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NASA NTRSDate not supplied

Metallic Powder Core Tubular Wire (PCTW) Development for Additive Manufacturing

NASA Langley Research Center (LaRC) in Hampton, VA, and the Center for Welding, Joining, and Coating Research (CWJCR) in the Department of Metallurgical and Materials Engineering at the Colorado School of Mines (CSM) in Golden, CO, have collaborated for nearly fifteen years to develop metallic powder core tubular wire (PCTW) feedstock for additive manufacturing (AM) using electron beam deposition. The motivation for this development was to offset dealloying observed during deposition of titanium and aluminum alloy solid wire feedstock in the LaRC electron beam freeform fabrication (EBF3) system and to explore novel alloy compositions by tailoring the powder fill. EBF3 is a fusion-based AM process that is performed under vacuum and is consequently prone to vaporization loss of low vapor pressure alloying elements. Research spanning four graduate student research projects succeeded in developing the basic methodology to fabricate PCTW, the mass balance equations used to define the powder fill, microstructure control through particulate inoculation, and the feasibility of producing metal matrix composite materials. Metallic PCTW is comprised of a thin foil sheath wrapped around a powder blend. Fabrication of PCTW at CSM was accomplished using a tubular wire mill system to first bend a flat strip into a u-shaped cross section, deposit a powder fill, create a lap joint to seal the wire, and draw to final diameter. Powder management systems were developed to ensure uniform mixing of powder constituents and identify feed rates for optimum fill ratios. Processing parameters were successfully developed for titanium and aluminum alloy sheaths to account for material work hardening during drawing. Mass balance equations were developed to account for compositional contributions of the sheath and powder fill. PCTW composition can be adjusted through selection of the sheath or powder materials. PCTWs were successfully developed to offset Al loss in deposits of Ti-6-4 and Mg loss in Al 6061, resulting in deposits that were within the composition limits for each material. Ti-6-4 deposits were fabricated using PCTW comprised of commercially pure (CP) titanium sheath and a fill of pre-alloyed Ti-6-4 powder with additions of elemental Al and V powders. Additions of both elements were required to account for the CP Ti from the sheath, and Al was further enhanced to offset documented losses in EBF3 deposits. For Al 6061 deposits, composition was modulated through the choice of sheath material. The PCTW was made using an Al 5052 sheath to supplement Mg content and a fill composition of pre-alloyed 6061 powder with additions of Si and Cu.The slower solidification rate of the EBF3 process compared with laser powder bed fusion processes can lead to coarse-grained microstructures and mechanical property anisotropy. EBF3deposits of Ti-6-4 exhibited large epitaxially grown β grains, which result in degraded mechanical properties in the deposition direction. Microstructure refinement was achieved through a combination of electron beam modulation and the use of a PCTW designed for Ti-6-4 deposits and modified by the addition of powder made from Fe and B. Resulting deposits exhibited reductions in β grain size, α phase colony intercept length and lath width, and an increased volume fraction of β phase. The mechanism of microstructure refinement was related to precipitation of boride particles. Hardness testing confirmed that mechanical property anisotropy was reduced and an overall increase in hardness was achieved.Metal matrix composite (MMC) materials offer strength and stiffness benefits over unreinforced materials. Two methods were investigated using PCTW technology for producing Al 6061 basedMMC materials; the direct addition of SiC reinforcing particles and the in-situ generation of reinforcements through reaction synthesis of precursor powders. Al 6061 based MMCs reinforced with SiC exhibited particle clustering and formation of aluminum carbides during deposition. The application of a Ni coating to the SiC particles prior to incorporation into the powder fill eliminated aluminum carbide formation and aided particle distribution during deposition. Modulation of beam focus and power further reduced aluminum carbide formation and aided particle distribution. In reaction synthesis, precursor additions undergo an exothermic reaction during deposition to form new ceramic products, generally of finer scale than the initial precursor components. The product phases provide reinforcement in the MMC and act as nucleation sites during solidification, resulting in grain refinement, improved mechanical properties, and reduced susceptibility to solidification cracking. Higher tensile strength and stiffness were demonstrated in Al 6061 based MMCs with 2 vol% reinforcement. These combined research efforts demonstrate the potential of PCTW technology for customizing of alloy composition and achieving microstructure control. A manufacturing process for titanium- and aluminum-based PCTWs was developed based on iterative design, theoretical calculations, and empirical data. PCTW technology successfully mitigated Al loss from Ti-6-4 and Mg loss in Al 6061, resulted in grain refinement in Ti-6-4, and demonstrated fabrication of Al based MMCs

