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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1975

Thermal expansion in the nickel-chromium-aluminum and cobalt-chromium-aluminum systems to 1200 degrees C

Thermal expansion data were obtained on 12 Ni-Cr-Al and 9 Co-Cr-Al alloys by high temperature X-ray diffraction. The data were computer fit to an empirical thermal expansion equation developed in the study. It is shown that the fit is excellent to good, and that the expansion constants depend on phase but not on composition. Phases for the Ni-Cr-Al system and Co-Cr-Al system are given. Results indicate that only alpha Cr has an expansion constant low enough to minimize oxide spalling or coating cracking induced by thermal expansion mismatch.

Lowell, C. E.↗
NASA NTRS1976

Oxidation behavior of nickel-chromium-aluminum-yttrium - Magnesium oxide and nickel-chromium-aluminum-yttrium - zirconate type of cermets

The 1100 and 1200 C cyclic oxidation resistance of dense Ni-Cr-Al-Y - MgO, Ni-Cr-Al-Y - CaZrO3, Ni-Cr-Al-Y - SrZrO3, Ni-Cr-Al-Y - MgZro3 cermets and a 70 percent dense Ni-Cr-Al-Y developmental material was determined. The cermets contained 60 and 50 volume percent of Ni-Cr-Al-Y which formed a matrix with the oxide particles imbedded in it. The cermets containing MgO were superior to cermets based on zirconates and to the porous Ni-Cr-Al-Y material.

Zaplatynsky, I.↗
NASA NTRS1984

Influence of aluminum oxide film on thermocompression bonding of gold wire to evaporated aluminum film

The influence of Al surface condition on the thermocompression bonding of Au wires to Al electrodes for integrated electric circuits was studied. Au wires were connected to Al electrodes by nail-head bonding after various Al surface treatments. Bonding was evaluated by measuring the wire pull strength and fraction of the number of failures at Au-Al bonds to the total number of failures. Dependence of the fraction on applied load was derived theoretically with a parameter named critical load to take into consideration the differences in Al surface condition. The relation also held explicately for various surface treatments. Characterization of the Al surface was carried out by electron microscopy for chemical analysis.

Iwata, S.↗
NASA NTRS1992

Properties of largest fragment produced by hypervelocity impact of aluminum spheres with thin aluminum sheets

Results are presented from hypervelocity impact tests in which 1.275 g spheres of 2017-T4 Al alloy were fired at normal incidence at eight thicknesses of 6061-T6 Al alloy sheets, with impact velocity of about 6.7 km/sec; additional data are presented for smaller and larger spheres than these, in the cases of other Al alloy impact bumpers. A large fragment of the projectile is observable at the center of the debris clouds generated upon impact. The velocity of these large fragments decreased continuously with increasing bumper thickness/projectile diameter ratio, from 99 percent to less than 80 percent of impact velocity; there is a linear increase in the size of the central projectile fragment with decreasing shock-induced stress in the projectile.

