle skin temperatures as high as 1,600 degrees Fahrenheit. A material that emerged from this research is a plasma-sprayed, self-lubricating metal- glass-fluoride coating able to reduce oxidation at very high temperatures. Technology is now in commercial use under the trade name Surf-Kote C-800, marketed by Hohman Plating and Manufacturing Inc. and manufactured under a patent license from NASA. Among its uses are lubrication for sliding contact bearings, shaft seals for turbopumps, piston rings for high performance compressors and hot glass processing machinery; it is also widely used in missile and space applications.

Source record↗

Compact Rare Earth Emitter Hollow Cathode

A compact, high-current, hollow cathode utilizing a lanthanum hexaboride (LaB6) thermionic electron emitter has been developed for use with high-power Hall thrusters and ion thrusters. LaB6 cathodes are being investigated due to their long life, high current capabilities, and less stringent xenon purity and handling requirements compared to conventional barium oxide (BaO) dispenser cathodes. The new cathode features a much smaller diameter than previously developed versions that permit it to be mounted on axis of a Hall thruster ( internally mounted ), as opposed to the conventional side-mount position external to the outer magnetic circuit ("externally mounted"). The cathode has also been reconfigured to be capable of surviving vibrational loads during launch and is designed to solve the significant heater and materials compatibility problems associated with the use of this emitter material. This has been accomplished in a compact design with the capability of high-emission current (10 to 60 A). The compact, high-current design has a keeper diameter that allows the cathode to be mounted on the centerline of a 6- kW Hall thruster, inside the iron core of the inner electromagnetic coil. Although designed for electric propulsion thrusters in spacecraft station- keeping, orbit transfer, and interplanetary applications, the LaB6 cathodes are applicable to the plasma processing industry in applications such as optical coatings and semiconductor processing where reactive gases are used. Where current electrical propulsion thrusters with BaO emitters have limited life and need extremely clean propellant feed systems at a significant cost, these LaB6 cathodes can run on the crudest-grade xenon propellant available without impact. Moreover, in a laboratory environment, LaB6 cathodes reduce testing costs because they do not require extended conditioning periods under hard vacuum. Alternative rare earth emitters, such as cerium hexaboride (CeB6) can be used in this configuration with possibly an even longer emitter life. This cathode is specifically designed to integrate on the centerline of a high-power Hall thruster, thus eliminating the asymmetries in the plasma discharge common to cathodes previously mounted externally to the thruster s magnetic circuit. An alternative configuration for the cathode uses an external propellant feed. This diverts a fraction of the total cathode flow to an external feed, which can improve the cathode coupling efficiency at lower total mass flow rates. This can improve the overall thruster efficiency, thereby decreasing the required propellant loads for different missions. Depending on the particular mission, reductions in propellant loads can lead to mission enabling capabilities by allowing launch vehicle step-down, greater payload capability, or by extending the life of a spacecraft.

Watkins, Ronald↗

New Trends in Coatings Developments for Turbine Blades: Materials Processing and Repair

Turbine engines for aeronautic applications now have to face strenuous requirements concerning not only operating performances but also reliability and repairability. This evolution of the specifications induces important consequences regarding the choice and the design of turbine blade protective coatings. This paper presents several key features concerning the deposition techniques and the real-life behavior of such coatings: (1) complex aluminides well suited to the protection against high temperature oxidation and hot corrosion of directionally solidified nickel-base superalloy turbine blades; (2) ceramic coatings used as thermal barriers - they have to exhibit both high resistance to thermomechanical fatigue and adequate smoothness; (3) processing techniques for thermal barriers, including plasma spraying, electron beam physical vapor deposition and plasma enhanced chemical vapor deposition; and (4) blades and coatings repair techniques.

S Alpérine↗

Plasma transport in the Io torus - The importance of microscopic diffusion

This paper considers the question of whether the distribution of mass in the Io plasma torus is consistent with the concept of interchange eddy transport. Specifically, the flux tube content exhibits a gradual decrease with increasing radial distance from the source near Io without any evidence for substantial density irregularity associated with the plasma source or loss. Using a simple one-dimensional numerical model to simulate macroscopic interchange eddy transport, it is demonstrated that this smooth equilibrium distribution of mass can occur but only with the inclusion of a minimal level of small scale microscopic mixing at a rate approaching Bohm diffusion. Otherwise, the system exhibits a chaotic appearance which never approaches an equilibrium distribution. Various physical mechanisms for the microscopic diffusion process which is required to provide a sufficiently rapid mixing of material between the macroscopic eddies are discussed.