Marcia S Domack↗
NASA NTRS1976

Introducing controlled matter into a fluid system

Device consisting of capsule holder and glass inner tube has been developed to handle controlled particulate-contamination samples. Premeasured quantity of particles can be injected into closed fluid system without contamination.

Hoffman, C. E.↗
NASA NTRS2003

Global and Regional Decreases in Tropospheric Oxidants from Photochemical Effects of Aerosols

We evaluate the sensitivity of tropospheric OH, O3, and O3 precursors to photochemical effects of aerosols not usually included in global models: (1) aerosol scattering and absorption of ultraviolet radiation and (2) reactive uptake of HO', NO2, and NO3. Our approach is to couple a global 3-D model of tropospheric chemistry (GEOS- CHEM) with aerosol fields from a global 3-D aerosol model (GOCART). Reactive uptake by aerosols is computed using reaction probabilities from a recent review (gamma(sub HO2) = 0.2, gamma(sub NO2) = 10(exp -4), gamma(sub NO3) = l0(exp -3). Aerosols decrease the O3 - O((sup 1)D) photolysis frequency by 5-20% at the surface throughout the Northern Hemisphere (largely due to mineral dust) and by a factor of 2 in biomass burning regions (largely due to black carbon). Aerosol uptake of HO2 accounts for 10-40% of total HOx radical ((triple bonds)OH + peroxy) loss in the boundary layer over polluted continental regions (largely due to sulfate and organic carbon) and for more than 70% over tropical biomass burning regions (largely due to organic carbon). Uptake of NO2 and NO3 accounts for 10-20% of total HNO3 production over biomass burning regions and less elsewhere. Annual mean OH concentrations decrease by 9% globally and by 5-35% in the boundary layer over the Northern Hemisphere. Simulated CO increases by 5- 15 ppbv in the remote Northern Hemisphere, improving agreement with observations. Simulated boundary layer O3 decreases by 15- 45 ppbv over India during the biomass burning season in March and by 5-9 ppbv over northern Europe in August, again improving comparison with observations. We find that particulate matter controls would increase surface O3 over Europe and other industrial regions.

Martin, Randall V.↗
NASA NTRSDate not supplied

Metallic Powder Core Tubular Wire Development for Additive Manufacturing

NASA Langley Research Center (LaRC) in Hampton, VA, and the Center for Welding, Joining, and Coating Research (CWJCR) in the Department of Metallurgical and Materials Engineering at the Colorado School of Mines (CSM) in Golden, CO, have collaborated for nearly fifteen years to develop metallic powder core tubular wire (PCTW) feedstock for additive manufacturing (AM) using electron beam deposition. The motivation for this development was to offset dealloying observed during deposition of titanium and aluminum alloy solid wire feedstock in the LaRC electron beam freeform fabrication (EBF3) system and to explore novel alloy compositions by tailoring the powder fill. EBF3 is a fusion-based AM process that is performed under vacuum and is consequently prone to vaporization loss of low vapor pressure alloying elements. Research spanning four graduate student research projects succeeded in developing the basic methodology to fabricate PCTW, the mass balance equations used to define the powder fill, microstructure control through particulate inoculation, and the feasibility of producing metal matrix composite materials.

powder core tubular wire (PCTW)↗
NASA NTRS2014

Development of Test Protocols for International Space Station Particulate Filters

