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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Thermal Control Replacement Materials Evaluated for Durability and Selected for the Hubble Space Telescope

During the Hubble Space Telescope (HST) second servicing mission, astronauts noticed that the outer layer of the multilayer insulation (MLI) was cracked in many locations around the telescope. The insulation s outer layer is composed of 5-mil (0.127 mm) Teflon FEP (DuPont; fluorinated ethylene propylene) with vapor-deposited aluminum (VDA) on the backside. The MLI blankets, which are used on over 80 percent of the external surface of the telescope, provide passive thermal control for equipment. Two large cracks were observed on the light shield directly above the high gain antenna. The upper light shield crack propagated from a cut placed in the blanket during installation around a handrail standoff. Two cracks propagated almost normal to each other, with the outer layer curling tightly as the cracks propagated. A second much larger vertical crack had started to curl and lift away from the telescope, as seen in the figure. MLI on the equipment bays was cracked extensively also, and in some areas it had pulled away from the bay. Continued degradation of the equipment bay insulation would potentially cause limited observations because of housekeeping boxes; for example, the data interface unit could overheat during some portions of the year, in certain sun angles.

deGroh, Kim K.↗
NASA NTRS1994

Microstructural analysis of cracks generated during welding of 2195 aluminum-lithium alloy

This research summarizes a series of studies conducted at Marshall Space Flight Center to characterize the properties of 2195 Al-Li alloy. 2195 Al-Li alloy, developed by Martin Marietta laboratories, is designated as a replacement of 2219 Al-Cu alloy for the External Tank (E.T.) of the space shuttle. 2195 Al-Li alloy with its advantage of increased strength per weight over its predecessor, 2219 Al-Cu alloy, also challenges current technology. 2195 Al-Li has a greater tendency to crack than its predecessor. The present study began with the observation of pore formation in 2195 Al-Li alloy in a thermal aging process. In preliminary studies, Talia and Nunes found that most of the two pass welds studied exhibited round and crack-like porosity at the weld roots. Furthermore, the porosity observed was associated with the grain boundaries. The porosity level can be increased by thermal treatment in the air. A solid state reaction proceeding from dendritic boundaries in the weld fusion zone was observed to correlate with the generation of the porosity.

Talia, George E.↗
NASA NTRS2007

Modeling Creep-Induced Stress Relaxation at the Leading Edge of SiC/SiC Airfoils

Anticipating the implementation of advanced SiC/SiC composites into internally cooled airfoil components within the turbine section of future aero-propulsion engines, the primary objective of this study was to develop physics-based analytical and finite-element modeling tools to predict the effects of composite creep and stress relaxation at the airfoil leading edges, which will generally experience large thermal gradients at high temperatures. A second objective was to examine how some advanced NASA-developed SiC/SiC systems coated with typical EBC materials would behave as leading edge materials in terms of long-term steady-state operating temperatures. Because of the complexities introduced by mechanical stresses inherent in internally cooled airfoils, a simple cylindrical thin-walled tube model subjected to thermal stresses only is employed for the leading edge, thereby obtaining a best-case scenario for the material behavior. In addition, the SiC/SiC composite materials are assumed to behave as isotropic materials with temperature-dependent viscoelastic creep behavior as measured in-plane on thin-walled panels. Key findings include: (1) without mechanical stresses and for typical airfoil geometries, as heat flux is increased through the leading edge, life-limiting tensile crack formation will occur first in the hoop direction on the inside wall of the leading edge; (2) thermal gradients through all current SiC/SiC systems should be kept below approx.300 F at high temperatures to avoid this cracking; (3) at temperatures near the maximum operating temperatures of advanced SiC/SiC systems, thermal stresses induced by the thermal gradients will beneficially relax with time due to creep; (4) although stress relaxation occurs, the maximum gradient should still not exceed 300oF because of residual tensile stress buildup on the airfoil outer wall during cool-down; and (5) without film cooling and mechanical stresses, the NASA-developed N26 SiC/SiC system with thru-thickness Sylramic-iBN fiber reinforcement and a typical EBC coating has the potential of offering a maximum long-term steady-state operating temperature of approx.3100 F at the surface of the EBC.