Mei, YI↗

Microtextured metals for stray-light suppression in the Clementine startracker

Anodized blacks for suppressing stray light in optical systems can now be replaced by microscopically textured metal surfaces. An application of these black surfaces to the Clementine star-tracker navigational system, which will be launched in early 1994 to examine the Moon, en route to intercept an asteroid, is detailed. Rugged black surfaces with Lambertian BRDF less than 10(exp -2) srad(sup -1) are critical for suppressing stray light in the star-tracker optical train. Previously available materials spall under launch vibrations to contaminate mirrors and lenses. Microtextured aluminum is nearly as dark, but much less fragile. It is made by differential ion beam sputtering, which generates light-trapping pores and cones slightly smaller than the wavelength to be absorbed. This leaves a sturdy but light-absorbing surface that can survive challenging conditions without generating debris or contaminants. Both seeded ion beams and plasma immersion (from ECR plasmas) extraction can produce these microscopic textures without fragile interfaces. Process parameters control feature size, spacing, and optical effects (THR, BRDF). Both broad and narrow absorption bands can be engineered with tuning for specific wavelengths and applications. Examples are presented characterized by FTIR in reflection librators (0.95 normal emissivity), heat rejection, and enhanced nucleate boiling.

Johnson, E. A.↗

Z-Pinch Pulsed Plasma Propulsion Technology Development

Fusion-based propulsion can enable fast interplanetary transportation. Magneto-inertial fusion (MIF) is an approach which has been shown to potentially lead to a low cost, small reactor for fusion break even. The Z-Pinch/dense plasma focus method is an MIF concept in which a column of gas is compressed to thermonuclear conditions by an axial current (I approximates 100 MA). Recent advancements in experiments and the theoretical understanding of this concept suggest favorable scaling of fusion power output yield as I(sup 4). This document presents a conceptual design of a Z-Pinch fusion propulsion system and a vehicle for human exploration. The purpose of this study is to apply Z-Pinch fusion principles to the design of a propulsion system for an interplanetary spacecraft. This study took four steps in service of that objective; these steps are identified below. 1. Z-Pinch Modeling and Analysis: There is a wealth of literature characterizing Z-Pinch physics and existing Z-Pinch physics models. In order to be useful in engineering analysis, simplified Z-Pinch fusion thermodynamic models are required to give propulsion engineers the quantity of plasma, plasma temperature, rate of expansion, etc. The study team developed these models in this study. 2. Propulsion Modeling and Analysis: While the Z-Pinch models characterize the fusion process itself, propulsion models calculate the parameters that characterize the propulsion system (thrust, specific impulse, etc.) The study team developed a Z-Pinch propulsion model and used it to determine the best values for pulse rate, amount of propellant per pulse, and mixture ratio of the D-T and liner materials as well as the resulting thrust and specific impulse of the system. 3. Mission Analysis: Several potential missions were studied. Trajectory analysis using data from the propulsion model was used to determine the duration of the propulsion burns, the amount of propellant expended to complete each mission considered. 4. Vehicle Design: To understand the applicability of Z-Pinch propulsion to interplanetary travel, it is necessary to design a concept vehicle that uses it -- the propulsion system significantly impacts the design of the electrical, thermal control, avionics and structural subsystems of a vehicle. The study team developed a conceptual design of an interplanetary vehicle that transports crew and cargo to Mars and back and can be reused for other missions. Several aspects of this vehicle are based on a previous crewed fusion vehicle study -- the Human Outer Planet Exploration (HOPE) Magnetized Target Fusion (MTF) vehicle. Portions of the vehicle design were used outright and others were modified from the MTF design in order to maintain comparability.

Polsgrove, Tara↗

Demonstration of a Fiber Optic Regression Probe

The capability to provide localized, real-time monitoring of material regression rates in various applications has the potential to provide a new stream of data for development testing of various components and systems, as well as serving as a monitoring tool in flight applications. These applications include, but are not limited to, the regression of a combusting solid fuel surface, the ablation of the throat in a chemical rocket or the heat shield of an aeroshell, and the monitoring of erosion in long-life plasma thrusters. The rate of regression in the first application is very fast, while the second and third are increasingly slower. A recent fundamental sensor development effort has led to a novel regression, erosion, and ablation sensor technology (REAST). The REAST sensor allows for measurement of real-time surface erosion rates at a discrete surface location. The sensor is optical, using two different, co-located fiber-optics to perform the regression measurement. The disparate optical transmission properties of the two fiber-optics makes it possible to measure the regression rate by monitoring the relative light attenuation through the fibers. As the fibers regress along with the parent material in which they are embedded, the relative light intensities through the two fibers changes, providing a measure of the regression rate. The optical nature of the system makes it relatively easy to use in a variety of harsh, high temperature environments, and it is also unaffected by the presence of electric and magnetic fields. In addition, the sensor could be used to perform optical spectroscopy on the light emitted by a process and collected by fibers, giving localized measurements of various properties. The capability to perform an in-situ measurement of material regression rates is useful in addressing a variety of physical issues in various applications. An in-situ measurement allows for real-time data regarding the erosion rates, providing a quick method for empirically anchoring any analysis geared towards lifetime qualification. Erosion rate data over an operating envelope could also be useful in the modeling detailed physical processes. The sensor has been embedded in many regressing media for the purposes of proof-of-concept testing. A gross demonstration of its capabilities was performed using a sanding wheel to remove layers of metal. A longer-term demonstration measurement involved the placement of the sensor in a brake pad, monitoring the removal of pad material associated with the normal wear-and-tear of driving. It was used to measure the regression rates of the combustable media in small model rocket motors and road flares. Finally, a test was performed using a sand blaster to remove small amounts of material at a time. This test was aimed at demonstrating the unit's present resolution, and is compared with laser profilometry data obtained simultaneously. At the lowest resolution levels, this unit should be useful in locally quantifying the erosion rates of the channel walls in plasma thrusters. .