Air quality control on the International Space Station (ISS) is a vital requirement for maintaining a clean environment for the crew and the hardware. This becomes a serious challenge in pressurized space compartments since no outside air ventilation is possible, and a larger particulate load is imposed on the filtration system due to lack of gravitational settling. The ISS Environmental Control and Life Support System (ECLSS) uses a filtration system that has been in use for over 14 years and has proven to meet this challenge. The heart of this system is a traditional High- Efficiency Particulate Air (HEPA) filter configured to interface with the rest of the life support elements and provide effective cabin filtration. Over the years, the service life of these filters has been re-evaluated based on limited post-flight tests of returned filters and risk factors. On earth, a well designed and installed HEPA filter will last for several years, e.g. in industrial and research clean room applications. Test methods for evaluating these filters are being developed on the basis of established test protocols used by the industry and the military. This paper will discuss the test methods adopted and test results on prototypes of the ISS filters. The results will assist in establishing whether the service life can be extended for these filters. Results from unused filters that have been in storage will also be presented to ascertain the shelf life and performance deterioration, if any and determine if the shelf life may be extended.

Aerosol↗
NASA NTRS2015

Development of Test Protocols for International Space Station Particulate Filters

Air quality control on the International Space Station (ISS) is a vital requirement for maintaining a clean environment for the crew and the hardware. This becomes a serious challenge in pressurized space compartments since no outside air ventilation is possible, and a larger particulate load is imposed on the filtration system due to lack of gravitational settling. The ISS Environmental Control and Life Support System (ECLSS) uses a filtration system that has been in use for over 14 years and has proven to meet this challenge. The heart of this system is a traditional High-Efficiency Particulate Air (HEPA) filter configured to interface with the rest of the life support elements and provide effective cabin filtration. The filter element for this system has a non-standard cross-section with a length-to-width ratio (LW) of 6.6. A filter test setup was designed and built to meet industry testing standards. A CFD analysis was performed to initially determine the optimal duct geometry and flow configuration. Both a screen and flow straighter were added to the test duct design to improve flow uniformity and face velocity profiles were subsequently measured to confirm. Flow quality and aerosol mixing assessments show that the duct flow is satisfactory for the intended leak testing. Preliminary leak testing was performed on two different ISS filters, one with known perforations and one with limited use, and results confirmed that the testing methods and photometer instrument are sensitive enough to detect and locate compromised sections of an ISS BFE.Given the engineering constraints in designing spacecraft life support systems, it is anticipated that non-industry standard filters will be required in future designs. This work is focused on developing test protocols for testing the ISS BFE filters, but the methodology is general enough to be extended to other present and future spacecraft filters. These techniques for characterizing the test duct and perform leak testing can be applied to conducting acceptance testing and inventory testing for future manned exploration programs with air revitalization filtration needs, possibly even for in-situ filter element integrity testing for extensively long-duration missions. We plan to address the unique needs for test protocols for crewed spacecraft particulate filters by preparing the initial version of a standard, to be documented as a NASA Technical Memorandum (TM).

Filtration↗
NASA NTRS1998

Suspension of SiC Powders in Allyhydridopolycarbosilane (AHPCS): Control of Rheology

Inert particulate fillers can be blended with preceramic polymers prior to infiltration of composite preforms to increase pyrolysis yield and decrease shrinkage, thus reducing the number of infiltration/ pyrolysis cycles required for densification. However, particulate filler loadings and concentration of added dispersants necessary to maintain low viscosity (< 0.50 N.s/sq m) slurries vary with the characteristics of the particular AHPCS polymer batch. These batch to batch variations occur with alterations in the synthesis process and method of allyl substitution, which in turn alter polymer structure and molecular weight distribution. A number of different polymer batches were characterized by NMR, GPC and thermal analysis, and the influence of polymer structure on rheology of filled systems determined. When the high molecular weight fraction increased to too great a level, suitably fluid slurries could no longer be attained.

Hurwitz, Frances I.↗
NASA NTRS1986

Improved Electronic Control for Electrostatic Precipitators

Electrostatic precipitators remove particulate matter from smoke created by burning refuse. Smoke exposed to electrostatic field, and particles become electrically charged and migrate to electrically charged collecting surfaces. New microprocessor-based electronic control maintains precipitator power at maximum particulate-collection level. Control automatically senses changes in smoke composition due to variations in fuel or combustion and adjusts precipitator voltage and current accordingly. Also, sensitive yet stable fault detection provided.

