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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Simulated Service and Stress Corrosion Cracking Testing for Friction Stir Welded Spun Form Domes

Damage tolerance testing development was required to help qualify a new spin forming dome fabrication process for the Ares 1 program at Marshall Space Flight Center (MSFC). One challenge of the testing was due to the compound curvature of the dome. The testing was developed on a sub-scale dome with a diameter of approximately 40 inches. The simulated service testing performed was based on the EQTP1102 Rev L 2195 Aluminum Lot Acceptance Simulated Service Test and Analysis Procedure generated by Lockheed Martin for the Space Shuttle External Fuel Tank. This testing is performed on a specimen with an induced flaw of elliptical shape generated by Electrical Discharge Machining (EDM) and subsequent fatigue cycling for crack propagation to a predetermined length and depth. The specimen is then loaded in tension at a constant rate of displacement at room temperature until fracture occurs while recording load and strain. An identical specimen with a similar flaw is then proof tested at room temperature to imminent failure based on the critical offset strain achieved by the previous fracture test. If the specimen survives the proof, it is then subjected to cryogenic cycling with loads that are a percentage of the proof load performed at room temperature. If all cryogenic cycles are successful, the specimen is loaded in tension to failure at the end of the test. This standard was generated for flat plate, so a method of translating this to a specimen of compound curvature was required. This was accomplished by fabricating a fixture that maintained the curvature of the specimen rigidly with the exception of approximately one-half inch in the center of the specimen containing the induced flaw. This in conjunction with placing the center of the specimen in the center of the load train allowed for successful testing with a minimal amount of bending introduced into the system. Stress corrosion cracking (SCC) tests were performed using the typical double beam assembly and with 4-point loaded specimens under alternate immersion conditions in a 3.5% NaCl environment for 90 days. In addition, experiments were conducted to determine the threshold stress intensity factor for SCC (K1SCC) of Al-Li 2195 which to our knowledge has not been determined previously. The successful simulated service and stress corrosion testing helped to provide confidence to continue to Ares 1 scale dome fabrication.

Stewart, Thomas J.↗
NASA NTRS2013

Net Shape Spin Formed Cryogenic Aluminum Lithium Cryogenic Tank Domes for Lower Cost Higher Performance Launch Vehicles

With the goal of lower cost (simplified manufacturing and lower part count) and higher performance (higher strength to weight alloys) the NASA Technical Maturation Program in 2006 funded a proposal to investigate spin forming of space launch vehicle cryogenic tank domes. The project funding continued under the NASA Exploration Technology Development Program through completion in FY12. The first phase of the project involved spin forming of eight, 1 meter diameter "path finder" domes. Half of these were processed using a concave spin form process (MT Aerospace, Augsburg Germany) and the other half using a convex process (Spincraft, Boston MA). The convex process has been used to produce the Ares Common Bulkhead and the concave process has been used to produce dome caps for the Space Shuttle light weight external tank and domes for the NASDA H2. Aluminum Lithium material was chosen because of its higher strength to weight ratio than the Aluminum 2219 baseline. Aluminum lithium, in order to obtain the desired temper (T8), requires a cold stretch after the solution heat treatment and quench. This requirement favors the concave spin form process which was selected for scale up. This paper describes the results of processing four, 5.5 meter diameter (upper stage scale) net shaped spin formed Aluminum Lithium domes. In order to allow scalability beyond the limits of foundry and rolling mills (about 12 foot width) the circular blank contained one friction stir weld (heavy lifter scales require a flat blank containing two welds). Mechanical properties data (tensile, fracture toughness, stress corrosion, and simulated service testing) for the parent metal and weld will also be discussed.

Curreri, Peter A.↗
NASA NTRS2004

Corrosion Performance of Stainless Steels in a Simulated Launch Environment

At the Kennedy Space Center, NASA relies on stainless steel (SS) tubing to supply the gases and fluids required to launch the Space Shuttle. 300 series SS tubing has been used for decades but the highly corrosive environment at the launch pad has proven to be detrimental to these alloys. An upgrade with higher alloy content materials has become necessary in order to provide a safer and long lasting launch facility. In the effort to find the most suitable material to replace the existing AISI 304L SS ([iNS S30403) and AISI 316L SS (UNS S31603) shuttle tubing, a study involving atmospheric exposure at the corrosion test site near the launch pads and electrochemical measurements is being conducted. This paper presents the results of an investigation in which stainless steels of the 300 series, 304L, 316L, and AISI 317L SS (UNS S31703) as well as highly alloyed stainless steels 254-SMO (UNS S32154), AL-6XN (N08367) and AL29-4C ([iNS S44735) were evaluated using direct current (DC) electrochemical techniques under conditions designed to simulate those found at the Space Shuttle Launch pad. The electrochemical results were compared to the atmospheric exposure data and evaluated for their ability to predict the long-term corrosion performance of the alloys.

