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NASA NTRS1991

Applying NASA's explosive seam welding

The status of an explosive seam welding process, which was developed and evaluated for a wide range of metal joining opportunities, is summarized. The process employs very small quantities of explosive in a ribbon configuration to accelerate a long-length, narrow area of sheet stock into a high-velocity, angular impact against a second sheet. At impact, the oxide films of both surface are broken up and ejected by the closing angle to allow atoms to bond through the sharing of valence electrons. This cold-working process produces joints having parent metal properties, allowing a variety of joints to be fabricated that achieve full strength of the metals employed. Successful joining was accomplished in all aluminum alloys, a wide variety of iron and steel alloys, copper, brass, titanium, tantalum, zirconium, niobium, telerium, and columbium. Safety issues were addressed and are as manageable as many currently accepted joining processes.

Bement, Laurence J.↗

NASA NTRS1992

Preliminary results for LDEF/HEPP thermal control samples

Specimens of Kapton coated with black paint, white paint, and thin film oxides were flown at three locations aboard the Long Duration Exposure Facility (LDEF) to evaluate their resistance to atomic oxygen erosion. Post flight emittance and solar absorptance measurements are compared with pre-flight values.

Kauder, Lonny↗

NASA NTRS1992

Extreme ultraviolet filters for 58.4 and 83.4 nm

We report the design of an EUV filter for He I at 58.4 nm and the design and fabrication of an EUV filter for O II at 83.4 nm. Both filters are designed as combinations of three narrow-band reflection filters. The net transmittance through both EUV filters is close to 10 percent with bandwidths less than 10 nm, and blocking better than 0.005 percent for out-of-band wavelengths. A theoretical calculation of the 83.4 nm filter predicts higher values for the peak transmittance than the measured spectral performance of the fabricated filter. Since aluminum is one of the film materials used for the fabrication of EUV filters, the aluminum film oxidation can be modeled in order to explain the discrepancy between the theory and experiment. Since the filters operate at angles of incidence up to 50 deg, the optical components of a system can serve as both the filtering and imaging elements.

Zukic, Muamer↗

NASA NTRS1994

Guanidine Soaps As Vehicles For Coating Ceramic Fibers

Soaps made from strong organic base guanidine and organic fatty acids serve as vehicles and binders for coating ceramic fibers, various smooth substrates, and other problematic surfaces with thin precious-metal or metal-oxide films. Films needed to serve as barriers to diffusion in fiber/matrix ceramic composite materials. Guanidine soaps entirely organic and burn off, leaving no residues.

Philipp, Warren H.↗

NASA NTRS1992

Analysis of samples of reflector materials which are multicoated and metal samples with oxide coatings which have been exposed the space environment in LDEF testing

The use of low angle x-ray diffraction (XRD), x-ray photoelectron spectrometry (XPS), and Auger spectrometry have been tested as suitable methods for analysis of thin oxide films on metal substrates exposed to the space environment during Long Duration Exposure Facility (LDEF) testing. No significant changes in the composition of silicon monoxide overcoats on aluminum surfaces was found. XPS and Auger testing appear to be more suitable for ultrathin films than XRD.

Neely, W. C.↗

NASA NTRS1993

Solidification of eutectic system alloys in space (M-19)