Piekutowski, Andrew J.↗
NASA NTRS2010

Physical and Electrical Characterization of Aluminum Polymer Capacitors

Conductive polymer aluminum capacitor (PA capacitor) is an evolution of traditional wet electrolyte aluminum capacitors by replacing liquid electrolyte with a solid, highly conductive polymer. On the other hand, the cathode construction in polymer aluminum capacitors with coating of carbon and silver epoxy for terminal connection is more like a combination of the technique that solid tantalum capacitor utilizes. This evolution and combination result in the development of several competing capacitor construction technologies in manufacturing polymer aluminum capacitors. The driving force of this research on characterization of polymer aluminum capacitors is the rapid progress in IC technology. With the microprocessor speeds exceeding a gigahertz and CPU current demands of 80 amps and more, the demand for capacitors with higher peak current and faster repetition rates bring conducting polymer capacitors to the center o( focus. This is because this type of capacitors has been known for its ultra-low ESR and high capacitance. Polymer aluminum capacitors from several manufacturers with various combinations of capacitance, rated voltage, and ESR values were obtained and tested. The construction analysis of the capacitors revealed three different constructions: conventional rolled foil, the multilayer stacking V-shape, and a dual-layer sandwich structure. The capacitor structure and its impact on the electrical characteristics has been revealed and evaluated. A destructive test with massive current over stress to fail the polymer aluminum capacitors reveals that all polymer aluminum capacitors failed in a benign mode without ignition, combustion, or any other catastrophic failures. The extraordinary low ESR (as low as 3 mOMEGA), superior frequency independence reported for polymer aluminum capacitors have been confirmed. For the applications of polymer aluminum capacitors in space programs, a thermal vacuum cycle test was performed. The results, as expected, show no impact on the electrical characteristics of the capacitors. The breakdown voltage of polymer capacitors has been evaluated using a steady step surge test. Initial results show the uniform distribution in the breakdown voltage for polymer aluminum capacitors. Polymer aluminum capacitors with a combination of very high capacitance, extraordinary low ESR, excellent frequency stability, and non-ignite benign failure mode make it a niche fit in space applications for both today and future. Polymer capacitors are apparently also the best substitutes of the currently used MnO2-based tantalum capacitors in the low voltage range. However, some critical aspects are still to be addressed in the next phase of the investigation for PA capacitors. These include the long term reliability test of 125 C dry life and 85 C/85%RH humidity, the failure mechanism and de-rating, the radiation tolerance, and the high temperature performance. All of the above requires the continuous NEPP funding and support.

Liu, David (Donghang)↗
NASA NTRS1973

Evaluation of magnesium-aluminum eutectic to improve combustion efficiency in low burning rate propellants

A previous investigation indicated that combustion efficiency of low burning-rate propellants could be improved if the aluminum fuel was replaced by aluminum particles coated with a magnesium-aluminum eutectic alloy (ALCAL). The purpose of the present investigation was to evaluate the possibility of improving the combustion efficiency of these propellants by admixing the eutectic with the aluminum rather than coating the aluminum. Tests of three propellants similar in every respect except for the metal fuel were conducted in test motors with 4.54 kg (10 lbm) of propellant. The first propellant used aluminum fuel; the second contained aluminum admixed with magnesium-aluminum eutectic; the third used ALCAL. The test results show the the admixed fuel gave better low burning-rate combustion efficiency than the other two. The test results also showed that the ALCAL was deficient in that much, if not all, of the coating material could be found as the fine particles in a bimodal mix of aluminum and eutectic. The combustion efficiency of low burning-rate aluminized propellants can be significantly improved by mixing a small amount of magnesium-aluminum alloy with the aluminum fuel.

Northam, B. G.↗
NASA NTRS2010

Orbital fabrication of aluminum foam and apparatus therefore

A process for producing foamed aluminum in space comprising the steps of: heating aluminum until it is molten; applying the force of gravity to the molten aluminum; injecting gas into the molten aluminum to produce molten foamed aluminum; and allowing the molten foamed aluminum to cool to below melting temperature. The apparatus for carrying out this invention comprises: a furnace which rotates to simulate the force of gravity and heats the aluminum until it is molten; a door on the furnace, which is opened for charging the aluminum into the furnace, closed for processing and opened again for removal of the foamed aluminum; a gas injection apparatus for injecting gas into the molten aluminum within the furnace; and an extraction apparatus adjacent the door for removing the foamed aluminum from the furnace.

Tucker, Dennis S.↗
NASA NTRS1993

Experimental study of void formation during aluminum solidification in reduced gravity

Void formation due to volumetric shrinkage and liquid/vapor reorientation during aluminum solidification was observed in real time by using a radiographic viewing system in normal and reduced gravity. An end-chill directional solidification furnace with water quench was designed and constructed to solidify aluminum samples during the approximately 16 sec of reduced gravity (+/-0.02g) achieved by flying an aircraft through a parabolic trajectory. In the first series of tests the aluminum was contained in a vacuum sealed, pyrolytic boron nitride crucible. An ullage space was present during each test. Void formation was recorded for two cases: a nonwetting system, and a wetting system where wetting occurred between the aluminum and the crucible lid. The void formation in the nonwetting case was similar in normal and reduced gravity, with a single vapor cavity forming at the top of the crucible. In the wetting case during reduced gravity surface tension caused two voids to form in the top corners of the crucible, but during normal gravity only one large void formed across the top. In the second series of tests the aluminum was contained in a pyrolytic boron nitride crucible that was placed in a stainless steel container and sealed in an environment of argon plus 4 percent hydrogen. An ullage space was present during each test. Void formation was recorded for two cases: a nonwetting system, and a wetting system where wetting occurred between the aluminum and one side wall and the lid. The void for nation in the nonwetting case was similar in normal and reduced gravity, with a single vapor cavity forming at the top of the crucible, although the meniscus became more convex in reduced gravity. In the wetting case the aluminum did not climb up the corners in 1g, and one large symmetric void resulted at the top when the aluminum had solidified. In the wetting case during reduced gravity the molten aluminum was drawn up the wetted wall and partially across the lid by a capillary underpressure; however, on the nonwetting wall the aluminum moved down. One void resulted along the nonwetting side of the container continuing to the top on the same side.

