Current status and opportunities for improved high-temperature materials for advanced turbojet engines
Material development review of high temperature materials, superalloys, alloys, and refractory metals for turbojet engines
TURBOJET ENGINE↗
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Abundant Solar Nebula Solids in Comets
Comets have been proposed to consist of unprocessed interstellar materials together with a variable amount of thermally annealed interstellar grains. Recent studies of cometary solids in the laboratory have shown that comets instead consist of a wide range of materials from across the protoplanetary disk, in addition to a minor complement of interstellar materials. These advances were made possible by the return of direct samples of comet 81P/Wild 2 coma dust by the NASA Stardust mission and recent advances in microscale analytical techniques. Isotopic studies of 'cometary' chondritic porous interplanetary dust particles (CP-IDPs) and comet 81P/Wild 2 Stardust samples show that preserved interstellar materials are more abundant in comets than in any class of meteorite. Identified interstellar materials include sub-micron-sized presolar silicates, oxides, and SiC dust grains and some fraction of the organic material that binds the samples together. Presolar grain abundances reach 1 weight percentage in the most stardust-rich CP-IDPs, 50 times greater than in meteorites. Yet, order of magnitude variations in presolar grain abundances among CP-IDPs suggest cometary solids experienced significant variations in the degree of processing in the solar nebula. Comets contain a surprisingly high abundance of nebular solids formed or altered at high temperatures. Comet 81P/Wild 2 samples include 10-40 micron-sized, refractory Ca- Al-rich inclusion (CAI)-, chondrule-, and ameboid olivine aggregate (AOA)-like materials. The O isotopic compositions of these refractory materials are remarkably similar to their meteoritic counterparts, ranging from 5 percent enrichments in (sup 16) O to near-terrestrial values. Comet 81P/Wild 2 and CP-IDPs also contain abundant Mg-Fe crystalline and amorphous silicates whose O isotopic compositions are also consistent with Solar System origins. Unlike meteorites, that are dominated by locally-produced materials, comets appear to be composed of materials that were formed across a wide swath of the early protoplanetary disk.
Messenger, S.↗
Trends in high temperature materials technology for advanced aircraft turbine engines
The utilization of high temperature materials for turbine blades, disks, vanes, and combustors is reviewed. The use of directionally solidified eutectic alloys and of metal fiber reinforced superalloys as turbine blade materials is discussed. The application of powder metallurgy to the production of turbine disks is considered. It is shown that oxide-dispersion strengthened alloys (including NiCr and NiCr-Al) and ceramics are the best refractory turbine vane materials. The use of heat resistant sheet alloys as combustor materials is examined. The cost benefits to be derived from the application of high temperature technology to advanced CTOL and STOL engines are described.
Blankenship, C. P.↗
Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy
Additive friction stir deposition (AFSD) is a solid-state metal additive manufacturing technique, which utilizes frictional heating and plastic deformation to create large deposits and parts. Much like its cousin processes, friction stir welding and friction stir processing, AFSD has seen the most compatibility and use with lower-temperature metals, such as aluminum; however, there is growing interest in higher-temperature materials, such as titanium and steel alloys. In this work, we explore the deposition of an ultrahigh-temperature refractory material, specifically, a tantalum–tungsten (TaW) alloy. The solid-state nature of AFSD means refractory process temperatures are significantly lower than those for melt-based additive manufacturing techniques; however, they still pose difficult challenges, especially in regards to AFSD tooling. In this study, we perform initial deposition trials of TaW using twin-rod-style AFSD with a high-temperature tungsten–rhenium-based tool. Many challenges arise because of the high temperatures of the process and high mechanical demand on AFSD machine hardware to process the strong refractory alloy. Despite these challenges, successful deposits of the material were produced and characterized. Mechanical testing of the deposited material shows improved yield strength over that of the annealed reference material, and this strengthening is mostly attributed to the refined recrystallized microstructure typical of AFSD. These findings highlight the opportunities and challenges associated with ultrahigh-temperature AFSD, as well as provide some of the first published insights into twin-rod-style AFSD process behaviors.
