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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 415 records · Page 23
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NASA NTRS1999

Metals for Cryotank Structures. Present and Future: MSFC Perspective

The Cryogenic Tank Technology Program (CTTP) program has been a cooperative effort between NASA LARC, NASA MSFC, NASA Headquarters, and industry (Lockheed Martin Aeronautics, Lockheed Martin Manned Space Systems, Wyman Gordon, and Ladish). The scope of the CTTP is to develop state-of-the-art, flight-size, flight-quality, low cost hardware, and use this hardware to design, fabricate and test an all aluminum-lithium, all near net shape-component 14' diameter cryogenic tank with a unique low profile bulkhead design. The logical conclusion to the CTTP is to validate these various technologies to a Technology Readiness Level (TRL) of 6 through the proposed structural test program. The CTTP supports the advancement of key enabling technologies required for aluminum lithium cryogenic tanks. The technologies are focused towards innovative and low cost manufacturing processes such as near net shape technologies: one piece spun formed domes, extruded barrel panels, and one piece roll forged ring frames. Other innovative technologies include the friction stir weld process and weight-efficient low profile bulkhead designs. All of these technologies are of primary importance for NASA's mission plan for reusable and expendable launch vehicles. This program fills the niche for an all 2195 aluminum lithium alloy cryogenic tank which is not being covered by existing NASA technology work.

Vaughn, Timothy P.↗
NASA NTRS1997

The International Space Station Assembly on Schedule

As engineers continue to prepare the International Space Station (ISS) for in-orbit assembly in the year 2002, ANSYS software has proven instrumental in resolving a structural problem in the project's two primary station modules -- Nodes 1 and 2. Proof pressure tests performed in May revealed "low temperature, post-yield creep" in some of the Nodes' gussets, which were designed to reinforce ports for loads from station keeping and reboost motion of the entire space station. An extensive effort was undertaken to characterize the creep behavior of the 2219-T851 aluminum forging material from which the gussets were made. Engineers at Sverdrup Technology, Inc. (Huntsville, AL) were responsible for conducting a combined elastic-plastic-creep analysis of the gussets to determine the amount of residual compressive stress which existed in the gussets following the proof pressure tests, and to determine the stress-strain history in the gussets while on-orbit. Boeing, NASA's Space Station prime contractor, supplied the Finite Element Analysis (FEA) model geometry and developed the creep equations from the experimental data taken by NASA's Marshall Space Flight Center and Langley Research Center. The goal of this effort was to implement the uniaxial creep equations into a three dimensional finite element program, and to determine analytically whether or not the creep was something that the space station program could live with. The objective was to show analytically that either the creep rate was at an acceptable level, or that the node module had to be modified to lower the stress levels to where creep did not occur. The elastic-plastic-creep analysis was performed using the ANSYS finite element program of ANSYS, Inc. (Houston, PA). The analysis revealed that the gussets encountered a compressive stress of approximately 30,000 pounds per square inch (psi) when unloaded. This compressive residual stress significantly lowered the maximum tension stress in the gussets which decreased the creep strain rate. The analysis also showed that the gussets would not experience a great deal of creep from future pressure tests if braces or struts proposed by Boeing were installed to redistribute stress away from them. Subsequent analysis of on-orbit station keeping and reboost loads convinced Boeing that the gussets should be removed altogether.

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NASA NTRS1997

Chromospheric Structure and Dynamics--Observations

The chromosphere is a highly structured dynamic 'layer' of the solar outer atmosphere. Here, not only are the effects of mechanical heating first evident (moving upward in altitude from the deep photosphere), but also the amount of nonradiative energy deposited is far greater than in the albeit much hotter overlying transition region and corona. Further, the chromosphere is by far the thickest zone of the solar atmosphere with respect to the pressure scale height. A major goal of stellar astrophysics is to understand how the chromosphere is heated and why it adopts its peculiar structure. A cursory examination of solar filtergrams and high-resolution movies demonstrates that much of the chromospheric "action" must be occurring on fine spatial scales and short times; particularly in the cell interior transient brightenings, but also in the longer-lived network fragments. That regime of investigation is far removed from what one usually associates with "synoptic" measurements. Nevertheless, synoptic observations of chromospheric indices, filtergrams, and globally-averaged profile parameters (e.g., for Ca II) not only can provide important insight concerning the crucial role of the cycle-variable part of the solar magnetic field; but they also can forge a key link with analogous measurements of the stars, where often the phenomena can be significantly exaggerated from the solar case, but high spatial resolution reconnaissance is not even a remote possibility. In addition to discussing the synoptic aspects of chromospheric structure and dynamics, I will summarize new insights into the general problem of the solar chromosphere that have been obtained recently with the SUMER far-ultraviolet spectrometer on SOHO.

