Search NASA⌕ Search

SEARCH · Search NASA

Results for “CORROSION TEST”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
NASA NTRS1976

Propellant material compatibility program and results

The effects of long-term (up to 10 years) contact of inert materials with earth-storable propellants were studied for the purpose of designing chemical propulsion system components that can be used for current as well as future planetary spacecraft. The primary experimental work, and results to date are reported. Investigations include the following propellants: hydrazine, hydrazine-hydrazine nitrate blends, monomethyl-hydrazine, and nitrogen tetroxide. Materials include: aluminum alloys, corrosion-resistant steels, and titanium alloys. More than 700 test specimen capsules were placed in long-term storage testing at 43 C in the special material compatibility facility. Material ratings relative to the 10-year requirement have been assigned.

Toth, L. R.↗
NASA NTRS1985

Corrosion behavior of surface films on boron-implanted high purity iron and stainless steels

Boron (dose, 2 x 10 to the 17th ions/sq cm) was implanted into high purity iron, AISI 316 austenitic stainless steel, and AISI 440C martensitic stainless steel, at 40 keV. The film structure of implanted samples was examined and characterized by contrast and diffraction analyses utilizing transmission electron microscopy. The effect of B(+) ion implantation on the corrosion behavior was studied using the potentiodynamic polarization technique. Tests were performed in deaerated 1 N H2SO4 and 0.1 M NaCl solutions. Scanning electron microscopy was used to examine the morphology of the corroded surfaces after testing.

Kim, H. J.↗
NASA NTRS1991

NASA/ASEE Summer Faculty Fellowship Program. 1991 Research Reports

Reports from the NASA/ASEE Summer Faculty Fellowship Program are presented. The editors are responsible for selecting appropriately qualified faculty to address some of the many problems of current interest to NASA Kennedy. Some representative titles are as follows: Development of an Accelerated Test Method for the Determination of Susceptibility to Atmospheric Corrosion; Hazardous Gas Leak Analysis in the Space Shuttle; Modeling and Control of the Automated Radiator Inspection Device; Study of the Finite Element Software Packages at KSC; Multispectral Image Processing for Plants; Algorithms for Contours Depicting Static Electric Fields during Adverse Weather Conditions; Transient Study of a Cryogenic Hydrogen Filling System; and Precision Cleaning Verification of Nonvolatile Residues by using Water, Ultrasonics, and Turbidity Analyses.

Hosler, E. Ramon↗
NASA NTRS1993

High energy density aluminum-oxygen cell

An alternative to a secondary battery as the power source for vehicle propulsion is a fuel cell. An example of this is the metal-air fuel cell using metals such as aluminum, zinc, or iron. Aluminum is a particularly attractive candidate, having high energy and power densities, being environmentally acceptable, and having a large, established industrial base for production and distribution. An aluminum-oxygen system is currently under development for a UUV test vehicle, and recent work has focussed upon low corrosion aluminum alloys and an electrolyte management system for processing the by-products of the energy-producing reactions. This paper summarizes the progress made in both areas. Anode materials capable of providing high utilization factors over current densities ranging from S to 150 mA/sq cm have been identified. These materials are essential to realizing an acceptable mission life for the UUV. With respect to the electrolyte management system, a filter/precipitator unit has been successfully operated for over 250 hours in a large scale, half-cell system.

Rudd, E. J.↗
NASA NTRS1995

New generation of plasma-sprayed mullite coatings on silicon carbide

Mullite is promising as a protective coating for silicon-based ceramics in aggressive high-temperature environments. Conventionally plasma-sprayed mullite on SiC tends to crack and debond on thermal cycling. It is shown that this behavior is due to the presence of amorphous mullite in the conventionally sprayed mullite. Heating the SiC substrate during the plasma spraying eliminated the amorphous phase and produced coatings with dramatically improved properties. The new coating exhibits excellent adherence and crack resistance under thermal cycling between room temperature and 1000 to 1400 C. Preliminary tests showed good resistance to Na2CO3-induced hot corrosion.