Lang, Jerry↗
NASA NTRS1985

Examination of coating failure by acoustic emission

Coatings of NiCrAlY bond coat with a zirconia - 12 wt percent yttria overlay were applied to disc-shaped specimens of U-700 alloy. A waveguide of 1 mm diameter platinum was TIG welded to the specimen and allowed it to be suspended in a tubular furnace. The specimen was thermally cycled to 1150 C, and the acoustic emission (AE) monitored. The weight gain per thermal cycle was also measured. A computer system based on the IBM-XT microcomputer was used extensively to acquire the AE data with respect to temperature. This system also controlled the temperature by using a PD software loop. Several different types of AE analyses were performed. A major feature of these tests, not addressed by previous work in this area, was that the coatings covered 100 percent of the specimen and also that the AE was amplified at two different levels. It is believed that this latter feature allows a qualitative appraisal of the relative number of cracks per AE event. The difference in AE counts between the two channels is proportional to the number of cracks per AE event, and this parameter may be thought of as the crack density. The ratio of the AE count difference to the AE count magnitude of one channel is inversely proportional to the crack growth. Both of these parameters allow the crack distribution and crack growth within each specimen to be qualitatively followed during the thermal cycling operation. Recent results which used these principles will be presented.

Berndt, Christopher C.↗
NASA NTRS1973

Additional thermal fatigue data on nickel- and cobalt-base superalloys, part 1

The fluidized bed technique was used to measure the relative thermal fatigue resistance of twenty-one superalloys. Among the thirty-six variations of composition, solidification method, and surface protection the cycles to cracking differed by two to three orders of magnitude. Some alloys suffered serious weight losses and oxidation. Thermal fatigue data, oxidation, and dimensional changes are reported. The types of superalloys are identified.

Howes, M. A. H.↗
NASA NTRS1987

Study of the mechanical behavior of a 2-D carbon-carbon composite

The out-of-plane fracture of a 2-D carbon-carbon composite was observed and characterized to gain an understanding of the factors influencing the stress distribution in such a laminate. Finite element analyses of a two-ply carbon-carbon composite under in-plane, out-of-plane, and thermal loading were performed. Under in-plane loading all components of stress were strong functions of geometry. Additionally, large thermal stresses were predicted. Out-of-plane tensile tests revealed that failure was interlaminar, and that cracks propagated along the fiber-matrix interface. An elasticity solution was utilized to analyze an orthotropic fiber in an isotropic matrix under uniform thermal load. The analysis reveals that the stress distributions in a transversely orthotropic fiber are radically different than those predicted assuming the fiber to be transversely isotropic.

Avery, W. B.↗
NASA NTRS1974

Glass fiber addition strengthens low-density ablative compositions

Approximately 15% of E-glass fibers was added to compositions under test and greatly improved char stability. Use of these fibers also reduced thermal strains which, in turn, minimized char shrinkage and associated cracks, subsurface voids, and disbonds. Increased strength allows honeycomb core reinforcement to be replaced by equivalent amount of glass fibers.

Chandler, H. H.↗
NASA NTRS1978

Block 2 solar cell module environmental test program

Environmental tests were performed of on 76 solar cell modules produced by four different manufacturers. The following tests were performed: (1) 28 day temperature and humidity; (2) rain and icing; (3) salt fog; (4) sand and dust; (5) vacuum/steam/pressure; (6) fungus; (7) temperature/altitude; and (8) thermal shock. Environmental testing of the solar cell modules produced cracked cells, cracked encapsulant and encapsulant delaminations on various modules. In addition, there was some minor cell and frame corrosion.

Holloway, K. L.↗
NASA NTRS1982

Anaerobic polymers as high vacuum leak sealants

Anaerobic polymers are useful as solventless leak sealants with good vacuum properties at moderate temperatures. Loctite 290 can seal leaks in a range generally encountered in carefully constructed ultrahigh vacuum and high vacuum systems. It was found that small leaks are sealed best under vacuum, whereas large leaks should be sealed at atmospheric pressure. The high-temperature behavior of Loctite 290 is limited by its fast cure, which prevents deep penetration into small leaks; cracking eventually occurs at the entrance to the leak. Repeated thermal cycling to about 300 C is possible, however, provided viscosity, curing time, and leak size are properly matched to ensure penetration into the body of the leak. This may require special formulations for high temperature vacuum applications.