It is well known that in the liquid state eutectic alloys are theoretically homogeneous under 1 g conditions. However, the homogeneous solidified structure of this alloy is not obtained because thermal convection and non-equilibrium solidification occur. The present investigators have clarified the solidification mechanisms of the eutectic system alloys under 1 g conditions by using the in situ observation method; in particular, the primary crystals of the eutectic system alloys never nucleated in the liquid, but instead did so on the mold wall, and the crystals separated from the mold wall by fluid motion caused by thermal convection. They also found that the equiaxed eutectic grains (eutectic cells) are formed on the primary crystals. In this case, the leading phase of the eutectic must agree with the phase of the primary crystals. In space, no thermal convection occurs so that primary crystals should not move from the mold wall and should not appear inside the solidified structure. Therefore no equiaxed eutectic grains will be formed under microgravity conditions. Past space experiments concerning eutectic alloys were classified into two types of experiments: one with respect to the solidification mechanisms of the eutectic alloys and the other to the unidirectional solidification of this alloy. The former type of experiment has the problem that the solidified structures between microgravity and 1 g conditions show little difference. This is why the flight samples were prepared by the ordinary cast techniques on Earth. Therefore it is impossible to ascertain whether or not the nucleation and growth of primary crystals in the melt occur and if primary crystals influence the formation of the equiaxed eutectic grains. In this experiment, hypo- and hyper-eutectic aluminum copper alloys which are near eutectic point are used. The chemical compositions of the samples are Al-32.4mass%Cu (Hypo-eutectic) and Al-33.5mass%Cu (hyper-eutectic). Long rods for the samples are cast by the Ohno Continuous Casting Process and they show the unidirectionally solidified structure. Each flight and ground sample was made of these same rods. The dimensions of all samples are 4.5 mm in diameter and 23.5 mm in length. Each sample is put in a graphite capsule and then vacuum sealed in a double silica ampoule. Then the ampoule is put in the tantalum cartridge and sealed by electron beam welding. For onbard experiments, a Continuous Heating Furnance (CHF) will be used for melting and solidifying samples under microgravity conditions. Six flight samples will be used. Four samples are hypo-eutectic and two are hyper-eutectic alloys. The surface of the two hypo-eutectic alloy samples are covered with aluminum oxide film to prevent Marangoni convection expected under microgravity conditions. Each sample will be heated to 700 C and held at that temperature for 5 min. After that the samples will be allowed to cool to 500 C in the furnace and they will be taken out of the furnace for He gas cooling. The heating and cooling diagrams for the flight experiments are shown. After collecting the flight samples, the solidified structures of the samples will be examined and the mechanisms of eutectic solidification under microgravity conditions will be determined. It is likely that successful flight experiment results will lead to production of high quality eutectic alloys and eutectic composite materials in space.

Ohno, Atsumi↗

NASA NTRS1994

X-Ray Absorption Spectroscopy in High Temperature Oxidation of Metals and Alloys

An experimental technique is described that allows for the joint study of the kinetics and of the oxide structure during the high temperature oxidation of metal surfaces. Oxygen is supplied at the metal through an electrochemical oxygen pump and the oxygen pressure, at the metal surface, is measured during oxidation by a YSZ (yttria stabilized zirconia) oxygen sensor. XAS (x-ray absorption spectroscopy) is performed in fluorescence mode at the cation K edge and after each oxidation step. An appropriate analysis of the XAS spectra could provide information on both the oxidation kinetics and oxide structure. Experimental data on the high temperature oxidation of nickel, cobalt, and Fe(64%)Ni(36%) alloy, at low oxygen pressure, are reported and analyzed according to the proposed data reduction. These results indicate the presented technique to be particularly suitable for studying the hot corrosion of oxide film too thick for common surface spectroscopy (AUGER, ESCA) and too thin for conventional thermogravimetric technique.

Daniele Gozzi↗

NASA NTRS2000

SiC-Based Gas Sensor Development

Silicon carbide based Schottky diode gas sensors are being developed for applications such as emission measurements and leak detection. The effects of the geometry of the tin oxide film in a Pd/SnO2/SiC structure will be discussed as well as improvements in packaging SiC-based sensors. It is concluded that there is considerable versatility in the formation of SiC-based Schottky diode gas sensing structures which will potentially allow the fabrication of a SiC-based gas sensor array for a variety of gases and temperatures.

Hunter, G. W.↗

NASA NTRS2000

Explosive Joining for the Mars Sample Return Mission

A unique, small-scale, ribbon explosive joining process is being developed as an option for closing and sealing a metal canister to allow the return of a pristine sample of the Martian surface and atmosphere to Earth. This joining process is accomplished by an explosively driven, high-velocity, angular collision of the metal, which melts and effaces the oxide films from the surfaces to allow valence electron sharing to bond the interface. Significant progress has been made through more than 100 experimental tests to meet the goals of this ongoing developmental effort. The metal of choice, aluminum alloy 6061, has been joined in multiple interface configurations and in complete cylinders. This process can accommodate dust and debris on the surfaces to be joined. It can both create and sever a joint at its midpoint with one explosive input. Finally, an approach has been demonstrated that can capture the back blast from the explosive.

