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Approach using bond-cover coat of unplasticized rubber between soft rubber and adhesive eliminates diffusion problem. Approach is useful in making improved seals in automobile engines, industrial and public plumbing, and in other areas using soft-rubber-to-metal bonds. Seals and gaskets made this way would not have to be replaced very often, reducing cost of maintenance.
Transducer with only three moving parts senses flow of clear or translucent fluid. Displacement of diaphragm by force of flow detected electrooptically and displayed by panel meter or other device. Transducer used to measure flow of gasoline to automobile engine.
Zyttrite-doped material outperforms MgO-doped material above 1,200 degrees C. New ceramic material produced by addition of 10 weight percent zyttrite (yttria-stabilized zirconia) to (silicon nitride) offers significantly-improved high-temperature properties (those of MgO-doped Si3N4 ceramic). Work also showed that controlled Si3N4 powder with 10 weight percent zyttrite, significant improvement in room-temperature strength achieved. Variety of high-temperature structural applications are silicon nitride and silicon carbide. Potential for use in aircraft and automobile engines and in electric-power generating systems. Improved properties strongly suggest that the 10-weight percent zyttrite/Si3N4 material has strong potential for high-temperature applications.
Silicon carbide is of great interest for structural use in aircraft and automobile engines. This ceramic combines high thermal conductivity and low coefficient of thermal expansion, and consequently has good thermal shock resistance. However, like other ceramics, silicon carbide shows strength variability due to processing flaws such as large voids, shrinkage cracks, and inclusions. Agglomerates in the starting powder seem to be the predominant cause of such defects. Improved processing techniques such as slurry pressing and hot isostatic pressing (HIP) were employed to minimize these defects and to improve strength and reliability in the fabricated material. For this purpose 2-inch diameter disks were fabricated by various consolidation techniques. These include: dry pressing and sintering, slurry pressing and sintering, and slurry pressing and HIPing. The results are discussed.
In new technique, primary objective to develop method to distribute uniformly-thin powder-metal-alloy layers between alternate fiber layers prior to consolidation. Involves use of sheets of frozen alloy powder. These laminae, interspersed with fiber mats, used to make metal/fiber composites. In addition to aerospace applications, this technique, appropriately modified, has potential in the manufacture of future automobile engines or components including molded ceramics.
Design for pump that handles mixtures of liquid and gas efficiently. Containing only one rotor, pump is combination of centrifuge, pitot pump, and blower. Applications include turbomachinery in powerplants and superchargers in automobile engines. Efficiencies lower than those achieved in separate components. Nevertheless, design is practical and results in low consumption of power.
In the use of piezo-quartz indicators for high-speed automobile engines, the interpretation of pressure-time diagrams made by an oscillograph offers certain difficulties. On the one hand, the scale of the pressure amplitudes is not always the same under all conditions, while, on the other hand, the atmospheric zero line may be shifted from its correct position in the oscillogram. These facts make necessary to verify the readings of the quartz indicators by direct calibration before and after each series of tests and, on the basis of the results, to determine the scale for the oscillograms.
NASA has an interest in turbines related primarily to aeronautics and space applications. Airbreathing turbine engines provide jet and turboshaft propulsion, as well as auxiliary power for aircraft. Propellant-driven turbines provide rocket propulsion and auxiliary power for spacecraft. Closed-cycle turbine engines using inert gases, organic fluids, and metal fluids have been studied for providing long-duration electric power for spacecraft. Other applications of interest for turbine engines include land-vehicle (cars, trucks, buses, trains, etc.) propulsion power and ground-based electrical power. In view of the turbine-system interest and efforts at Lewis Research Center, a course entitled 'Turbine Design and Application' was presented during 1968-69 as part of the In-house Graduate Study Program. The course was somewhat revised and again presented in 1972-73. Various aspects of turbine technology were covered including thermodynamic and fluid-dynamic concepts, fundamental turbine concepts, velocity diagrams, losses, blade aerodynamic design, blade cooling, mechanical design, operation, and performance. The notes written and used for the course have been revised and edited for publication. Such a publication can serve as a foundation for an introductory turbine course, a means for self-study, or a reference for selected topics. Any consistent set of units will satisfy the equations presented. Two commonly used consistent sets of units and constant values are given after the symbol definitions. These are the SI units and the U.S. customary units. A single set of equations covers both sets of units by including all constants required for the U.S. customary units and defining as unity those not required for the SI units. Three volumes are compiled into one.