Korman, Valentin↗

Studies of mechano-chemical interactions in the tribological behavior of materials

Mechano-chemical interaction studies can contribute to the understanding of wear and friction of materials. Specific examples of experimental results relative to the subject are discussed. There are two parts: one describes the synergistic effect of corrosion and wear of iron sliding on sapphire in sulfuric acid, and the other describes the effect of surface films on the wear and friction of plasma-deposited diamondlike carbon (amorphous hydrogenated carbon) films in sliding contact with silicon nitride. The concentration of acid (pH) is an important factor in controlling the iron loss caused by wear-corrosion processes in sulfuric acid. The mechanical action can cause chemical reactions to proceed much faster than they would otherwise. The diamondlike carbon (DLC) films are shown to behave tribologically much like bulk diamond. In a dry nitrogen environment, a mechano-chemical reaction produces a substance which greatly decreases the coefficient of friction. In a moist air environment, mechano-chemical interactions drastically reduce the wear life of DLC films and water vapor greatly increases friction.

Miyoshi, Kazuhisa↗

Studies of mechanochemical interactions in the tribological behavior of materials

Mechanochemical interaction studies can contribute to the understanding of wear and friction of materials. Specific examples of experimental results relative to the subject are discussed. There are two parts: one describes the synergistic effect of corrosion and wear of iron sliding on sapphire in sulfuric acid, and the other describes the effect of surface films on the wear and friction of plasma-deposited diamondlike carbon (amorphous hydrogenated carbon) films in sliding contact with silicon nitride. The concentration of acid (pH) is an important factor in controlling the iron loss caused by wear-corrosion processes in sulfuric acid. The mechanical action can cause chemical reactions to proceed much faster than they would otherwise. The diamondlike carbon (DLC) films are shown to behave tribologically much like bulk diamond. In a dry nitrogen environment, a mechanochemical reaction produces a substance which greatly decreases the coefficient of friction. In a moist air environment, mechanochemical interactions drastically reduce the wear life of DLC films and water vapor greatly increases friction.

Miyoshi, Kazuhisa↗

Design of a prototype Advanced Main Combustion Chamber for the Space Shuttle Main Engine

Development of a prototype advanced main combustion chamber is underway at NASA Marshall Space Flight Center. The Advanced Main Combustion Chamber (AMCC) project is being approached utilizing a 'concurrent engineering' concept where groups from materials, manufacturing, stress, quality, and design are involved from the initiation of the project. The AMCC design has been tailored to be compatible with the investment casting process. Jacket, inlet/outlet manifolds, inlet/outlet neck coolant flow splitters, support ribs, actuator lugs, and engine controller mounting bracket will all be a part of the one-piece AMCC casting. Casting of the AMCC in a one-piece configuration necessitated a method of forming a liner in its structural jacket. A method of vacuum plasma spraying the liner is being developed. In 1994, the AMCC will be hot-fired on the Technology Test Bed Space Shuttle Main Engine.

Lackey, J. D.↗

Optimization of Indium Bump Morphology for Improved Flip Chip Devices

Flip-chip hybridization, also known as bump bonding, is a packaging technique for microelectronic devices that directly connects an active element or detector to a substrate readout face-to-face, eliminating the need for wire bonding. In order to make conductive links between the two parts, a solder material is used between the bond pads on each side. Solder bumps, composed of indium metal, are typically deposited by thermal evaporation onto the active regions of the device and substrate. While indium bump technology has been a part of the electronic interconnect process field for many years and has been extensively employed in the infrared imager industry, obtaining a reliable, high-yield process for high-density patterns of bumps can be quite difficult. Under the right conditions, a moderate hydrogen plasma exposure can raise the temperature of the indium bump to the point where it can flow. This flow can result in a desirable shape where indium will efficiently wet the metal contact pad to provide good electrical contact to the underlying readout or imager circuit. However, it is extremely important to carefully control this process as the intensity of the hydrogen plasma treatment dramatically affects the indium bump morphology. To ensure the fine-tuning of this reflow process, it is necessary to have realtime feedback on the status of the bumps. With an appropriately placed viewport in a plasma chamber, one can image a small field (a square of approximately 5 millimeters on each side) of the bumps (10-20 microns in size) during the hydrogen plasma reflow process. By monitoring the shape of the bumps in real time using a video camera mounted to a telescoping 12 magnifying zoom lens and associated optical elements, an engineer can precisely determine when the reflow of the bumps has occurred, and can shut off the plasma before evaporation or de-wetting takes place.

Jones, Todd J.↗