Bement, Laurence J.↗

NASA NTRS2000

Gravity-Related Transport Process in Off-Axis Sputtering Deposition

In the synthesis of epitaxial oxide films, reactive off-axis sputtering deposition techniques have demonstrated the advantages of fabricating high quality epitaxial films. Due to the collisions between the sputtered species and the residue gases, the kinetic energy of species was reduced and the transport of depositing species changed from a ballistic movement to a diffusive drift in which the transport species were almost thermalized. A gravity effect could appear in the transport process. Three transport regimes were observed when the growth pressures vary from 5 mTorr to 150 mTorr. Film growth rate, depositing orientations, crystal structure, surface morphology, and compositions were characterized. A gravity related phenomenon was revealed in film growth at the relative low growth pressures.

Zhu, Shen↗

NASA NTRS2001

Evaluation of Ti-48Al-2Nb Under Fretting Conditions

An investigation was conducted to examine the fretting behavior of lambda-TiAl (Ti-48Al-2Cr-2Nb) in contact with a nickel-base superalloy (Inconel 718) in air at temperatures from 23 to 550 C. Fretting wear experiments were conducted with 9.4-mm-diameter hemispherical Inconel (IN) 718 pins in contact with Ti-48Al-2Cr-2Nb flats (and the reverse) at loads from 1 to 40 N and fretting frequencies from 50 to 160 Hz with slip amplitudes from 50 to 200 microns for 1 to 20 million fretting cycles. The results were similar for both combinations of pin and flat. Reference fretting wear experiments were also conducted with 9.4-mm-diameter hemispherical Ti-6Al-4V pins in contact with IN718 flats. The interfacial adhesive bonds between Ti-48Al-2Cr-2Nb and IN718 in contact were generally stronger than the cohesive bonds in the cohesively weaker Ti-48Al-2Cr-2Nb. The failed Ti-48Al-2Cr-2Nb subsequently transferred to the IN718 surface at any fretting condition. The wear scars produced on Ti-48Al-2Cr-2Nb contained metallic and oxide wear debris, scratches, plastically deformed asperities, cracks, and fracture pits. Oxide layers readily formed on the Ti-48Al-2Cr-2Nb surface at 550 C, but cracks easily occurred in the oxide layers. Factors including fretting frequency, temperature, slip amplitude, and load influenced the fretting behavior of Ti-48Al-2Cr-2Nb in contact with IN718. The wear volume loss of Ti-48Al-2Cr-2Nb generally decreased with increasing fretting frequency. The increasing rate of oxidation at elevated temperatures up to 200 C led to a drop in wear volume loss at 200 C. However, the fretting wear increased as the temperature was increased from 200 to 550 C. The highest temperatures of 450 and 550 C resulted in oxide film disruption with generation of cracks, loose wear debris, and pits on the Ti-48Al-2Cr-2Nb wear surface. The wear volume loss generally increased as the slip amplitude increased. The wear volume loss also generally increased as the load increased. Increasing slip amplitude and increasing load both tended to produce more metallic wear debris, causing severe abrasive wear in the contacting metals.

Miyoshi, Kazuhisa↗

NASA NTRS2001

Evaluation of Ti-48Al-2Cr-2Nb Under Fretting Conditions

The fretting behavior of Ti-48Al-2Cr-2Nb (y-TiAl) in contact with the nickel-base superalloy 718 was examined in air at temperatures from 296 to 823 K (23 to 550 C). The interfacial adhesive bonds between Ti-48Al-2Cr-2Nb and superalloy 718 were generally stronger than the cohesive bonds within Ti-48Al-2Cr-2Nb. The failed Ti-48Al-2Cr-2Nb debris subsequently transferred to the superalloy 718. In reference experiments conducted with Ti-6Al-4V against superalloy 718 under identical fretting conditions, the degree of transfer was greater for Ti-6A1-4V than for Ti-48Al-2Cr-2Nb. Wear of Ti-48Al-2Cr-2Nb generally decreased with increasing fretting frequency. The increasing rate of oxidation at elevated temperatures led to a drop in wear at 473 K. However, fretting wear increased as the temperature was increased from 473 to 823 K. At 723 and 823 K, oxide film disruption generated cracks, loose wear debris, and pits on the Ti-48Al-2Cr-2Nb wear surface. Both increasing slip amplitude and increasing load tended to produce more metallic wear debris, causing severe abrasive wear in the contacting metals.