Modeling solidification microstructures has become an area of intense study in recent years. The properties of large scale cast products, ranging from automobile engine blocks to aircraft components and other industrial applications, are strongly dependent on the physics that occur at the mesoscopic and microscopic length scales during solidification. The predominant morphology found in solidification microstructures is the dendrite, a tree-like pattern of solid around which solidification proceeds. The microscopic properties of cast products are determined by the length scales of these dendrites, and their associated segregation profiles. For this reason understanding the mechanisms for pattern selection in dendritic growth has attracted a great deal of interest from the experimental and theoretical communities. In particular, a great deal of research has been undertaken to understand such issues as dendrite morphology, shape and growth speed. Experiments on dendrite evolution in pure materials by Glicksman and coworkers on succinonitrile (SCN), and more recently pivalic acid (PVA), as well as other transparent analogs of metals, have provided tests of theories for dendritic growth, and have stimulated considerable theoretical progress. These experiments have clearly demonstrated that in certain parameter ranges the physics of the dendrite tip can be characterized by a steady value for the dendrite tip velocity, radius of curvature and shape. Away from the tip, the time-dependent dendrite exhibits a characteristic sidebranching as it propagates, which is not yet well understood. These experiments are performed by observing individual dendrites growing into an undercooled melt. The experiments are characterized by the dimensionless undercooling. Most experiments are performed at low undercooling.
RCA has applied the results of NASA sponsored research in producing (LSIs), Large Scale Integrated Circuits, for its own product line -- communications equipment (for example) -- and for use in products manufactured by other companies such as the automobile engine analyzer developed by Chrysler Corp. Analyzer employs an LSI array to diagnose and solve problems for as many as 60 engine functions in less than four minutes. RCA's computerized system enables design in one to three months of LSIs which once required six to 12 months, and there has been an attendant reduction in design costs.
Everyone knows that an automobile engine wastes fuel and energy when it runs with a fuel-rich mixture. 'Lean' burning, mixing in more air and less fuel, is better for the environment. But lean mixtures also lead to engine misfiring and rough operation. No one knows the ultimate limits for lean operation, for 'weak' combustion that is friendly to the environment while still moving us around. This is where the accidental verification of a decades-old prediction may have strong implications for designing and running low-emissions engines in the 21st century. In 1944, Soviet physicist Yakov Zeldovich predicted that stationary, spherical flames are possible under limited conditions in lean fuel-air mixtures. Dr. Paul Ronney of the University of Southern California accidentally discovered such 'flame balls' in experiments with lean hydrogen-air mixtures in 1984 during drop-tower experiments that provided just 2.2 seconds of near weightlessness. Experiments aboard NASA's low-g aircraft confirmed the results, but a thorough investigation was hampered by the aircraft's bumpy ride. And stable flame balls can only exist in microgravity. The potential for investigating combustion at the limits of flammability, and the implications for spacecraft fire safety, led to the Structure of Flame Balls at Low Lewis-number (SOFBALL) experiment flown twice aboard the Space Shuttle on the Microgravity Sciences Laboratory-1 (MSL-1) in 1997. Success there led to the planned reflight on STS-107. Flame balls are the weakest fires yet produced in space or on Earth. Typically each flame ball produced only 1 watt of thermal power. By comparison, a birthday candle produces 50 watts. The Lewis-number measures the rate of diffusion of fuel into the flame ball relative to the rate of diffusion of heat away from the flame ball. Lewis-number mixtures conduct heat poorly. Hydrogen and methane are the only fuels that provide low enough Lewis-numbers to produce stable flame balls, and even then only for very weak, barely flammable mixtures. Nevertheless, under these conditions flame balls give scientists the opportunity to test models in one of the simplest combustion experiments possible. SOFBALL-2 science objectives include: Improving our understanding of the flame ball phenomenon; Determining the conditions under which flame balls exist; Testing predictions of flame ball lifetimes; Acquiring more precise data for critical model comparison.