Lee, Kang N.↗
NASA NTRS2002

The Use af Ion Vapor Deposited Aluminum (IVD) for the Space Shuttle Solid Rocket Booster (SRB)

The USA LLC Materials & Processes (M&P) Engineering Department had recommended the application and evaluation of Ion Vapor Deposition (IVD) aluminum to SRB Hardware for corrosion protection and elimination of hazardous materials and processes such as cadmium plating. IVD is an environmentally friendly process that has no volatile organic compounds (VOCs), or hazardous waste residues. It lends itself to use with hardware exposed to corrosive seacoast environments as found at Kennedy Space Center (KSC), and Cape Canaveral Air Force Station (CCAFS), Florida. Lifting apparatus initially coated with cadmium plating for corrosion protection; was stripped and successfully re-coated with IVD aluminum after the cadmium plating no longer protected the GSE from corrosion, Since then, and after completion of a significant test program, the first flight application of the IVD Aluminum process on the Drogue Parachute Ratchet Assembly is scheduled for 2002.

Novak, Howard L.↗
NASA NTRS2017

Chemical and Microstructural Changes in Metallic and Ceramic Materials Exposed to Venusian Surface Conditions

The chemical and microstructural behavior of steels (304, 310, 316, and 1018), nickel-based alloys (beta-NiAl, G30, and 625), gold, coatings (4YSZ, SilcoNert(TradeMark) 1040 (SilcoTek Co.), Dursan(TradeMark) (SilcoTek Co.), and porcelain), and bulk ceramics (alpha-Al2O3, fused quartz, beta-SiC, and alpha-Si3N4) were probed after exposure to supercritical fluid with temperature, pressure, and composition mimicking the Venus lower atmosphere. Exposures were carried out in the Glenn Extreme Environments Rig (GEER) chamber with the Venusian gas mixture (96.5% CO2, 3.5% N2, 30 ppm H2O, 150 ppm SO2, 28 ppm CO, 15 ppm OCS, 3 ppm H2S, 0.5 ppm HCl, and 5 ppb HF) at 92 bar (1330 psi) and 467 C (873 F) for durations of 10 and 42 days. An additional 21-day exposure was done to stainless steel uncoated and coated with SilcoNert(TradeMark) and Dursan(TradeMark). Samples were characterized before and after the experiment by gravimetric analysis, X-ray diffraction, X-ray photoelectron and Auger electron spectroscopies, and cross section electron microscopy analysis. All steels exposed for 10 and 42 days formed double-layered scales consisting mainly of metal (Cr, Fe, Ni) oxides and sulfides showing different chemistry, microstructure, and crystalline phases. The alloys G30 and 625 formed double-layered scales consisting mainly of nickel sulfides. After 10 days, the beta-NiAl exhibited no detectable scale, suggesting only a very thin film was formed. The 304 and 316 stainless steels coated with 4YSZ that were exposed for 10 and 42 days exhibited no significant oxidation. Steel 1018 coated with 4YSZ exhibited a corrosion scale of iron and/or chromium oxide formed at the base of the alloy. The 304 steel coated with porcelain did not exhibit corrosion, although the coating exhibited recession. SilcoNert(TradeMark) exposed for 10 and 42 days exhibited recession, although no oxidation was found to occur at the base of the alloy. Stainless steel 316 coated with Dursan(TradeMark)  exhibited corrosion at the base of the alloy. All ceramics tested showed no clear evidence of reaction. The weight-gain-per-area performance of the materials exposed in the GEER for 10 and 42 days are reported from the lowest to the highest weight gain per area as follows: gold did not exhibit any weight change; nickel-based alloys: beta- NiAl < G30 < 625; steels: 304 < 310 < 316 < 1018; ceramics: considering the experimental uncertainties, no weight change was observed for all ceramics of this work (alpha-Al2O3, Si3N4, SiC, and amorphous SiO2).