Miyoshi, Kazuhisa↗

NASA NTRS2002

Electron Field Emission Properties of Textured Platinum Surfaces

During ground tests of electric microthrusters and space tests of electrodynamic tethers the electron emitters must successfully operate at environmental pressures possibly as high as 1x10(exp -4) Pa. High partial pressures of oxygen, nitrogen, and water vapor are expected in such environments. A textured platinum surface was used in this work for field emission cathode assessments because platinum does not form oxide films at low temperatures. Although a reproducible cathode conditioning process did not evolve from this work, some short term tests for periods of 1 to 4 hours showed no degradation of emission current at an electric field of 8 V/mm and background pressures of about 1x10(exp -6) Pa. Increases of background pressure by air flow to about 3x10(exp -4) Pa yield a hostile environment for the textured platinum field emission cathode.

Sovey, James S.↗

NASA NTRS1989

Explosive Joining

Laurence J. Bement of Langley Research Center invented a technique to permit metal joining operations under hazardous or inaccessible conditions. The process, which provides a joint with double the strength of the parent metal, involves the use of very small quantities of ribbon explosive to create hermetically sealed joints. When the metal plates are slammed together by the explosion's force, joining is accomplished. The collision causes a skin deep melt and ejection of oxide films on the surfaces, allowing a linkup of electrons that produce superstrong, uniform joints. The technique can be used to join metals that otherwise would not join and offers advantages over mechanical fasteners and adhesives. With Langley assistance, Demex International Ltd. refined and commercialized the technology. Applications include plugging leaking tubes in feedwater heaters. Demex produces the small plugs, associated sleeves and detonators. The technology allows faster plugging, reduces downtime, cuts plugging costs and increases reliability.

Source record↗

NASA NTRS2014

Measurement and Control of Oxygen Partial Pressure in an Electrostatic Levitator

Recently the NASA Marshall Space Flight Center electrostatic levitation (ESL) laboratory has been upgraded to include an oxygen control system. This system allows the oxygen partial pressure within the vacuum chamber to be measured and controlled, at elevated temperatures, theoretically in the range from 10(exp -36) to 10(exp 0) bar. The role of active surface agents in liquid metals is fairly well known; however, published surface tension data typically has large scatter, which has been hypothesized to be caused by the presence of oxygen. The surface tension of metals is affected by even a small amount of adsorption of oxygen. It has even been shown that oxygen partial pressures may need to be as low as 10(exp -24) bar to avoid oxidation. While electrostatic levitation is done under high vacuum, oxide films or dissolved oxygen may have significant effects on materials properties, such as surface tension and viscosity. Therefore, the ability to measure and control the oxygen partial pressure within the chamber is highly desirable. The oxygen control system installed at MSFC contains a potentiometric sensor, which measures the oxygen partial pressure, and an oxygen ion pump. In the pump, a pulse-width modulated electric current is applied to yttrium-stabilized zirconia, resulting in oxygen transfer into or out of the system. Also part of the system is a control unit, which consists of temperature controllers for the sensor and pump, PID-based current loop for the ion pump, and a control algorithm. This system can be used to study the effects of oxygen on the thermophysical properties of metals, ceramics, glasses, and alloys. It can also be used to provide more accurate measurements by processing the samples at very low oxygen partial pressures. The oxygen control system will be explained in more detail and an overview of its use and limitations in an electrostatic levitator will be described. Some preliminary measurements have been made, and the results to date will be provided.