36 MATERIALS SCIENCE↗
Advanced Materials for the Lunar Surface: Multiscale Computational Design of Refractory Alloys and Carbides
Emerging operational environments, such as the lunar surface, present novel challenges for NASA and drive the need for advanced materials in applications like fission surface power systems. To address these demands, computational materials science is rapidly evolving to augment or replace costly and hazardous empirical testing. Although materials selection at NASA remains predominantly experimentally driven, advanced simulation methodologies are being steadily integrated into the engineering lifecycle. This work details the application of multiscale simulation techniques—including first-principles calculations, CALPHAD, dislocation dynamics, and molecular dynamics—at NASA's Ames Research Center to evaluate advanced materials for extreme environments. First, we present contributions to the Space Nuclear Propulsion Project. Be-cause propellant channel coatings in nuclear thermal rockets must withstand high-pressure, high-temperature hydro-gen, optimizing these materials is critical. First-principles calculations were employed to establish a rigorous quantitative and qualitative understanding of the behavior of the refractory carbides ZrC, NbC, and their mixtures in high-enthalpy hydrogen environments. This necessitated the generation of high-fidelity thermodynamic models for both stoichiometric and carbon-depleted carbides, both with and without the presence of hydrogen. Furthermore, we highlight efforts under the Refractory Alloy Additive Manufacturing Build Optimization (RAAMBO) project, where existing and novel alloy compositions were assessed for additive manufacturing printability and subsequent performance in applications such as heat pipes and rocket nozzle extensions. This was accomplished through a comprehensive multiscale simulation framework that bridged the gap from the nanometer to the millimeter scale. Across both initiatives, rigorous validation against empirical data was prioritized. By systematically employing a verified and validated computational frame-work, we demonstrate how simulation effectively supports multidisciplinary engineering efforts, builds project-wide confidence, and drives critical materials development.
computational materials↗
Fibrous refractory composite insulation
A refractory composite insulating material was prepared from silica fibers and aluminosilicate fibers in a weight ratio ranging from 1:19 to 19:1, and about 0.5 to 30% boron oxide, based on the total fiber weight. The aluminosilicate fiber and boron oxide requirements may be satisfied by using aluminoborosilicate fibers and, in such instances, additional free boron oxide may be incorporated in the mix up to the 30% limit. Small quantities of refractory opacifiers, such as silicon carbide, may be also added. The composites just described are characterized by the absence of a nonfibrous matrix.
Leiser, D. B.↗
Electrolytic preparation of high dielectric films quarterly report no. 3, feb. - may 1965
Electrolytic preparation of high dielectric materials in thin film form on refractory metal surfaces
THIN FILM↗
Presence, segregation and reactivity of H, C and N dissolved in some refractory oxides
The sources of impurities, particularly carbon, in high melting oxides and silicates are discussed, along with detection and quantification methods. The impurities are important for their effects on bulk material properties through the media of, e.g., surface or grain boundary characteristics. The impurities are usually encountered by the contact of the oxide (refractory) material with volatiles such as H2O and CO2, which become incorporated in the material and form anion complexes with oxygen acting as a covalent bonded ligand. The specific processes undergone by MgO in assimilating C impurities are delineated, using data obtained with X-ray photoelectron spectroscopy, Auger electron spectroscopy, secondary ion mass spectrometry and nuclear reaction profiling. Finally, maintenance of a supersaturated solid solution with C impurities by space charge control is described as a means of offset impurity effects.
