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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Stress corrosion evaluation of HP 9Ni-4Co-0.30C steel plate welds

A stress corrosion cracking (SCC) investigation was conducted on HP 9Ni-4Co-0.30C steel plate welds (welded by using straight polarity plasma arc and HP 9Ni-4Co-0.20C weld wire) since this material is being considered for use in the Advanced Solid Rocket Motor (ASRM) program. Prior to the welding, the material was double tempered at 538 C (1,000 F). After welding, only part of the material was stress relieved at 510 C (950 F) for 3 h. Round tensile specimens obtained from nonstress-relieved material were tested in 100-percent relative humidity at 38 C (100 F), in 3.5-percent NaCl alternate immersion, and in 5-percent salt spray at 35 C (95 F). Specimens obtained from stress-relieved material were tested in alternate immersion. The stress levels were 50, 75, and 90 percent of the corresponding 0.2-percent yield strength (YS). All the nonstress-relieved specimens exposed to salt spray and alternate immersion failed. Stress-relieved specimens (exposed to alternate immersion) failed at 75 and 90 percent of YS. No failures occurred at 50 percent of YS in the stress-relieved specimens which indicates a beneficial effect of the stress relief on the SCC resistance of these welds. The stress relief also had a positive effect on the mechanical properties of the welds (the most important being an increase of 21 percent on the YS). Under the conditions of these tests, the straight polarity plasma are welded HP 9Ni4Co-0.30C steel plate was found highly susceptible to SCC in the nonstress-relieved condition. This susceptibility to SCC was reduced by stress relieving.

Torres, Pablo D.↗
NASA NTRS1977

The stress corrosion resistance and the cryogenic temperature mechanical properties of annealed Nitronic 60 bar material

Ambient and cryogenic temperature mechanical properties and the ambient temperature stress corrosion properties of annealed, straightened, and centerless ground Nitronic 60 stainless steel alloy bar material are presented. The mechanical properties of longitudinal specimens were evaluated at test temperatures from ambient to liquid hydrogen. The tensile test data indicated increasing strength with decreasing temperature to -196 C. Below liquid nitrogen temperature the smooth tensile and notched tensile strengths decreased slightly while the elongation and reduction of area decreased drastically. The Charpy V-notched impact energy decreased steadily with decreasing test temperature. Stress corrosion tests were performed on longitudinal tensile specimens and transverse C-ring specimens exposed to: alternate immersion in a 3.5% NaCl bath; humidity cabinet; and a 5% salt spray atmosphere. The longitudinal tensile specimens experienced no corrosive attack. Approximately 3/4 of the transverse C-rings exposed to alternate immersion and to salt spray experienced a pitting attack on the top and bottom ends. Additional stress corrosion tests were performed on transverse tensile specimens. No failures occurred in the 90% stressed specimens exposed for 90 days in the alternate immersion and salt spray environments

Montano, J. W. L.↗
NASA NTRS1976

The Stress Corrosion Resistance and the Cryogenic Temperature Mechanical Behavior of 18-3 Mn (Nitronic 33) Stainless Steel Parent and Welded Material

The ambient and cryogenic temperature mechanical properties and the ambient temperature stress corrosion results of 18-3 Mn (Nitronic 33)stainless steel, longitudinal and transverse, as received and as welded (TIG) material specimens manufactured from 0.063 inch thick sheet material, were described. The tensile test results indicate an increase in ultimate tensile and yield strengths with decreasing temperature. The elongation remained fairly constant to -200 F, but below that temperature the elongation decreased to less than 6.0% at liquid hydrogen temperature. The notched tensile strength (NTS) for the parent metal increased with decreasing temperature to liquid nitrogen temperature. Below -320 F the NTS decreased rapidly. The notched/unnotched (N/U) tensile ratio of the parent material specimens remained above 0.9 from ambient to -200 F, and decreased to approximately 0.65 and 0.62, respectively, for the longitudinal and transverse directions at liquid hydrogen temperature. After 180 days of testing, only those specimens exposed to the salt spray indicated pitting and some degradation of mechanical properties.