SanSoucie, Michael P.↗

NASA NTRS2015

Effects of Oxygen Partial Pressure on the Surface Tension of Liquid Nickel

The NASA Marshall Space Flight Center's electrostatic levitation (ESL) laboratory has been recently upgraded with an oxygen partial pressure controller. This system allows the oxygen partial pressure within the vacuum chamber to be measured and controlled, theoretically in the range from 10‐36 to 100 bar. The oxygen control system installed in the ESL laboratory's main chamber consists of an oxygen sensor, oxygen pump, and a control unit. The sensor is a potentiometric device that determines the difference in oxygen activity in two gas compartments (inside the chamber and the air outside of the chamber) separated by an electrolyte, which is yttria‐stabilized zirconia. The pump utilizes coulometric titration to either add or remove oxygen. The system is controlled by a desktop control unit, which can also be accessed via a computer. The controller performs temperature control for the sensor and pump, PID-based current loop, and a control algorithm. Oxygen partial pressure has been shown to play a significant role in the surface tension of liquid metals. Oxide films or dissolved oxygen may lead to significant changes in surface tension. The effects of oxygen partial pressure on the surface tension of undercooled liquid nickel will be analyzed, and the results will be presented. The surface tension will be measured at several different oxygen partial pressures while the sample is undercooled. Surface tension will be measured using the oscillating drop method. While undercooled, each sample will be oscillated several times consecutively to investigate how the surface tension behaves with time while at a particular oxygen partial pressure.

SanSoucie, Michael P.↗

NASA NTRS2016

Silver Ion Biocide Delivery System for Water Disinfection

U.S. space exploration missions have long considered returning to the Moon and exploration of Mars that challenge life support systems. For these long duration missions, there is interest in replacing the iodine water treatment system with ionic silver, a proven biocide. For long duration exploration missions, it is imperative that an effective biocide be used that prevents microbial growth, biofilm formation, and microbially induced corrosion in the water storage and distribution systems while minimizing logistical supply requirements associated with the biocide delivery system. Two biocide delivery systems have been developed that electrochemically produce silver ions for disinfecting water throughout the water storage and distribution system. One system uses a newly developed hybrid micro-filtration and ion-exchange membrane to produce an abundance of silver ions at the 1000 ppb level upstream in the water distribution system to prevent biofilm growth. This is followed by a downstream collection module that electrochemically removes these silver ions before the water is discharged. Another approach uses a membraneless reactor to produce a 1000 ppb silver ion concentration level that also has a mechanically driven electrode cleaning mechanism that removes oxide films ensuring long life operation. By maintaining a sufficiently high level of silver ions throughout the water storage and distribution system, biofilm formation is suppressed. This approach overcomes present concerns where spurious silver deposition occurs on the container and flow line surfaces thus lowering the silver ion concentration to unsatisfactory disinfection levels.

Slote, Benjamin M.↗

NASA NTRS2019

Corrosion on Mars: Effect of the Mars Environment on Spacecraft Materials

This report presents the results of a one-year project, funded by NASA’s Kennedy Space Center Innovation Fund in FY18, to conduct a theoretical study on the effect of the Mars environment on spacecraft materials. Corrosion resistance is one of the most important properties in selecting materials for landed spacecraft and structures that will support surface operations for the human exploration of Mars. Currently, the selection of materials is done by assuming that the corrosion behavior of a material on Mars will be the same as that on Earth. This is understandable since there is no data on the corrosion resistance of materials in the Mars environment. However, given that corrosion is defined as the degradation of a metal that results from its chemical interaction with the environment, it cannot be assumed that corrosion is going to be the same in both environments since they are significantly different. The goal of this research was to develop a systematic approach to understand corrosion of spacecraft materials on Mars by conducting a literature search of available data, relevant to corrosion in the Mars environment. This project was motivated by the suggestion, by a team of researchers, that some of the structural degradation observed on Curiosity's wheels may have been caused by corrosive interactions with the transient liquid brines, reported to be present on Mars, while the most significant damage was attributed to rock scratching. An extensive literature search, on data relevant to corrosion on Mars, confirmed the need to investigate the interaction between materials, used for spacecraft and structures designed to support long-term surface operations on Mars, and the Mars environment. Previous preliminary experiments, designed to look at the interaction between aerospace aluminum alloy (AA7075-T73) and the gases present in the Mars atmosphere, at 20 degC and a pressure of 700 Pa, showed that there is an interaction between the small amount of oxygen present in the Mars gas and the alloy, when there is a scratch that removes the protective aluminum oxide film. Further studies are needed to consider many other important components of the Mars environment that can affect this interaction such as: the presence of brines, the interaction between these brines and materials, the effect of radiation on these interactions, and the possible catalytic effects of the clays present in the Martian regolith. This theoretical study provides strong justification to conduct experimental work to investigate the interaction between spacecraft materials with simulated Martian environments to reduce Mars exploration costs.

Calle, Luz M.↗