Kendall, B. R. F.↗
NASA NTRS1982

Fracture behavior of low-density fibrous ceramics

A study has been carried out to characterize the fracture behavior of a particular class of silica tiles used in the thermal protection system of the Space Shuttle with emphasis on the strength distribution and time dependence of strength. The approach adopted is based on fracture mechanics concepts developed in recent years for the design of brittle materials. The study confirms that proof-testing and tile densification should lead to improved reliability of the thermal protection system. The research also suggests that the subcritical crack growth behavior of the fibrous tiles is similar to that observed in bulk glass of similar composition and that failure occurs by the tensile fracture and fragmentation of individual fibers.

Green, D. J.↗
NASA NTRS1986

Post-perihelion brightening of Halley's Comet: A case of nuclear summer

Increased brightness and gas production rates for Halley's comet after perihelion are explained as a result of seasonal effects on an obliquely rotating nucleus. The highly eccentric cometary orbit causes a rapid change in solar declination as the comet rounds perihelion, resulting in drastic changes in the insolation reaching the Northern and Southern Hemispheres of the nucleus. The rapid heating of the Northern Hemisphere post-perihelion likely results in substantial cracking of the non-volatile surface crust due to thermal stresses, exposing areas of fresh volatile ices. The orientation of the triaxial ellipsoid nucleus may also play a role in exposing more surface area to continuous sunlight and sublimation after perihelion. Post-perihelion brightening models based on heat flow and storage in sub-surface layers of the nucleus pre-perihelion are likely not viable because of the low thermal conductivities of porous, low density cometary surface materials.

Weissman, Paul R.↗
NASA NTRS1991

Thermographic inspection of fatigue cracks in riveted plates

A theoretical and experimental analysis of the inspection of reiveted plates using the thermoelastic effect is presented. Theoretically, a model is employed to estimate the thermoelastic response expected from a cracked and uncracked rivet hole. The stress invariant, which causes the thermoelastic response, is calculated for the cracked case using an FEM model and for the uncracked case using a theoretical approximation. The differences in the two thermal responses are reduced when the effects of optical spatial averaging, thermal conduction, and a concentric blind area representing the rivet heat are considered. It is suggested that discrimination between the cracked and uncracked cases for short cracks will improve with increasing frequency of stress oscillation. Measurements are shown for aerospace aluminum samples with and without fatigue cracks propagating from holes in a plate. The effect of mean stress on the thermoelastic response is illustrated, and the results are qualitatively compared with the finite element analysis.

Welch, Christopher S.↗
NASA NTRS1996

More About Brazing Or Welding NiAl Without Filler

Two reports present additional information about two processes for joining, brazing, or welding workpieces made of nickel aluminide alloys, without use of filler metal. Joining processes involve uniform heating in vacuum-controlled furnace. Eliminates internal thermal gradients in workpieces joined and greatly reduces tendency toward cracking.

Moore, Thomas J.↗
NASA NTRS2003

Numerical Modeling, Thermomechanical Testing, and NDE Procedures for Prediction of Microcracking Induced Permeability of Cryogenic Composites

Reusable Space Vehicles will include light cryogenic composite fuel tanks that must not leak excessively even after multiple launches. Damage in cryogenic composite fuel tanks induced during manufacturing and advanced by thermomechanical cycling can accelerate leakage of the propellant. Whether the leakage exceeds tolerable levels depends on many factors, including pressure gradients, microcrack density, other damage such as delamination, connectivity of the cracks, residual stresses from manufacture, service-induced stresses from thermal and mechanical loads, and composite lay-up. Although it is critical to experimentally characterize permeability during various thermal and mechanical load histories, optimal design depends on having analytical models that can predict the effect of various parameters on performance. Our broad goal is to develop such models that are experimentally validated by destructive and non-destructive evaluation means.