Montano, J. W.↗
NASA NTRS2011

Timescale Correlation between Marine Atmospheric Exposure and Accelerated Corrosion Testing

Evaluation of metal-based structures has long relied on atmospheric exposure test sites to determine corrosion resistance in marine environments. Traditional accelerated corrosion testing relies on mimicking the exposure conditions, often incorporating salt spray and ultraviolet (UV) radiation, and exposing the metal to continuous or cyclic conditions of the corrosive environment. Their success for correlation to atmospheric exposure is often a concern when determining the timescale to which the accelerated tests can be related. Accelerated laboratory testing, which often focuses on the electrochemical reactions that occur during corrosion conditions, has yet to be universally accepted as a useful tool in predicting the long term service life of a metal despite its ability to rapidly induce corrosion. Although visual and mass loss methods of evaluating corrosion are the standard and their use is imperative, a method that correlates timescales from atmospheric exposure to accelerated testing would be very valuable. This work uses surface chemistry to interpret the chemical changes occurring on low carbon steel during atmospheric and accelerated corrosion conditions with the objective of finding a correlation between its accelerated and long-term corrosion performance. The current results of correlating data from marine atmospheric exposure conditions at the Kennedy Space Center beachside corrosion test site, alternating seawater spray, and immersion in typical electrochemical laboratory conditions, will be presented. Key words: atmospheric exposure, accelerated corrosion testing, alternating seawater spray, marine, correlation, seawater, carbon steel, long-term corrosion performance prediction, X-ray photoelectron spectroscopy.

Montgomery, Eliza L.↗
NASA NTRS1973

Environmental testing of REI-Mullite thermal protection system for the space shuttle orbiter

Tests conducted to evaluate performances in the natural environments of salt spray, humidity, rain, vacuum, and cryogenic temperatures have shown the ceramic mullite fiber is completely compatible and that these environments have no adverse effects on subsequent mission performance. Rain erosion testing has indicated a damage threshold that must be accounted for in the final design. Tests conducted to evaluate the performance of ceramic mullite fiber to induced acoustic, re-entry, and structural load environments again have shown complete capability to fulfill mission environments. Although minor cracking of the sidewall coating was seen to occur throughout the induced environment test program, sidewall designs configured to provide increased flexibility have been successfully tested.

Gluck, R.↗
DOE OSTI2022

The Electrochemical Behavior of As-Prepared Aluminum Alloy A360 Produced by Selective Laser Melting Fabrication with and without a Trivalent Chromium Process Conversion Coating

In this paper, we report on the electrochemical behavior and corrosion resistance of as-prepared aluminum alloy, A360 (AlSi10Mg), fabricated by additive manufacturing, with and without a trivalent chromium process conversion coating. Selective laser melting was the 3D printing process used for the alloy build. The corrosion suppression provided by the coating system was assessed through electrochemical measurements and accelerated degradation testing during a 14-day continuous neutral salt-spray exposure. The results indicate that the conversion coating can be formed by solution pretreating (degreasing and deoxidation) the alloy (X-Z plane perpendicular to the build plane) with its native surface roughness (as-prepared) followed by immersion for 10, 15 or 20 min in the coating bath. All three immersion times provide an equivalent level of corrosion protection to the alloy. The conversion coating suppresses both anodic and cathodic currents, increases the polarization resistance, and provides both anodic and cathodic corrosion protection to the as-prepared alloy. The conversion-coated specimens exhibit good stand-alone corrosion resistance during a 14-day neutral salt-spray exposure with corrosion intensity values (g/m 2 -year) ~10x lower than values for the uncoated, as-prepared alloy specimens.

36 MATERIALS SCIENCE↗
NASA NTRS2014

High-Performance Polyimide Powder Coatings

Researchers at NASA's Kennedy Space Center have developed advanced powder coatings for longer-lasting, improved corrosion control. The results of preliminary tests of the coatings and their resistance to salt spray corrosion are very encouraging, and commercial partners are sought for further development.

coatings↗
NASA NTRS1985

Deposition of Na2SO4 from salt-seeded combustion gases of a high velocity burner rig

With a view to developing simulation criteria for the laboratory testing of high-temperature materials for gas turbine engines, the deposition rates of sodium sulfate from sodium salt-seeded combustion gases were determined experimentally using a well instrumented high-velocity burner. In the experiments, Na2SO4, NaCl, NaNO3, and simulated sea salt solutions were injected into the combustor of the Mach 0.3 burner rig operating at constant fuel/air ratios. The deposits formed on an inert rotating collector were then weighed and analyzed. The experimental results are compared to Rosner's vapor diffusion theory. Some additional test results, including droplet size distribution of an atomized salt spray, are used in interpreting the deposition rate data.