Calle, Luz Marina↗
NASA NTRS1985

Turbine airfoil deposition models and their hot corrosion implications

This research project deals with the prediction of single- and multi-component salt(-solution) deposition, flow and oxide dissolution and their effects on the lifetime of turbine blades. Goals include rationalizing and helping to predict corrosion patterns on operational gas turbine (GT) rotor blades and stator vanes, and ultimately providing some of the tools required to design laboratory simulators and future corrosion resistant high-performance engines. Necessary background developments are reviewed. Results and tentative conclusions for single species (Na sub 2 SO sub 4 (1)) condensation, binary salt-solution (Na sub 2 SO sub 4-K sub 2 SO sub 4) condensation, and burner-rig testing of alloy materials are outlined.

Rosner, D. E.↗
NASA NTRS2005

Electrochemical Impedance Spectroscopy of Alloys in a Simulated Space Shuttle Launch Environment

Corrosion studies began at NASA/Kennedy Space Center in 1966 during the Gemini/Apollo Programs with the evaluation of long-term protective coatings for the atmospheric protection of carbon steel. An outdoor exposure facility on the beach near the launch pad was established for this purpose at that time. The site has provided over 35 years of technical information on the evaluation of the long-term corrosion performance of many materials and coatings as well as on maintenance procedures. Results from these evaluations have helped NASA find new materials and processes that increase the safety and reliability of our flight hardware, launch structures, and ground support equipment. The launch environment at the Kennedy Space Center (KSC) is extremely corrosive due to the combination of ocean salt spray, heat, humidity, and sunlight. With the introduction of the Space Shuttle in 1981, the already highly corrosive conditions at the launch pad were rendered even more severe by the acidic exhaust from the solid rocket boosters. Over the years, many materials have been evaluated for their corrosion performance under conditions similar to those found at the launch pads. These studies have typically included atmospheric exposure and evaluation with conventional electrochemical methods such as open circuit potential (OCP) measurements, polarization techniques, and electrochemical impedance spectroscopy (EIS). The atmosphere at the Space Shuttle launch site is aggressive to most metals and causes severe pitting in many of the common stainless steel alloys such as type 304L stainless steel (304L SS). A study was undertaken to find a more corrosion resistant material to replace the existing 304L SS tubing. This paper presents the results from atmospheric exposure as well as electrochemical measurements on the corrosion resistance of AL-6XN (UNS N08367) and 254-SMO (UNS S32154). Type 304L SS (UNS S30403) was used as a control. Conditions at the Space Shuttle launch pad were simulated by using a hydrochloric acid (HC1) and alumina (Al203) slurry rinse for the atmospheric exposure and an electrolyte consisting of 3.55% sodium chloride (NaC1) with increased concentrations of hydrochloric acid (HC1) for the electrochemical measurements. The results from both types of measurements revealed the superior corrosion performance of the higher-alloyed materials. Unlike 304L SS, 254-SMO and AL-6XN exhibited a significantly improved resistance to corrosion as the concentration of hydrochloric acid in he 3.55% NaCl electrolyte solution was increased.

Calle, L. M.↗
NASA NTRS1984

Turbine Airfoil Deposition Models

Gas turbine failures associated with sea-salt ingestion and sulfur-containing fuel impurities have directed attention to alkali sulfate deposition and the associated hot corrosion of gas turbine (GT) blades under some GT operating conditions. These salt deposits form thin, molten films which undermine the protective metal oxide coating normally found on GT blades. The prediction of molten salt deposition, flow and oxide dissolution, and their effects on the lifetime of turbine blades are examined. Goals include rationalizing and helping to predict corrosion patterns on operational GT rotor blades and stators, and ultimately providing some of the tools required to design laboratory simulators and future corrosion-resistant high-performance engines. Necessary background developments are reviewed first, and then recent results and tentative conclusions are presented along with a brief account of the present research plans.