Costa, Gustavo C. C.↗
NASA NTRS2011

External Tank - The Structure Backbone

The External Tank forms the structural backbone of the Space Shuttle in the launch configuration. Because the tank flies to orbital velocity with the Space Shuttle Orbiter, minimization of weight is mandatory, to maximize payload performance. Choice of lightweight materials both for structure and thermal conditioning was necessary. The tank is large, and unique manufacturing facilities, tooling, handling, and transportation operations were required. Weld processes and tooling evolved with the design as it matured through several block changes, to reduce weight. Non Destructive Evaluation methods were used to assure integrity of welds and thermal protection system materials. The aluminum-lithium alloy was used near the end of the program and weld processes and weld repair techniques had to be refined. Development and implementation of friction stir welding was a substantial technology development incorporated during the Program. Automated thermal protection system application processes were developed for the majority of the tank surface. Material obsolescence was an issue throughout the 40 year program. The final configuration and tank weight enabled international space station assembly in a high inclination orbit allowing international cooperation with the Russian Federal Space Agency. Numerous process controls were implemented to assure product quality, and innovative proof testing was accomplished prior to delivery. Process controls were implemented to assure cleanliness in the production environment, to control contaminants, and to preclude corrosion. Each tank was accepted via rigorous inspections, including non-destructive evaluation techniques, proof testing, and all systems testing. In the post STS-107 era, the project focused on ascent debris risk reduction. This was accomplished via stringent process controls, post flight assessment using substantially improved imagery, and selective redesigns. These efforts were supported with a number of test programs to simulate combined environments. Processing improvements included development and use of low spray guns for foam application, additional human factors considerations for production, use of high fidelity mockups during hardware processing with video review, improved tank access, extensive use of non destructive evaluation, and producibility enhancements. Design improvements included redesigned bipod fittings, a bellows heater, a feedline camera active during ascent flight, removal of the protuberance airload ramps, redesigned ice frost ramps, and titanium brackets replaced aluminum brackets on the liquid oxygen feedline. Post flight assessment improved due to significant addition of imagery assets, greatly improving situational awareness. The debris risk was reduced by two orders of magnitude. During this time a major natural disaster was overcome when Katrina damaged the manufacturing facility. Numerous lessons from these efforts are documented within the paper.

Welzyn, Kenneth↗
NASA NTRS1981

Application of improved technology to a preprototype vapor compression distillation /VCD/ water recovery subsystem

Vapor compression distillation (VCD) is considered the most efficient water recovery process for spacecraft application. This paper reports on a preprototype VCD which has undergone the most extensive operational and component development testing of any VCD subsystem to date. The component development effort was primarily aimed at eliminating corrosion and the need for lubrication, upgrading electronics, and substituting nonmetallics in key rotating components. The VCD evolution is documented by test results on specific design and/or materials changes. Innovations worthy of further investigation and additional testing are summarized for future VCD subsystem development reference. Conclusions on experience gained are presented.

Johnson, K. L.↗
NASA NTRS2024

Plasma Rapid Oxidation Technique for Extending Component Tenability (PROTECT)

Additive manufacturing (AM) is increasingly utilized in aerospace applications. However, post-processing is required for many applications, so intricate designs are limited. Plasma electrolytic oxidation (PEO) was investigated as a post-processing treatment on Ti-6-4 (or Ti-6Al-4V: Alpha-beta titanium alloy with a high specific strength and excellent corrosion resistance)additively manufactured specimens. The “Keronite Black” PEO treatment reduced the surface roughness (Ra) of test specimens by approximately 0.5 μm. This reduction in Ra compared to the as-printed sample was hypothesized to benefit corrosion and fatigue properties because increased Ra is known to negatively impact corrosion and fatigue characteristics. Up to a 101% improvement in the corrosion potential (Ɛcorr) was observed. Although fatigue characteristics varied by PEO parameters, there was no significant fatigue debit due to the PEO treatment. Additionally, no effect to adhesion characteristics was observed due to PEO treatment. It is recommended that additional studies investigate the ability of PEO treatments to improve the corrosion, fatigue, chemical compatibility, radiation hardening, particle shedding characteristics, and flammability/oxidizer compatibility of aerospace additively manufactured components.