Santoro, G. J.↗
NASA NTRS1980

Evaluation of the stress corrosion cracking resistance of several high strength low alloy steels

The stress corrosion cracking resistance was studied for high strength alloy steels 4130, 4340, for H-11 at selected strength levels, and for D6AC and HY140 at a single strength. Round tensile and C-ring type specimens were stressed up to 100 percent of their yield strengths and exposed to alternate immersion in salt water, salt spray, the atmosphere at Marshall Space Flight Center, and the seacoast at Kennedy Space Center. Under the test conditions, 4130 and 4340 steels heat treated to a tensile strength of 1240 MPa (180 ksi), H-11 and D6AC heat treated to a tensile strength of 1450 MPa (210 ksi), and HY140 (1020 MPa, 148 ksi) are resistant to stress corrosion cracking because failures were not encountered at stress levels up to 75 percent of their yield strengths. A maximum exposure period of one month for alternate immersion in salt water or salt spray and three months for seacoast is indicated for alloy steel to avoid false indications of stress corrosion cracking because of failure resulting from severe pitting.

Humphries, T. S.↗
DOE OSTI2020

A scalable approach of using biomass derived glycerol to synthesize cathode materials for lithium-ion batteries

Glycerol, a main byproduct of biodiesel, was used as the fuel agent in a scalable flame-assisted spray pyrolysis approach to synthesize micron-size cathode materials. Single droplet combustion, particle morphology, and electrochemical performance were examined considering the effects of salt concentration, water addition, and post-annealing time on synthesizing Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 (NCM111) cathode materials. Single droplet tests showed that a sufficient amount of water in the glycerol-based precursor could delay droplet inflation and ignition. Moreover, using a two-fluid atomization nozzle, spray tests demonstrated that adding water would result in less wrinkled and more uniform particles. Nevertheless, increasing water proportion in the precursor could reduce the reaction heat, resulting in that samples prepared with water addition needed longer post-annealing time to improve their electrochemical performance. Using the precursor without water, the best performed NCM111 cathode material was synthesized with only 2 h of post-annealing. It has a discharge capacity of 163.3 mAh/g at 0.1C and 85.5% capacity retention at 1C after 100 cycles. Furthermore, the current work confirmed the capability of using glycerol as a sustainable fuel agent to synthesize NCM111 cathode materials, and also provided basic conditions for the development of large-scale production in the future.

25 ENERGY STORAGE↗
NASA NTRS1973

An Apollo compatible cloud physics experiment.

Consideration of the utilization of a low-gravity environment to obtain experimental information, in the area of cloud microphysics, which cannot be obtained in ground laboratories. The experiment discussed is designed to obtain quantitative answers about evaporation and breakup of salt particles from ocean spray and other sources. In addition to salt nuclei distribution mechanisms, this breakup has ecological importance in relation to the spreading of salt mists from salted highways and spreading of brine cooling tower spray from electrical power generation plants. This experiment is being submitted for consideration on the Apollo-Soyuz Test Program in 1975.

Eaton, L. R.↗
NASA NTRS1972

Development of termination and utilization concepts for flat conductor cables. Volume 1: Development of low profile flat conductor cable connecting device and permanent splice

The development of low-profile flat conductor cable (FCC) connecting device and FCC permanent splice methods are discussed. The design goal for the low-profile connecting device was to mate and unmate FCC harness to a typical spacecraft component with a maximum height of 3/8 in. The results indicate that the design, fabrication, and processing of the low-profile connecting device are feasible and practical. Some redesign will be required to achieve the goal of 3/8 in. Also, failures were experienced subsequent to salt spray and humidity exposure. Five different FCC permanent splice methods were considered. Subsequent to evaluation of these five methods, two design concepts were chosen for development tests.

Source record↗
NASA NTRS1995

Improved Hermetic Feedthrough Seals For Optical Fibers

Improved inorganic sealing materials withstand widely ranging temperatures. Hermetic feedthrough seals for optical fibers withstand temperatures from as low as minus 325 degrees F (about minus 198 degrees C) to as high as 392 degrees F (about 200 degrees C) while maintaining helium leak rate of below 10 to the negative 11th power cm(3)/s. Demonstrated to perform exceptionally through salt spray, sinusoidal and random vibrations (20 to 2000 Hz), mechanical shock (40 g's) thermal shock at extreme temperatures, humidity, and radiation (neutron fluence, gamma, and ion) testing.

Fan, Robert Jui-Lin↗
DOE OSTI2022

OCEANFILMS (Organic Compounds from Ecosystems to Aerosols: Natural Films and Interfaces via Langmuir Molecular Surfactants) sea spray organic aerosol emissions – implementation in a global climate model and impacts on clouds