The High Temperature Integrated Electronics and Sensor (HTIES) Program at the NASA Lewis Research Center is currently developing silicon carbide (SiC) for use in harsh conditions where silicon, the semiconductor used in nearly all of today's electronics, cannot function. Silicon carbide's demonstrated ability to function under extreme high-temperature, high-power, and/or high-radiation conditions will enable significant improvements to a far-ranging variety of applications and systems. These range from improved high-voltage switching for energy savings in public electric power distribution and electric vehicles, to more powerful microwave electronics for radar and cellular communications, to sensor and controls for cleaner-burning, more fuel-efficient jet aircraft and automobile engines.
The High Temperature Integrated Electronics and Sensors (HTIES) team at the NASA Lewis Research Center is developing silicon carbide (SiC) for use in harsh conditions where silicon, the semiconductor used in nearly all of today's electronics, cannot function. Silicon carbide's demonstrated ability to function under extreme high-temperature, high power, and/or high-radiation conditions will enable significant improvements to a far ranging variety of applications and systems. These improvements range from improved high-voltage switching for energy savings in public electric power distribution and electric vehicles, to more powerful microwave electronics for radar and cellular communications, to sensors and controls for cleaner-burning, more fuel-efficient jet aircraft and automobile engines. In the case of jet engines, uncooled operation of 300 to 600 C SiC power actuator electronics mounted in key high-temperature areas would greatly enhance system performance and reliability. Because silicon cannot function at these elevated temperatures, the semiconductor device circuit components must be made of SiC. Lewis' HTIES group recently fabricated and characterized high-temperature SiC rectifier diodes whose record-breaking characteristics represent significant progress toward the realization of advanced high-temperature actuator control circuits. The first figure illustrates the 600 C probe-testing of a Lewis SiC pn-junction rectifier diode sitting on top of a glowing red-hot heating element. The second figure shows the current-versus voltage rectifying characteristics recorded at 600 C. At this high temperature, the diodes were able to "turn-on" to conduct 4 A of current when forward biased, and yet block the flow of current ($quot;turn-off") when reverse biases as high as 150 V were applied. This device represents a new record for semiconductor device operation, in that no previous semiconductor electronic device has ever simultaneously demonstrated 600 C functionality, and 4-A turn-on and 150-V rectification. The high operating current was achieved despite severe device size limitations imposed by present-day SiC wafer defect densities. Further substantial increases in device performance can be expected when SiC wafer defect densities decrease as SiC wafer production technology matures.
The semiconductor silicon carbide (SiC) has long been known for its outstanding resistance to harsh environments (e.g., thermal stability, radiation resistance, and dielectric strength). However, the ability to produce device-quality material is severely limited by the inherent crystalline defects associated with this material and their associated electronic effects. Much progress has been made recently in the understanding and control of these defects and in the improved processing of this material. Because of this work, it may be possible to produce SiC-based solar cells for environments with high temperatures, light intensities, and radiation, such as those experienced by solar probes. Electronics and sensors based on SiC can operate in hostile environments where conventional silicon-based electronics (limited to 350 C) cannot function. Development of this material will enable large performance enhancements and size reductions for a wide variety of systems--such as high-frequency devices, high-power devices, microwave switching devices, and high-temperature electronics. These applications would supply more energy-efficient public electric power distribution and electric vehicles, more powerful microwave electronics for radar and communications, and better sensors and controls for cleaner-burning, more fuel-efficient jet aircraft and automobile engines. The 6H-SiC polytype is a promising wide-bandgap (Eg = 3.0 eV) semiconductor for photovoltaic applications in harsh solar environments that involve high-temperature and high-radiation conditions. The advantages of this material for this application lie in its extremely large breakdown field strength, high thermal conductivity, good electron saturation drift velocity, and stable electrical performance at temperatures as high as 600 C. This behavior makes it an attractive photovoltaic solar cell material for devices that can operate within three solar radii of the Sun.