Freund, F.↗
Landform Evolution Modeling of Sedimentary Processes on Icy Worlds: the Cases of Hyperion and Helene
Sedimentary activity (erosion, transportation and deposition) is a major landscape-shaping process on many icy worlds of the outer solar system for which an understanding of this process is central to their geologic characterizations. Several recent studies, lead by the authors, have identified the effects of sedimentary activity on icy satellite landforms and recognized the role of mass wasting and volatile loss and redistribution in the evolution of these features. We apply state of the art, physics based, landform evolution modeling to icy satellite sedimentary landforms in order to fully quantitatively characterize how their morphologies change with time, and what their present appearances imply for the initial abundance and distribution of loose material, volatiles, and refractories in original pristine landforms. We will present results of our landform evolution modeling to the development of the landscapes of the Saturnian moons of Hyperion and Helene. Our current conclusions for Hyperion are that its unique appearance can be explained in part by the loss to space of ballistic ejecta during impact events. In order to create the smooth surfaces and the reticulate, honeycomb pattern of narrow divides between old craters, appreciable subsequent modification of crater morphology must occur through mass-wasting processes accompanied by sublimation, probably facilitated by the loss of CO2 as a component of the relief-supporting matrix of the bedrock. This mass wasting effectively destroys small craters, at least in part accounting for the paucity of sub-kilometer craters on Hyperion. Helene’s unusual morphology consists of broad depressions (modified large craters) and a generally smooth surface patterned with streaks and grooves. The streaks appear to be oriented down-gradient, as are the grooves. This pattern suggests intensive mass-wasting as a dominant process. Our initial modeling of this surface suggests a Bingham-like rheological behavior for the loose down-slope moving material. Interestingly, as a Bingham flow, the models indicate that aperiodic "intermittent" behavior to be present, suggesting that periods of quiet steady landform evolution are punctuated short periods of active surface readjustment.
Saturnian moons↗
A decade of progress in refractory metals
Progress in refractory metals for structural applications - facilities, manufacturing, processing, and research and development
MATERIALS SCIENCE↗
AOI [1] Advanced Manufacturing of Ceramic Anchors with Embedded Sensors for Process and Health Monitoring of Coal Boilers
Researchers at West Virginia University (WVU) developed methods to fabricate and test ceramic anchors with an embedded sensor technology for monitoring the health and processing conditions within pulverized coal (PC) and fluidized-bed combustion (FBC) boiler systems. The technology included the development of advanced manufacturing processes for 2D/3D printing electroceramic (conductive ceramic) sensor designs within the ceramic anchor microstructure during the manufacturing process. This advanced manufacturing process would allow for the precise control of local microstructure and composition in order to engineer layer-by-layer any protective and electrically active materials within the refractory anchor. This 3D printing technology would permit the rapid and controlled design of the refractory microstructure and embedded sensor design throughout the volume of the ceramic anchor. The work also included a method to interconnect the sensors to boiler shell through the anchor clamp, where the sensor signals will be processed by low-power electronics and transmitted wirelessly to a central processing hub. The end-goal of the program was to produce a ceramic anchor sensor system which would be ready for implementation within a coal boiler, and/or other similar refractory liner systems (such as that in the glass and metal manufacturing areas). The project objectives were to: 1) Define the chemical and microstructural stability, in addition to the electrical properties, of oxide and non-oxide ceramic composites to be embedded within the ceramic anchor compositions that may operate up to 1400ºC; 2) Develop and implement the 2D/3D printing technology to pattern and control the microstructure of the ceramic anchor and embedded sensor circuits; 3) Develop an interconnect technology which will permit easy installation of the ceramic anchors and signal collection at the boiler shell; 4) Develop low power analog electronics and wireless communication hardware to efficiently collect the sensor signal at each processing unit and transmit data to a central hub for data analysis; 5) Demonstrate the smart ceramic anchor system for temperature and liner fracture within a high-temperature processing unit, such as a boiler furnace or glass melting furnace floor/wall liner.
20 FOSSIL-FUELED POWER PLANTS↗
Electrolytic preparation of high dielectric thin films quarterly report, 4 nov. 1964 - 3 feb. 1965
High dielectric materials in thin film form on refractory metal substrates - electrolysis
REFRACTORY METAL↗
Copper/nickel eutectic brazing of titanium
Technique joins titanium or one of its alloys to materials, such as iron, nickel or cobalt base material, or to refractory metals. To ensure formation of a satisfactory bond, the temperature, time, environment and pressure must be controlled.
Kutchera, R. E.↗
Improved Ceramic for Heat Exchangers
Most promising composition developed in investigation consisted of mixed oxides described generically as ZrMAS. Has been commercially designated as GE-7808. Material was obtained from low-cost clay/talc mixture. Overall assessment of ZrMAS indicates it is a viable candidate for heat-exchanger application in automotive gas-turbine engines and possibly other areas that require dielectric materials of moderate refractoriness, good corrosion resistance, and excellent thermal-shock resistance.