Sea spray aerosol is one of the major sources of atmospheric particulate matter globally. It has increasingly been recognized that organic matter derived from ocean biological precursors contributes significantly to the composition of submicron sea spray and may modify sea spray aerosol impacts on clouds and climate. This paper describes the implementation of the OCEANFILMS (Organic Compounds from Ecosystems to Aerosols: Natural Films and Interfaces via Langmuir Molecular Surfactants) parameterization for sea spray organic aerosol emissions in a global Earth system model, the Energy Exascale Earth System Model (E3SM). OCEANFILMS is a physically based model that links sea spray chemistry with ocean biogeochemistry using a Langmuir partitioning approach. We describe the implementation details of OCEANFILMS within E3SM, compare simulated aerosol fields with observations, and investigate impacts on simulated clouds and climate. Four sensitivity cases are tested, in which organic emissions either strictly add to or strictly replace sea salt emissions (in mass and number) and are either fully internally or fully externally mixed with sea salt. The simulation with internally mixed, added organics agrees reasonably well with observed seasonal cycles of organic matter in marine aerosol and has been selected as the default configuration of the E3SM. In this configuration, sea spray organic aerosol contributes an additional source of cloud condensation nuclei, adding up to 30 cm -3 to Southern Ocean boundary-layer cloud condensation nuclei concentrations (supersaturation = 0.1 %). The addition of this new aerosol source strengthens shortwave radiative cooling by clouds by -0.36 W m -2 in the global annual mean and contributes more than -3.5 W m -2 to summertime zonal mean cloud forcing in the Southern Ocean, with maximum zonal mean impacts of about -4 W m -2 around 50–60°S. This is consistent with a previous top-down, satellite-based empirical estimate of the radiative forcing by sea spray organic aerosol over the Southern Ocean. Through its mechanistic approach, OCEANFILMS offers a path towards improved understanding of the feedbacks between ocean biology, sea spray organic matter, and climate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1981

Evaluation of several corrosion protective coating systems on aluminum

A study of several protective coating systems for use on aluminum in seawater/seacoast environments was conducted to review the developments made on protective coatings since early in the Space Shuttle program and to perform comparative studies on these coatings to determine their effectiveness for providing corrosion protection during exposure to seawater/seacoast environments. Panels of 2219-T87 aluminum were coated with 21 different systems and exposed to a 5 percent salt spray for 4000 hr. Application properties, adhesion measurements, heat resistance and corrosion protection were evaluated. For comparative studies, the presently specified Bostik epoxy system used on the SRB structures was included. Results of these tests indicate four systems with outstanding performance and four additional systems with protection almost as good. These systems are based on a chromated pretreatment, a chromate epoxy primer, and a polyurethane topcoat. Consideration for one of these systems should be included for those applications where superior corrosion protection for aluminum surfaces is required.

Higgins, R. H.↗
DOE OSTI2026

Designing carbon wetting layers with inorganic salts as additives for enhanced adhesion and molten sodium wettability in electrochemical application

ß” alumina solid-state electrolyte (BASE) is considered one of the most promising materials for sodium batteries due to its high ionic conductivity and exceptional stability with molten sodium. However, at lower operating temperatures, the poor physical contact at the liquid-solid interface between molten sodium and BASE results in high interfacial resistance. In this study, we explore the optimization of carbon wetting layers with various salt additives to enhance adhesion and improve molten sodium wettability. Using a spray-coating method, carbon layers incorporating sodium hexametaphosphate (Na6(PO3)6, SHMP) as an additive demonstrate superior adhesion, mechanical stability, and enhanced wettability with molten sodium. Scanning Electron Microscopy (SEM) analysis reveals that SHMP preserves the porous carbon network required for efficient sodium transport while minimizing structural defects such as cracks and voids. Electrochemical testing using Na symmetric cells confirms that SHMP-modified layers significantly reduce interfacial resistance and overpotential, outperforming No salts counterparts. These findings highlight that the strategic incorporation of suitable additives, such as SHMP, in the design of microscale carbon layers could significantly enhance the performance of molten sodium batteries at lower operating temperatures.

Han, Henry H.↗
NASA NTRS1980

Stress corrosion cracking evaluation of martensitic precipitation hardening stainless steels

The resistance of the martensitic precipitation hardening stainless steels PH13-8Mo, 15-5PH, and 17-4PH to stress corrosion cracking was investigated. Round tensile and c-ring type specimens taken from several heats of the three alloys were stressed up to 100 percent of their yield strengths and exposed to alternate immersion in salt water, to salt spray, and to a seacoast environment. The results indicate that 15-5PH is highly resistant to stress corrosion cracking in conditions H1000 and H1050 and is moderately resistant in condition H900. The stress corrosion cracking resistance of PH13-8Mo and 17-4PH stainless steels in conditions H1000 and H1050 was sensitive to mill heats and ranged from low to high among the several heats included in the tests. Based on a comparison with data from seacoast environmental tests, it is apparent that alternate immersion in 3.5 percent salt water is not a suitable medium for accelerated stress corrosion testing of these pH stainless steels.

Humphries, T. S.↗