Jennifer Williams↗
NASA NTRS1982

Effect of fuel to air ratio on Mach 0.3 burner rig hot corrosion of ZrO2-Y2O3 thermal barrier coatings

A Mach 0.3 burner rig test program was conducted to determine how the fuel to air mass ratio affects the durability of ZrO2-Y2O3/Ni-16Cr-6Al-0.31Y thermal barrier coating systems in combustion products containing 5 ppm Na and 2 ppm V. As the fuel to air mass ratio was increased from 0.039 to 0.049, the durability of ZrO2-6Y2O3, ZrO2-8Y2O3 and ZrO2-12Y2O3 coatings decreased. ZrO2-8Y2O3 coatings were approximately 2X and 1.3X more durable than ZrO2-12Y2O3 and ZrO2-6Y2O3 coatings respectively at the fuel to air mass ratio of 0.039. The number of one hour cycles endured by ZrO2-8Y2O3 coatings varied from averages of 53 to 200 for the fuel to air mass ratios of 0.049 and 0.039, respectively. At the fuel to air mass ratio of 0.049, all ZrO2-Y2O3 coated specimens failed in 40 to 60 one hour cycles

Hodge, P. E.↗
NASA NTRS1999

Design Through Simulation of a Molecular Sieve Column for Treatment of MON-3

The presence of water in propellant-grade MON-3 is a concern in the Aerospace Industry. NASA Johnson Space Center (JSC), White Sands Test Facility (WSTF) Propulsion Department has evaluated many types of molecular sieves for control of iron, the corrosion product of water in Mixed Oxides of Nitrogen (MON-3). In 1995, WSTF initiated laboratory and pilot-scale testing of molecular sieve type 3A for removal of water and iron. These tests showed sufficient promise that a series of continuous recycle tests were conducted at WSTF. Periodic samples of the circulating MON-3 solution were analyzed for water (wt %) and iron (ppm, wt). This test column was modeled as a series of transfer units; i. e., each unit represented the height equivalent of a theoretical plate. Such a model assumes there is equilibrium between the adsorbent material and the effluent stream from the unit. Operational and design parameters were derived based on the simulation results. These parameters were used to predict the design characteristics of a proposed molecular sieve column for removal of water and iron from MON-3 at the NASA Kennedy Space Center (KSC). In addition, these parameters were used to simulate a small, single-pass operation column at KSC currently used for treating MON-3. The results of this work indicated that molecular sieve type 3A in 1/16 in. diameter pellets, in a column 2.5 ft. in diameter, 18 ft. in height, and operated at 25 gpm is adequate for the required removal of water and iron from MON-3.

Swartz, A. Ben↗
NASA NTRS2012

International Space Station (ISS) Potable Water Dispenser (PWD) Beverage Adapter (BA) Redesign

The Potable Water Dispenser used on the International Space Station (ISS) interfaces with food and drink packages using the Beverage Adapter and Needle. Unexpected leakage has been seen in this interface. The Beverage Adapter used on ]orbit was returned to the ground for Test, Teardown, and Evaluation. The results of that investigation prompted a redesign of the Beverage Adapter and Needle. The Beverage Adapter materials were changed to be more corrosion resistant, and the Needle was redesigned to preclude leakage. The redesigns have been tested and proven.

Edgerly, Rachel↗
NASA NTRS1985

Powder metallurgy bearings for advanced rocket engines

Traditional ingot metallurgy was pushed to the limit for many demanding applications including antifriction bearings. New systems require corrosion resistance, better fatigue resistance, and higher toughness. With conventional processing, increasing the alloying level to achieve corrosion resistance results in a decrease in other properties such as toughness. Advanced powder metallurgy affords a viable solution to this problem. During powder manufacture, the individual particle solidifies very rapidly; as a consequence, the primary carbides are very small and uniformly distributed. When properly consolidated, this uniform structure is preserved while generating a fully dense product. Element tests including rolling contact fatigue, hot hardness, wear, fracture toughness, and corrosion resistance are underway on eleven candidate P/M bearing alloys and results are compared with those for wrought 440C steel, the current SSME bearing material. Several materials which offer the promise of a significant improvement in performance were identified.