Ayres, Thomas R.↗
NASA NTRS2000

Assessment of Low Cycle Fatigue Behavior of Powder Metallurgy Alloy U720

The fatigue lives of modem powder metallurgy disk alloys are influenced by variabilities in alloy microstructure and mechanical properties. These properties can vary as functions of variables the different steps of materials/component processing: powder atomization, consolidation, extrusion, forging, heat treating, and machining. It is important to understand the relationship between the statistical variations in life and these variables, as well as the change in life distribution due to changes in fatigue loading conditions. The objective of this study was to investigate these relationships in a nickel-base disk superalloy, U720, produced using powder metallurgy processing. Multiple strain-controlled fatigue tests were performed at 538 C (1000 F) at limited sets of test conditions. Analyses were performed to: (1) assess variations of microstructure, mechanical properties, and LCF failure initiation sites as functions of disk processing and loading conditions; and (2) compare mean and minimum fatigue life predictions using different approaches for modeling the data from assorted test conditions. Significant variations in life were observed as functions of the disk processing variables evaluated. However, the lives of all specimens could still be combined and modeled together. The failure initiation sites for tests performed at a strain ratio R(sub epsilon) = epsilon(sub min)/epsilon(sub max) of 0 were different from those in tests at a strain ratio of -1. An approach could still be applied to account for the differences in mean and maximum stresses and strains. This allowed the data in tests of various conditions to be combined for more robust statistical estimates of mean and minimum lives.

Gabb, Tomothy P.↗
NASA NTRS2000

Vacuum Plasma Spray of CuCrNb Alloy for Advanced Liquid - Fuel Combustion Chambers

The copper-8 atomic percent chromium-4 atomic percent niobium (CuCrNb) alloy was developed by Glenn Research Center (formally Lewis Research Center) as an improved alloy for combustion chamber liners. In comparison to NARloy-Z, the baseline (as in Space Shuttle Main Engine) alloy for such liners, CuCrNb demonstrates mechanical and thermophysical properties equivalent to NARloy-Z, but at temperatures 100 C to 150 C (180 F to 270 F) higher. Anticipated materials related benefits include decreasing the thrust cell liner weight 5% to 20%, increasing the service life at least two fold over current combustion chamber design, and increasing the safety margins available to designers. By adding an oxidation and thermal barrier coating to the liner, the combustion chamber can operate at even higher temperatures. For all these benefits, however, this alloy cannot be formed using conventional casting and forging methods because of the levels of chromium and niobium, which exceed their solubility limit in copper. Until recently, the only forming process that maintains the required microstructure of CrNb intermetallics is powder metallurgy formation of a billet from powder stock, followed by extrusion. This severely limits its usefulness in structural applications, particularly the complex shapes required for combustion chamber liners. Vacuum plasma spray (VPS) has been demonstrated as a method to form structural articles including small combustion chambers from the CuCrNb alloy. In addition, an oxidation and thermal barrier layer can be formed integrally on the hot wall of the liner that improve performance and extend service life. This paper discusses the metallurgy and thermomechanical properties of VPS formed CuCrNb versus the baseline powder metallurgy process, and the manufacturing of small combustion chamber liners at Marshall Space Flight Center using the VPS process. The benefits to advanced propulsion initiatives of using VPS to fabricate combustion chamber liners while maintaining the superior CuCrNb properties are also presented.

Zimmerman, Frank↗
NASA NTRS2000

Technology Assessment of Doe's 55-we Stirling Technology Demonstrator Convector (TDC)

The Department of Energy (DOE), Germantown, Maryland and the NASA Glenn Research Center (GRC), Cleveland, Ohio are developing a Stirling Convertor for an advanced radioisotope power system as a potential power source for spacecraft on-board electric power for NASA deep space science missions. The Stirling Convertor is being evaluated as an alternative high efficiency power source to replace Radioisotope Thermoelectric Generators (RTGs). Stirling Technology Company (STC), Kennewick, Washington, is developing the highly efficient, long life 55-We free-piston Stirling Convertor known as the Technology Demonstrator Convertor (TDC) under contract to DOE. GRC provides Stirling technology expertise under a Space Act Agreement with the DOE. Lockheed Martin Astronautics (LMA), Valley Forge, Pennsylvania is the current power system integrator for the Advanced Radioisotope Power System (ARPS) Project for the DOE. JPL is responsible for the Outer Planets/Solar Probe Project for NASA.