Johnston, D. F.↗
NASA NTRS1979

Controlled metal-film deposition on alumina substrates

Report describes results of investigation of preparation, nucleation and controlled growth of particulate deposits (palladium and iron) on electron-transparent alumina substrates. Results indicate that characteristic properties of metal deposits are strongly dependent on cleanliness, phase, and crystallographic orientation of substrate.

Lee, E. H.↗
NASA NTRS1980

Modification of the ECAS reference steam power generating plant to comply with the EPA 1979 new source performance standards

Detailed capital cost estimates for the ECAS and modified reference plants in mid-1978 dollars for both 250 and 175 F (394 and 353 K) stack gas reheat temperatures based on the cost estimates developed for the ECAS study are presented. The scope of the work included technical assessment of sulfur dioxide scrubber system design, on site calcination versus purchased lime, reheat of stack gas, effect of sulfur dioxide scrubber on particulate emission, and control of nitrogen oxides.

Fogelson, S. A.↗
NASA NTRS1993

Development of high temperature liquid lubricants for low-heat rejection: Heavy duty diesel engines

The objective of this DOE program was to develop a liquid lubricant that will allow advanced diesel engines to operate at top ring reversal temperatures approaching 500 C and sump temperatures approaching 250 C. The lubricants developed demonstrated at marginal increase in sump temperature capability, approximately 15 C, and an increase in top ring reversal temperature. A 15W-40 synthetic lubricant designated HTL-4 was the best lubricant developed in terms of stability, wear control, deposit control dispersancy, and particulate emissions.

Wiczynski, P. D.↗
NASA NTRS1998

Catastrophic Collapse of Particulate Clouds: Implications From Aggregation Experiments in the USML-1 and USML-2 Glovebox

Experiments with electrostatic aggregation of well-dispersed (nominally, mono-dispersed), freely suspended particles in the United States Microgravity Laboratory (USML) Glovebox have determined that filamentary aggregates are a universal product of grain interactions in relatively dense particulate clouds. Aggregate growth from the experimental particle clouds primarily involves dipole-dipole interactions for nonconducting materials; dipole interactions account for both attraction between grains as well as the cohesive force that maintains the integrity of the filamentary structures. When a cloud undergoes a turbulent-to-quiescent transition after damping of fluid and ballistic grain motions, aggregation occurs almost instantaneously and the cloud is transformed into a population of "heavier" clusters of material with organized electrical structures. This abrupt transformation could initiate catastrophic gravitational collapse of certain regions of particulate clouds, thus controlling the longevity and fate of cloud systems as diverse as protoplanetary dust disks and volcanic eruption plumes.

Marshall, John↗
NASA NTRS2020

Climate and air quality impacts due to mitigation of non-methane near-term climate forcers