Fleck, J. N.↗
NASA NTRS1987

Oxide-dispersion-strengthened turbine blades. Volume 2

The overall objective of Project 4 was to develop and test a high-temperature, uncooled gas turbine blade using MA6000 alloy. Production scale up of the MA6000 alloy was achieved with a fair degree of tolerance to non-optimum processing. The blade manufacturing process was also optimized. The mechanical, environmental, and physical property evaluations of MA6000 were conducted. The ultimate tensile strength, to about 704 C (1300 F), is higher than DS MAR-M 247 but with a corresponding lower tensile elongation. Also, above 982 C (1800 F) MA6000 tensile strength does not decrease as rapidly as MAR-M 247 because the ODS mechanism still remains active. Based on oxidation resistance and diffusional stability considerations, NiCrAlY coatings are recommended. CoCrAlY coating should be applied on top of a thin NiCrAlY coating if hot corrosion is expected. Vibration, whirlpit, and high-rotor-rig tests were conducted to ensure successful completion of the engine test of the MA6000 TFE731 high pressure turbine blades. Test results were acceptable. In production quantities, the cost of the Project 4 MA6000 blade is estimated to be twice that of a cast DS MAR-M 247 blade.

Millan, P. P., Jr.↗
NASA NTRS1992

Heat pipe fatigue test specimen: Metallurgical evaluation

An innovative creep/fatigue test was run to simulate the temperature, mechanical load, and sodium corrosion conditions expected in a heat pipe designed to supply thermal energy to a Stirling cycle power converter. A sodium-charged Inconel 718 heat pipe with a Nickel 200 screen wick was operated for 1090 hr at temperatures between 950 K (1250 F) and 1050 K (1430 F) while being subjected to creep and fatigue loads in a servo-hydraulic testing machine. After testing, the heat pipe was sectioned and examined using optical microscopy, scanning electron microscopy, and electron microprobe analysis with wavelength dispersive x-ray spectroscopy. The analysis concentrated on evaluating topographic, microstructural, and chemical changes in the sodium exposed surfaces of the heat pipe wall and wick. Surface changes in the evaporator, condenser, and adiabatic sections of the heat pipe were examined in an effort to correlate the changes with the expected sodium environment in the heat pipe. This report describes the setup, operating conditions, and analytical results of the sodium heat pipe fatigue test.

Walak, Steven E.↗
NASA NTRS2018

ECLSS Universal Waste Management System (UWMS) Metal Materials Compatibility Study - Elgiloy: Electrochemical and Crevice Corrosion Evaluation

Electrochemical evaluations were conducted on samples of Elgiloy in support of the materials compatibility program for the Environmental Control and Life Support System (ECLSS). Results were compared alongside three previously tested metals: Titanium 6Al-4V, Inconel 625, and Hastelloy C276. Titanium exhibited the best results of all the metals, indicating superior corrosive nobility and galvanic protection properties. Elgiloy demonstrated anti-corrosion behavior which appeared to be superior to the two nickel-chromium alloys. For this current effort, the results have clearly shown that Elgiloy possesses excellent corrosion protection properties and is galvanically compatible with the other three metals in the subject test media.

Lee, R. E.↗
NASA NTRS1982

Ceramic thermal barrier coatings for gas turbine engines

The results of studies concerning the high temperature corrosion resistance of ZrO2-Y2O3, ZrO2-MgO, and Ca2SiO4 plasma-sprayed coatings, which may be used as gas turbine engine thermal barriers, are reported. The coatings were evaluated in atmospheric burner rig and pressurized passage tests, using GT No. 2 fuel in pure form and with sodium, sulfur and vanadium corrosive impurities doping. It is found that, while the coatings performed well in both pressurized passage and burner rig tests with pure fuel chemical reactions between the ceramic coatings and combustion gases/condensates resulted in coating degradation with impure fuels. Chemical reactions between the ceramic coatings and vanadium compounds played a critical role in coating degradation.

Bratton, R. J.↗