Furlong, Richard↗
NASA NTRS2000

Fatigue Characterization of Alloy 10: a 1300F Disk Alloy for Small Gas Turbine Engines

A detailed fatigue characterization of Alloy 10, a high strength nickel-based disk alloy, was conducted on test coupons machined from a 'pancake' forging. Smooth bar, strain controlled fatigue testing at various R-ratios was run at representative bore, 750 F, and rim, 1300 F, temperatures. This was followed by notch fatigue testing (Kt=2) run under load control. Analysis of the fatigue data using a Smith-Watson-Topper approach and finite element analysis of the notch root was employed to understand material behavior in these tests. Smooth bar fatigue data showed a significant R-ratio dependence at either test temperature which could be accounted for using a Smith-Watson-Topper parameter (SWT). In general, fatigue life was longer at 750 F than 1300 F for a given SWT. For notch fatigue tests, life was longer at 750 F than 1300 F but only at higher stresses. This was attributed to differences in alloy strength. At lower stresses, finite element analysis suggested that convergence of fatigue life at both temperatures resulted from relaxation of stresses at the notch root in the 1300 F tests.

Gayda, John↗
NASA NTRS2000

NASA and Industry Benefits of ACTS High Speed Network Interoperability Experiments

This paper provides synopses of the design. implementation, and results of key high data rate communications experiments utilizing the technologies of NASA's Advanced Communications Technology Satellite (ACTS). Specifically, the network protocol and interoperability performance aspects will be highlighted. The objectives of these key experiments will be discussed in their relevant context to NASA missions, as well as, to the comprehensive communications industry. Discussion of the experiment implementation will highlight the technical aspects of hybrid network connectivity, a variety of high-speed interoperability architectures, a variety of network node platforms, protocol layers, internet-based applications, and new work focused on distinguishing between link errors and congestion. In addition, this paper describes the impact of leveraging government-industry partnerships to achieve technical progress and forge synergistic relationships. These relationships will be the key to success as NASA seeks to combine commercially available technology with its own internal technology developments to realize more robust and cost effective communications for space operations.

Zernic, M. J.↗
NASA NTRS2001

Investigation of the Large Scale Evolution and Topology of Coronal Mass Ejections in the Solar Wind

This investigation is concerned with the large-scale evolution and topology of coronal mass ejections (CMEs) in the solar wind. During the course of this three-year investigation, we have undertaken a number of studies that are discussed in more detail in this report. For example, we conducted an analysis of all CMEs observed by the Ulysses spacecraft during its in-ecliptic phase between 1 and 5 AU. In addition to studying the properties of the ejecta, we also analyzed the shocks that could be unambiguously associated with the fast CMEs. We also analyzed a series of 'density holes' observed in the solar wind that bear many similarities with CMEs. To complement this analysis, we conducted a series of 1-D and 2 1/2-D fluid, MHD, and hybrid simulations to address a number of specific issues related to CME evolution in the solar wind. For example, we used fluid simulations to address the interpretation of negative electron temperature-density relationships often observed within CME/cloud intervals. As part of this investigation, a number of fruitful international collaborations were forged. Finally, the results of this work were presented at nine scientific meetings and communicated in eight scientific, refereed papers.

Riley, Pete↗
NASA NTRS2001

The Tensile Properties of Advanced Nickel-Base Disk Superalloys During Quenching Heat Treatments

There is a need to increase the temperature capabilities of superalloy turbine disks. This would allow full utilization of higher temperature combustor and airfoil concepts under development. One approach to meet this goal is to modify the processing and chemistry of advanced alloys, while preserving the ability to use rapid cooling supersolvus heat treatments to achieve coarse grain, fine gamma prime microstructures. An important step in this effort is to understand the key high temperature tensile properties of advanced alloys as they exist during supersolvus heat treatments. This could help in projecting cracking tendencies of disks during quenches from supersolvus heat treatments. The objective of this study was to examine the tensile properties of two advanced disk superalloys during simulated quenching heat treatments. Specimens were cooled from the solution heat treatment temperatures at controlled rates, interrupted, and immediately tensile tested at various temperatures. The responses and failure modes were compared and related to the quench cracking tendencies of disk forgings.