Chiaramonte, Francis Paul, III↗
NASA NTRS1992

Aluminum-fueled rockets for the space transportation system

Aluminum-fueled engines, used to propel orbital transfer vehicles (OTV's), offer benefits to the Space Transportation System (STS) if scrap aluminum can be scavenged at a reasonable cost. Aluminum scavenged from Space Shuttle external tanks could replace propellants hauled from Earth, thus allowing more payloads to be sent to their final destinations at the same Shuttle launch rate. To allow OTV use of aluminum fuel, two new items would be required: a facility to reprocess aluminum from external tanks and an engine for the OTV which could burn aluminum. Design of the orbital transfer vehicle would have to differ substantially from current concepts for it to carry and use the aluminum fuel. The aluminum reprocessing facility would probably have a mass of under 15 metric tons and would probably cost less that $200,000,000. Development of an aluminum-burning engine would no doubt be extremely expensive (1 to 2 billion dollars), but this amount would be adequately repaid by increased STS throughput. Engine production cost is difficult to estimate, but even an extremely high cost (e.g., $250,000,000 per engine) would not significantly increase orbit-raising expenses.

Cutler, Andrew Hall↗
NASA NTRS2009

Validity of the Aluminum Equivalent Approximation in Space Radiation Shielding

The origin of the aluminum equivalent shield approximation in space radiation analysis can be traced back to its roots in the early years of the NASA space programs (Mercury, Gemini and Apollo) wherein the primary radiobiological concern was the intense sources of ionizing radiation causing short term effects which was thought to jeopardize the safety of the crew and hence the mission. Herein, it is shown that the aluminum equivalent shield approximation, although reasonably well suited for that time period and to the application for which it was developed, is of questionable usefulness to the radiobiological concerns of routine space operations of the 21 st century which will include long stays onboard the International Space Station (ISS) and perhaps the moon. This is especially true for a risk based protection system, as appears imminent for deep space exploration where the long-term effects of Galactic Cosmic Ray (GCR) exposure is of primary concern. The present analysis demonstrates that sufficiently large errors in the interior particle environment of a spacecraft result from the use of the aluminum equivalent approximation, and such approximations should be avoided in future astronaut risk estimates. In this study, the aluminum equivalent approximation is evaluated as a means for estimating the particle environment within a spacecraft structure induced by the GCR radiation field. For comparison, the two extremes of the GCR environment, the 1977 solar minimum and the 2001 solar maximum, are considered. These environments are coupled to the Langley Research Center (LaRC) deterministic ionized particle transport code High charge (Z) and Energy TRaNsport (HZETRN), which propagates the GCR spectra for elements with charges (Z) in the range I <= Z <= 28 (H -- Ni) and secondary neutrons through selected target materials. The coupling of the GCR extremes to HZETRN allows for the examination of the induced environment within the interior' of an idealized spacecraft as approximated by a spherical shell shield, and the effects of the aluminum equivalent approximation for a good polymeric shield material such as genetic polyethylene (PE). The shield thickness is represented by a 25 g/cm spherical shell. Although one could imagine the progression to greater thickness, the current range will be sufficient to evaluate the qualitative usefulness of the aluminum equivalent approximation. Upon establishing the inaccuracies of the aluminum equivalent approximation through numerical simulations of the GCR radiation field attenuation for PE and aluminum equivalent PE spherical shells, we Anther present results for a limited set of commercially available, hydrogen rich, multifunctional polymeric constituents to assess the effect of the aluminum equivalent approximation on their radiation attenuation response as compared to the generic PE.