Noh, Jae↗
NASA NTRS2004

Method Developed for Improving the Thermomechanical Properties of Silicon Carbide Matrix Composites

Today, a major thrust for achieving engine components with improved thermal capability is the development of fiber-reinforced silicon-carbide (SiC) matrix composites. These materials are not only lighter and capable of higher use temperatures than state-of-the-art metallic alloys and oxide matrix composites (approx. 1100 C), but they can provide significantly better static and dynamic toughness than unreinforced silicon-based monolithic ceramics. However, for successful application in advanced engine systems, the SiC matrix composites should be able to withstand component service stresses and temperatures for the desired component lifetime. Since the high-temperature structural life of ceramic materials is typically controlled by creep-induced flaw growth, a key composite property requirement is the ability to display high creep resistance under these conditions. Also, because of the possibility of severe thermal gradients in the components, the composites should provide maximum thermal conductivity to minimize the development of thermal stresses. State-of-the-art SiC matrix composites are typically fabricated via a three-step process: (1) fabrication of a component-shaped architectural preform reinforced by high-performance fibers, (2) chemical vapor infiltration of a fiber coating material such as boron nitride (BN) into the preform, and (3) infiltration of a SiC matrix into the remaining porous areas in the preform. Generally, the highest performing composites have matrices fabricated by the CVI process, which produces a SiC matrix typically more thermally stable and denser than matrices formed by other approaches. As such, the CVI SiC matrix is able to provide better environmental protection to the coated fibers, plus provide the composite with better resistance to crack propagation. Also, the denser CVI SiC matrix should provide optimal creep resistance and thermal conductivity to the composite. However, for adequate preform infiltration, the CVI SiC matrix process typically has to be conducted at temperatures below 1100 C, which results in a SiC matrix that is fairly dense, but contains metastable atomic defects and is nonstoichiometric because of a small amount of excess silicon. Because these defects typically exist at the matrix grain boundaries, they can scatter thermal phonons and degrade matrix creep resistance by enhancing grain-boundary sliding. To eliminate these defects and improve the thermomechanical properties of ceramic composites with CVI SiC matrices, researchers at the NASA Glenn Research Center developed a high-temperature treatment process that can be used after the CVI SiC matrix is deposited into the fiber preform.

Bhatt, Ramakrishna T.↗
NASA NTRS2004

An Engineering Look at Space Shuttle and ISS Operations

This slide presentation, in Spanish, is an overview of NASA's Space Shuttle operations and preparations for serving the International Space Station. There is information and or views of the shuttle's design, the propulsion system, the external tanks, the foam insulation, the reusable solid rocket motors, the vehicle assembly building (VAB), the mobile launcher platform being moved from the VAB to the launch pad. There is a presentation of some of the current issues with the space shuttle: cracks in the LH2 flow lines, corrosion and pitting, the thermal protection system, and inspection of the thermal protection system while in orbit. The shuttle system has served for more than 20 years, it is still a challenge to re-certify the vehicles for flight. Materials and material science remain as chief concerns for the shuttle,

Hernandez, Jose M.↗
NASA NTRS2011

Fabrication and Characterization of Brazed Joints for SiC-Metallic Systems Utilizing Refractory Metals

Metal to ceramic joining plays a key role for the integration of ceramics into many nuclear, ground and aero based technologies. In order to facilitate these technologies, the active metal brazing of silicon carbide (CVD beta-SiC, 1.1 mm thick, and hot-pressed alpha-SiC, 3 mm thick) to the refractory metals molybdenum and tungsten using active braze alloys was studied. The joint microstructure, composition, and microhardness were evaluated by optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and Knoop hardness testing. The braze alloys, Cusil-ABA, Ticusil and Copper-ABA, all formed sound joints with excellent wetting and chemical bonding with the SiC substrate. Despite the close thermal expansion match between the metal substrates and SiC, hairline cracks formed in alpha-SiC while beta-SiC showed no signs of residual stress cracking. The use of ductile interlayers to reduce the effect from residual stresses was investigated and joints formed with copper as an interlayer produced crack free systems utilizing both CVD and hot-pressed SiC.

Coddington, Bryan↗