Rosner, D. E.↗
NASA NTRS1990

Measurements and mechanisms of localized aqueous corrosion in aluminum-lithium alloys

Like most heat treatable aluminum alloys, localized corrosion and stress corrosion of Al-Li-Cu alloys is strongly dependent on the nature and distribution of second phase particles. To develop a mechanistic understanding of the role of localized corrosion in the stress corrosion process, bulk samples of T(sub 1) (Al2CuLi) and a range of Al-Cu-Fe impurity phases were prepared for electrochemical experiments. Potentiodynamic polarization and galvanic couple experiments were performed in standard 0.6 M NaCl and in simulated crevice solutions to assess corrosion behavior of these particles with respect to the alpha-Al matrix. A comparison of time to failure versus applied potential using a constant load, smooth bar SCC test technique in Cl(-), Cl(-)/CrO4(2-), and Cl(-)/CO3(2-) environments shows that rapid failures are to be expected when applied potentials are more positive than the breakaway potential (E sub br) of T(sub 1) (crack tip) but less than E(sub br) of alpha-Al (crack walls). It is shown that this criterion is not satisfied in aerated Cl(-) solutions. Accordingly, SCC resistance is good. This criterion is satisfied, however, in an alkaline isolated fissure exposed to a CO2 containing atmosphere. Rapid failure induced by these fissures was recently termed preexposure embrittlement. Anodic polarization shows that the corrosion behavior of T(sub 1) is relatively unaffected in alkaline CO3(2-) environments but the alpha-Al phase is rapidly passivated. X ray diffraction of crevice walls from artificial crevices suggests that passivation of alpha-Al occurs as hydrotalcite-type compound (LiAl2(OH)6)2(+) - CO3(2-) - nH2O.

Buchheit, Rudolph G., Jr.↗
NASA NTRS1992

Strength and fracture of glass in the lunar environment

Due to the lack of water on the moon, the effects of hydrolytic depolymerization - stress corrosion cracking - will be nonexistent in glasses produced and used on the moon. This would seem to make lunar glass very attractive for use in a wide variety of space engineering applications. We have applied the equation that describes stress corrosion cracking to lunar glass to show that, indeed, decreasing water vapor pressure results in an increase in strength. Experimental results on simulated lunar glass confirm this. The stress corrosion equation predicts an extremely high strength for glasses produced on the moon. This equation, however, cannot be applied to glasses under anhydrous conditions. In an environment completely devoid of water, the strength of glass will be determined by the fracture of the glass at the tip of a flaw, without the corrosive effects of water. Under this condition, in accordance with fracture theory, the strength of the glass will primarily be a function of the flaw size. Our experimental results show that the presence of surface flaws is more detrimental to the strength of simulated lunar glass than the effect of hydrolytic depolymerization.

Allen, Daniel D.↗
NASA NTRS2007

Numerical Simulations of Single Flow Element in a Nuclear Thermal Thrust Chamber

The objective of this effort is to develop an efficient and accurate computational methodology to predict both detailed and global thermo-fluid environments of a single now element in a hypothetical solid-core nuclear thermal thrust chamber assembly, Several numerical and multi-physics thermo-fluid models, such as chemical reactions, turbulence, conjugate heat transfer, porosity, and power generation, were incorporated into an unstructured-grid, pressure-based computational fluid dynamics solver. The numerical simulations of a single now element provide a detailed thermo-fluid environment for thermal stress estimation and insight for possible occurrence of mid-section corrosion. In addition, detailed conjugate heat transfer simulations were employed to develop the porosity models for efficient pressure drop and thermal load calculations.