Gabb, Timothy P.↗
NASA NTRS2002

Friction-Stir Welding of Aluminum For the Space Program

The Marshall Space Flight Center is developing and characterizing the friction stir welding process for the Space Shuttle and other space programs. This revolutionary process, invented and patented by The Weld Institute in England, offers tremendous advantages for joining aluminum for high performance applications. It is particularly suited for advanced aluminum-lithium alloys, such as 2195, the primary structural alloy used in the External Tank. The friction stir welding process joins metals with minimal heat input, resulting in high-strength joints with high ductility. It is a simple process to demonstrate using a common milling machine for sample parts, but relatively expensive to implement on large-scale hardware, due to the high cost of tooling needed to handle the high forging pressures characteristic of the process. Recent developments at the Marshall Space Flight Center have demonstrated friction stir welding on linear joints up to 5 meters (15 ft.), with material thickness ranging between 2.5 mm and 16.5 mm (0.100" to 0.650"). High efficiency weld joints have been produced in aluminum from the 2000, 5000, and 6000 series alloy systems. A "retractable pin tool" system was patented by MSFC that allows use of friction stir welding for joints with changing material thickness, and with less rigid tooling than previously considered. This presentation will describe the details of alloys welded to-date and technical advances under development at MSFC. These developments could have substantial benefit to industrial applications for welding aluminum.

Jones, Clyde S.↗
NASA NTRS2001

A Winning Cast

Howmet Research Corporation was the first to commercialize an innovative cast metal technology developed at Auburn University, Auburn, Alabama. With funding assistance from NASA's Marshall Space Flight Center, Auburn University's Solidification Design Center (a NASA Commercial Space Center), developed accurate nickel-based superalloy data for casting molten metals. Through a contract agreement, Howmet used the data to develop computer model predictions of molten metals and molding materials in cast metal manufacturing. Howmet Metal Mold (HMM), part of Howmet Corporation Specialty Products, of Whitehall, Michigan, utilizes metal molds to manufacture net shape castings in various alloys and amorphous metal (metallic glass). By implementing the thermophysical property data from by Auburn researchers, Howmet employs its newly developed computer model predictions to offer customers high-quality, low-cost, products with significantly improved mechanical properties. Components fabricated with this new process replace components originally made from forgings or billet. Compared with products manufactured through traditional casting methods, Howmet's computer-modeled castings come out on top.

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NASA NTRS2002

Investigation of Friction Stir Welding and Laser Engineered Net Shaping of Metal Matrix Composite Materials

The improvement in weld quality by the friction stir welding (FSW) process invented by TWI of Cambridge, England, patented in 1991, has prompted investigation of this process for advanced structural materials including Al metal matrix composite (Al-MMC) materials. Such materials can have high specific stiffness and other potential beneficial properties for the extreme environments in space. Developments of discontinuous reinforced Al-MMCs have found potential space applications and the future for such applications is quite promising. The space industry has recognized advantages of the FSW process over conventional welding processes such as the absence of a melt zone, reduced distortion, elimination of the need for shielding gases, and ease of automation. The process has been well proven for aluminum alloys, and work is being carried out for ferrous materials, magnesium alloys and copper alloys. Development work in the FSW welding process for joining of Al-MMCs is relatively recent and some of this and related work can be found in referenced research publications. NASA engineers have undertaken to spear head this research development work for FSW process investigation of Al-MMCs. Some of the reported related work has pointed out the difficulty in fusion welding of particulate reinforced MMCs where liquid Al will react with SiC to precipitate aluminum carbide (Al4C3). Advantages of no such reaction and no need for joint preparation for the FSW process is anticipated in the welding of Al-MMCs. The FSW process has been best described as a combination of extrusion and forging of metals. This is carried out as the pin tool rotates and is slowly plunged into the bond line of the joint as the pin tool's shoulder is in intimate contact with the work piece. The material is friction-stirred into a quality weld.