Herbell, T. P.↗
Microgravity nucleation and particle coagulation experiments support
Researchers at NASA Goddard Space Flight Center have embarked on a program to study the formation and growth of cosmic grains. This includes experiments on the homogeneous nucleation of refractory vapors of materials such as magnesium, lead, tin, and silicon oxides. As part of this program, the Chemical Engineering Department of the University of Virginia has undertaken to develop a math model for these experiments, to assist in the design and construction of the apparatus, and to analyze the data once the experiments have begun. Status Reports 1 and 2 addressed the design of the apparatus and the development of math models for temperature and concentration fields. The bulk of this report discusses the continued refinement of these models, and the assembly and testing of the nucleation chamber along with its ancillary equipment, which began in the spring of 1988.
Lilleleht, L. U.↗
Free-piston Stirling engine conceptual design and technologies for space power, phase 1
As part of the SP-100 program, a phase 1 effort to design a free-piston Stirling engine (FPSE) for a space dynamic power conversion system was completed. SP-100 is a combined DOD/DOE/NASA program to develop nuclear power for space. This work was completed in the initial phases of the SP-100 program prior to the power conversion concept selection for the Ground Engineering System (GES). Stirling engine technology development as a growth option for SP-100 is continuing after this phase 1 effort. Following a review of various engine concepts, a single-cylinder engine with a linear alternator was selected for the remainder of the study. The relationships of specific mass and efficiency versus temperature ratio were determined for a power output of 25 kWe. This parametric study was done for a temperature ratio range of 1.5 to 2.0 and for hot-end temperatures of 875 K and 1075 K. A conceptual design of a 1080 K FPSE with a linear alternator producing 25 kWe output was completed. This was a single-cylinder engine designed for a 62,000 hour life and a temperature ratio of 2.0. The heat transport systems were pumped liquid-metal loops on both the hot and cold ends. These specifications were selected to match the SP-100 power system designs that were being evaluated at that time. The hot end of the engine used both refractory and superalloy materials; the hot-end pressure vessel featured an insulated design that allowed use of the superalloy material. The design was supported by the hardware demonstration of two of the component concepts - the hydrodynamic gas bearing for the displacer and the dynamic balance system. The hydrodynamic gas bearing was demonstrated on a test rig. The dynamic balance system was tested on the 1 kW RE-1000 engine at NASA Lewis.
Penswick, L. Barry↗
Variations among chondrite groups: Constraints on nebular processes
Diverse proportions of the four major ingredients are found in the 13 chondrite groups. Ca-Al-rich inclusions (CAI) include amoeboid-olivine aggregates, which contain refractory nodules. Matrix material forms aggregates and rims on other constituents and contains micrometer-sized grains and a small, uniform concentration of presolar grains. Fe, Ni grains are mostly derived from hot chondrules. Although bulk nonvolatile chondritic elemental ratios are typically within 30% of solar values, individual CAI and some chondrules shown large deviations.
Scott, E. R. D.↗
Glass-rich chondrules in ordinary chondrites
There are two types of glass-rich chondrules in unequilibrated ordinary chondrites (OC): (1) porphyritic chondrules containing 55-85 vol% glass or microcrystalline mesostasis and (2) nonporphyritic chondrules, containing 90-99 vol% glass. These two types are similar in mineralogy and bulk composition to previously described Al-rich chondrules in OC. In addition to Si-, Al- and Na-rich glass or Ca-Al-rich microcrystalline mesostasis, glass-rich chondrules contain dendritic and skeletal crystals of olivine, Al2O3-rich low-Ca pyroxene and fassaite. Some chondrules contain relict grains of forsterite +/- Mg-Al spinel. We suggest that glass-rich chondrules were formed early in nebular history by melting fine-grained precursor materials rich in refractory (Ca, Al, Ti) an moderately volatite (Na, K) components (possibly related to Ca-Al-rich inclusions) admixed with coarse relict forsterite and spinel grains derived from previously disrupted type-I chondrules.
Krot, Alexander N.↗