Cheng, Gary↗
NASA NTRS2018

Sixty Earth-Days Test of a Prototype Pt/HTCC Alumina Package in Simulated Venus Environment

This paper presents experimental results of a prototype high temperature co-fired ceramic (HTCC) package with Au/Pt metallization in a three-phase harsh environment test that culminated with 60-day demonstration in simulated Venus surface environment of 465 degC with corrosive atmosphere at 90 bar pressure. The prototype package is based on previously developed and reported HTCC package successfully tested with multiple analog and digital silicon carbide (SiC) high temperatures semiconductor integrated circuits (ICs) at NASA Glenn Research Center in 500 degC Earth air ambient for over ten thousands hours, and short-term tested at temperatures above 800 degC. The three-phase harsh environment test started with 48 hours in 465 degC Earth air, followed by 48 hours in 465 degC nitrogen at 90 bar pressure and 1400 hours in simulated Venus surface environment of 465 degC with corrosive atmosphere at 90 bar. Initial analytical results of the package materials and surfaces after exposure to Venus environment are discussed to assess the stability of the packaging materials in the tested environments. The test in simulated Venus environment was implemented in the NASA Glenn Extreme Environment Rig (GEER). The results of this study suggest that an effective encapsulation of areas of surface metallization and vicinities may help to improve electrical performance of a HTCC alumina packaging system in Venus environment.

Chen, Liangyu↗
NASA NTRS1984

Oxidation and corrosion resistance of candidate Stirling engine heater-head-tube alloys

Sixteen candidate iron base Stirling engine heater head tube alloys are evaluated in a diesel fuel fired simulator materials test rig to determine their oxidation and corrosion resistance. Sheet specimens are tested at 820 C for 3500 hr in 5 hr heating cycles. Specific weight change data and an attack parameter are used to categorize the alloys into four groups; 10 alloys show excellent for good oxidation and corrosion resistance and six alloys exhibit poor or catastrophic resistance. Metallographic, X-ray, and electron microprobe analyses aid in further characterizing the oxidation and corrosion behavior of the alloys. Alloy compositions, expecially the reactive elements aluminum, titanium, and chromium, play a major role in the excellent oxidation and corrosion behavior of the alloys. The best oxidation resistance is associated with the formation of an iron nickel aluminum outer oxide scale, an intermediate oxide scale rich in chromium and titanium, and an aluminum outer oxide scale adjacent to the metallic substrate, which exhibits a zone of internal oxidation of aluminum and to some extent titanium.

Stephens, J. R.↗
NASA NTRS2018

Sixty Earth-Days Test of a Prototype Pt/HTCC Alumina Package in Simulated Venus Environment

This paper presents experimental results of a prototype high temperature co-fired ceramic (HTCC) package with Au/Pt metallization in a three-phase harsh environment test that culminated with 60-day demonstration in simulated Venus surface environment of 465 degrees Centigrade with corrosive atmosphere at 90 bars pressure. The prototype package is based on a previously developed and reported HTCC package successfully tested with multiple analog and digital silicon carbide (SiC) high temperatures semiconductor integrated circuits (ICs) at NASA Glenn Research Center in 500 degrees Centigrade Earth air ambient for over ten thousand hours, and short-term tested at temperatures above 800 degrees Centigrade. The three-phase harsh environment test started with 48 hours in 465 degrees Centigrade Earth air, followed by 48 hours in 465 degrees Centigrade nitrogen at 90-bar pressure and 1400 hours in simulated Venus surface environment of 465 degrees Centigrade with corrosive atmosphere at 90 bars. Initial analytical results of the package materials and surfaces after exposure to the Venus environment are discussed to assess the stability of the packaging materials in the tested environments. The test in a simulated Venus environment was implemented in the NASA Glenn Extreme Environment Rig (GEER). The results of this study suggest that an effective encapsulation of areas of surface metallization and vicinities may help to improve electrical performance of a HTCC alumina packaging system in Venus environment.

Chen, Liang-Yu↗
NASA NTRS1985

Stirling engine supporting research and technology

The supporting research and technology effort is intended to provide technical support to the current engine program and also to investigate advanced concepts for the next generation of Stirling engines. Technical areas represented are: seals, materials, engine experiments, combustion, system analysis, cseramics, and tribology. A collage of more recent work in each area is presented. Under seals, analysis and some experimental data on the effect of wear on rod seal performance is presented. The material work described concerns the effect of water content on hydrogen permeation. Results of experiments with the Philips' Advenco engine are presented. A comparison is made of two combustor nozzles, an air atomizing and an ultrasonic atomizing nozzle. A new venture in systems analysis to provide more rigorous Stirling engine simulation is discussed. The results of hydrogen corrosion tests on silicon carbide are presented. Friction and wear tests on candidate materials for engine hot ring tests are discussed.

Tomazic, W. A.↗