Driven under difficult field conditions, the Army Jeep shown went more than 22,000 miles without an oil change in a test conducted by the U.S. Army Mobility Equipment Research and Development Command. Key to this exceptionally long oil life was a set of piston ring seals made of a new synthetic rubber formula called RC-34; the seal pictured, photographed after its arduous Army trial, shows no signs of deterioration. The seal and the RC-34 material, which may soon be available for use in the family auto, were developed by Ramsey Corporation, St. Louis, Missouri, a division of TRW Automotive Worldwide. The oil in an automobile engine must be I replaced every few thousand miles not because it wears out but because it becomes contaminated. The contamination sources are gasoline and combustion gases which blow by the piston rings to mix with the oil, reducing the oil's ability to lubricate properly. Seeking to prolong oil life by eliminating "blowby," Ramsey Corporation looked for a better way to seal piston rings and used NASA technology as a departure point. The parent company TRW, under contract to NASA's Jet Propulsion Laboratory, had developed seals and bladders from a type of material called elastomers which where designed to withstand the environmental extremes of interplanetary flight. That effort formed a knowledge base for research which culminated in Ramsey's RC-34 elastomer.
The photos show automobile engines being tested for nitrous oxide emissions, as required by the Environmental Protection Agency (EPA), at the Research and Engineering Division of Ford Motor Company, Dearborn. Michigan. NASA technical information helped the company develop a means of calculating emissions test results. Nitrous oxide emission readings vary with relative humidity in the test facility. EPA uses a standard humidity measurement, but the agency allows manufacturers to test under different humidity conditions, then apply a correction factor to adjust the results to the EPA standard. NASA's Dryden Flight Research Center developed analytic equations which provide a simple, computer-programmable method of correcting for humidity variations. A Ford engineer read a NASA Tech Brief describing the Dryden development and requested more detailed information in the form of a technical support package, which NASA routinely supplies to industry on request. Ford's Emissions Test Laboratory now uses the Dryden equations for humidity-adjusted emissions data reported to EPA.
Semiconductor electronic devices and circuits based on silicon carbide (SiC) are being developed for use in high-temperature, high-power, and/or high-radiation conditions under which devices made from conventional semiconductors cannot adequately perform. The ability of SiC-based devices to function under such extreme conditions is expected to enable significant improvements in a variety of applications and systems. These include greatly improved high-voltage switching for saving energy in public electric power distribution and electric motor drives; more powerful microwave electronic circuits for radar and communications; and sensors and controls for cleaner-burning, more fuel-efficient jet aircraft and automobile engines.
Silicon carbide based semiconductor electronic devices and circuits are presently being developed for use in high-temperature, high-power, and high-radiation conditions under which conventional semiconductors cannot adequately perform. Silicon carbide's ability to function under such extreme conditions is expected to enable significant improvements to a far-ranging variety of applications and systems. These range from greatly improved high-voltage switching for energy savings in public electric power distribution and electric motor drives to more powerful microwave electronics for radar and communications to sensors and controls for cleaner-burning more fuel-efficient jet aircraft and automobile engines. In the particular area of power devices, theoretical appraisals have indicated that SiC power MOSFET's and diode rectifiers would operate over higher voltage and temperature ranges, have superior switching characteristics, and yet have die sizes nearly 20 times smaller than correspondingly rated silicon-based devices [8]. However, these tremendous theoretical advantages have yet to be widely realized in commercially available SiC devices, primarily owing to the fact that SiC's relatively immature crystal growth and device fabrication technologies are not yet sufficiently developed to the degree required for reliable incorporation into most electronic systems. This chapter briefly surveys the SiC semiconductor electronics technology. In particular, the differences (both good and bad) between SiC electronics technology and the well-known silicon VLSI technology are highlighted. Projected performance benefits of SiC electronics are highlighted for several large-scale applications. Key crystal growth and device-fabrication issues that presently limit the performance and capability of high-temperature and high-power SiC electronics are identified.