Ravinder M. Diwan↗
NASA NTRS2002

Fifth Annual Workshop on the Application of Probabilistic Methods for Gas Turbine Engines

These are the proceedings of the 5th Annual FAA/Air Force/NASA/Navy Workshop on the Probabilistic Methods for Gas Turbine Engines hosted by NASA Glenn Research Center and held at the Holiday Inn Cleveland West. The history of this series of workshops stems from the recognition that both military and commercial aircraft engines are inevitably subjected to similar design and manufacturing principles. As such, it was eminently logical to combine knowledge bases on how some of these overlapping principles and methodologies are being applied. We have started the process by creating synergy and cooperation between the FAA, Air Force, Navy, and NASA in these workshops. The recent 3-day workshop was specifically designed to benefit the development of probabilistic methods for gas turbine engines by addressing recent technical accomplishments and forging new ideas. We accomplished our goals of minimizing duplication, maximizing the dissemination of information, and improving program planning to all concerned. This proceeding includes the final agenda, abstracts, presentations, and panel notes, plus the valuable contact information from our presenters and attendees. We hope that this proceeding will be a tool to enhance understanding of the developers and users of probabilistic methods. The fifth workshop doubled its attendance and had the success of collaboration with the many diverse groups represented including government, industry, academia, and our international partners. So, "Start your engines!" and utilize these proceedings towards creating safer and more reliable gas turbine engines for our commercial and military partners.

Briscoe, Victoria↗
NASA NTRS2002

Quench Crack Behavior of Nickel-base Disk Superalloys

There is a need to increase the temperature capability of superalloy turbine disks to allow higher operating temperatures in advanced aircraft engines. When modifying processing and chemistry of disk alloys to achieve this capability, it is important to preserve the ability to use rapid cooling during supersolvus heat treatments to achieve coarse grain, fine gamma prime microstructures. An important step in this effort is an understanding of the key variables controlling the cracking tendencies of nickel-base disk alloys during quenching from supersolvus heat treatments. The objective of this study was to investigate the quench cracking tendencies of several advanced disk superalloys during simulated heat treatments. Miniature disk specimens were rapidly quenched after solution heat treatments. The responses and failure modes were compared and related to the quench cracking tendencies of actual disk forgings. Cracking along grain boundaries was generally observed to be operative. For the alloys examined in this study, the solution temperature not alloy chemistry was found to be the primary factor controlling quench cracking. Alloys with high solvus temperatures show greater tendency for quench cracking.

Gayda, John↗
NASA NTRS2003

Realistic Subscale Evaluations of the Mechanical Properties of Advanced Disk Superalloys

A series of experimental powder metallurgy disk alloys were evaluated for their processing characteristics and high temperature mechanical properties. Powder of each alloy was hot compacted, extruded, and isothermally forged into subscale disks. Disks were subsolvus and supersolvus heat treated, then quenched using procedures designed to reproduce the cooling paths expected in large-scale disks. Mechanical tests were then performed at 538, 704, and 815 C. Several alloys had superior tensile and creep properties at 704 C and higher temperatures, but were difficult to process and prone to quench cracking, chiefly due to their high gamma prime solvus temperature. Several other alloys had more favorable processing characteristics due to their lower gamma prime solvus temperature and balanced time-dependent properties at 704 C. Results indicate an experimental low solvus, high refractory alloy can build upon the best attributes of all these alloys, giving exceptional tensile and creep properties at high temperatures with good processing characteristics due to a low gamma prime solvus.

Gabb, Timothy P.↗
NASA NTRS1947

Determination of Stress-Rupture Parameters for Four Heat-Resisting Alloys

Stress-rupture data for four heat-resisting alloys are analyzed according to equations of the theory of rate processes. A method for determining the four parameters of structure and composition is demonstrated and the four parameters are determined for each of the alloys: forged S816, cast S816, cast S590, and cast Vitallium. It is concluded that parameters can be determined for an alloy provided sufficient reliable experimental data are available.

Lidman, William G.↗
NASA NTRS2003

Improving Vision

Many people are familiar with the popular science fiction series Star Trek: The Next Generation, a show featuring a blind character named Geordi La Forge, whose visor-like glasses enable him to see. What many people do not know is that a product very similar to Geordi's glasses is available to assist people with vision conditions, and a NASA engineer's expertise contributed to its development. The JORDY(trademark) (Joint Optical Reflective Display) device, designed and manufactured by a privately-held medical device company known as Enhanced Vision, enables people with low vision to read, write, and watch television. Low vision, which includes macular degeneration, diabetic retinopathy, and glaucoma, describes eyesight that is 20/70 or worse, and cannot be fully corrected with conventional glasses.

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