It is important to understand how future environmental policies will impact both climate change and air pollution. Although targeting near-term climate forcers (NTCFs), defined here as aerosols, tropospheric ozone, and precursor gases, should improve air quality, NTCF reductions will also impact climate. Prior assessments of the impact of NTCF mitigation on air quality and climate have been limited. This is related to the idealized nature of some prior studies, simplified treatment of aerosols and chemically reactive gases, as well as a lack of a sufficiently large number of models to quantify model diversity and robust responses. Here, we quantify the 2015–2055 climate and air quality effects of non-methane NTCFs using nine state-of-the-art chemistry–climate model simulations conducted for the Aerosol and Chemistry Model Intercomparison Project (AerChemMIP). Simulations are driven by two future scenarios featuring similar increases in greenhouse gases (GHGs) but with “weak” (SSP3-7.0) versus “strong” (SSP3-7.0-lowNTCF) levels of air quality control measures. As SSP3-7.0 lacks climate policy and has the highest levels of NTCFs, our results (e.g., surface warming) represent an upper bound. Unsurprisingly, we find significant improvements in air quality under NTCF mitigation (strong versus weak air quality controls). Surface fine particulate matter (PM2.5) and ozone (O3) decrease by −2.2±0.32 µg m−3 and −4.6±0.88 ppb, respectively (changes quoted here are for the entire 2015–2055 time period; uncertainty represents the 95 % confidence interval), over global land surfaces, with larger reductions in some regions including south and southeast Asia. Non-methane NTCF mitigation, however, leads to additional climate change due to the removal of aerosol which causes a net warming effect, including global mean surface temperature and precipitation increases of 0.25±0.12 K and 0.03±0.012 mm d−1, respectively. Similarly, increases in extreme weather indices, including the hottest and wettest days, also occur. Regionally, the largest warming and wetting occurs over Asia, including central and north Asia (0.66±0.20 K and 0.03±0.02 mm d−1), south Asia (0.47±0.16 K and 0.17±0.09 mm d−1), and east Asia (0.46±0.20 K and 0.15±0.06 mm d−1). Relatively large warming and wetting of the Arctic also occur at 0.59±0.36 K and 0.04±0.02 mm d−1, respectively. Similar surface warming occurs in model simulations with aerosol-only mitigation, implying weak cooling due to ozone reductions. Our findings suggest that future policies that aggressively target non-methane NTCF reductions will improve air quality but will lead to additional surface warming, particularly in Asia and the Arctic. Policies that address other NTCFs including methane, as well as carbon dioxide emissions, must also be adopted to meet climate mitigation goals.

Climate↗
NASA NTRS2016

Response of SO2 and Particulate Air Pollution to Local and Regional Emission Controls: A Case Study in Maryland

This paper addresses the questions of what effect local regulations can have on pollutants with different lifetimes and how surface observations and remotely sensed data can be used to determine the impacts. We investigated the decadal trends of tropospheric sulfur dioxide (SO2) and aerosol pollution over Maryland and its surrounding states, using surface, aircraft, and satellite measurements. Aircraft measurements indicated fewer isolated SO2 plumes observed in summers, a 40 decrease of column SO2, and a 20 decrease of atmospheric optical depth (AOD) over Maryland after the implementation of local regulations on sulfur emissions from power plants (90 reduction from 2010). Surface observations of SO2 and particulate matter (PM) concentrations in Maryland show similar trends. OMI SO2 and MODIS AOD observations were used to investigate the column contents of air pollutants over the eastern U.S.; these indicate decreasing trends in column SO2 (60 decrease) and AOD (20 decrease). The decrease of upwind SO2 emissions also reduced aerosol loadings over the downwind Atlantic Ocean near the coast by 20, while indiscernible changes of the SO2 column were observed. A step change of SO2 emissions in Maryland starting in 20092010 had an immediate and profound benefit in terms of local surface SO2 concentrations but a modest impact on aerosol pollution, indicating that short-lived pollutants are effectively controlled locally, while long-lived pollutants require regional measures.

satellite measurements↗
NASA NTRS2007

Initiation of Turbulent Spots in a Laminar Boundary Layer by Rigid Falling Particulates

A transitional laminar boundary layer is developed on a 1m wide km long flat plate in a 0.6m deep water channel with a freestream velocity of 15-50 cm/s. A particulate dispenser under computer control ejects individual particles having diameters of 1/3 delta into the free stream. The particulates are introduced with an initial velocity of U(sub infinity) in the direction of the free stream. They have differing specific gravities of 1.03-2.7 which introduces an additional non-dimensional parameter relating the time taken to traverse the boundary layer to the convective time scale. The particulates produce a wake in the upper region of the boundary layer as they sink towards the wall. Visualization data taken over the range 5 x 10(exp 4) less than Re(sub x) less than 5 x 10(exp 5) indicate that turbulent spots are produced by the disturbances due to the wake rather than by the particulates themselves. This suggests that the spot formation process in this case may be inviscid in nature and may not be strongly influenced by the presence of the wall.

Blackwelder, R. F.↗