Badavi, Francis F.↗
NASA NTRS2009

Cast Aluminum Alloys for High Temperature Applications Using Nanoparticles Al2O3 and Al3-X Compounds (X = Ti, V, Zr)

In this paper, the effect of nanoparticles Al2O3 and Al3-X compounds (X = Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their low cost, chemical stability and low diffusions rates in aluminum at high temperatures. The strengthening mechanism at high temperature for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. For Al2O3 nanoparticles, the test samples were prepared from special Al2O3 preforms, which were produced using ceramic injection molding process and then pressure infiltrated by molten aluminum. In another method, Al2O3 nanoparticles can also be homogeneously mixed with fine aluminum powder and consolidated into test samples through hot pressing and sintering. With the Al3-X nanoparticles, the test samples are produced as precipitates from in-situ reactions with molten aluminum using conventional permanent mold or die casting techniques. It is found that cast aluminum alloy using nanoparticles Al3-X is the most cost effective method to produce high strength aluminum alloys for high temperature applications in comparison to nanoparticles Al2O3. Furthermore, significant mechanical properties retention in high temperature environment could be achieved with Al3-X nanoparticles, resulting in tensile strength of nearly 3 times higher than most 300- series conventional cast aluminum alloys tested at 600 F.

Lee, Jonathan A.↗
NASA NTRSDate not supplied

Multiscale Modeling of the Uptake of Hydrogen Chloride on Anodized Aluminum in Relevance to Spacecraft Fire Safety

Fire safety is a critical component of space missions. An electrical fire within the spacecraft often produces gaseous hydrogen chloride (HCl) from the smoldering of wire insulation. These gases tend to stick to the interior materials of the spacecraft, which is often comprised of treated aluminum. Determining the rate of uptake for HCl by aluminum helps the safe design of the spacecraft to reduce catastrophic mission risk. Our previous studies showed that a one-step global reaction model for adsorption of HCl on aluminum is incapable of predicting the experimentally measured HCl uptake of anodized aluminum, compared to other treatments with thinner oxide layers. X-ray photoelectron spectroscopy revealed that aluminum chloride is found deep in the oxide layer of the anodized aluminum, implying that the transport of HCl within the oxide layer covering the aluminum surface must be considered. This work uses a multiscale modeling approach to predict the uptake of HCl. A pore model is developed wherein the HCl reacts with the aluminum oxide pore walls to create an aluminum chloride layer. The HCl then diffuses through that layer for further reaction, until the diffusion resistance grows too large, and the surface is said to be saturated. The pore model is then coupled with the reactor-scale model to predict overall HCl uptake. Results show that this new multiscale approach predicts the uptake of HCl far more accurately than previously used single-scale models.

Modeling↗
NASA NTRSDate not supplied

Weldability Investigation of Crack Resistant Aluminum Filler Metals Developed for Large Scale Additive Manufacturing and Industrial Welding Applications

In this study the NASA MSFC welding and manufacturing team investigated a new-age aluminum filler wire designed for welding and additive manufacturing (AM) of high strength aluminum alloys. High strength aluminum alloys are known to exhibit hot cracking and hot tearing issues during fusion welding operations. The goal of this investigation was to determine whether this new-age family of alloys can suppress the hot cracking and hot tearing issues exhibited during welding of high strength aluminum alloys and to do an initial characterization of the mechanical performance of welds created using these filler wires. This study focuses on fusion welding of aluminum alloy 6061 and compares the weldability characteristics of five aluminum filler metals and two forms of 6061 base material. The MSFC team utilized manual gas tungsten arc welding (GTAW) to conduct all welding operations and carried out metallographic analysis accompanied with mechanical testing to evaluate the performance of the welds created during this study. During the study it was observed that the new-age filler wires facilitated grain refinement in the weld fusion zone and were capable of creating crack free welds in aluminum alloy 6061 while exhibiting properties that met or exceeded conventional off the shelf aluminum filler metals.

Welding↗
NASA NTRS2009

Effects of Hypervelocity Impacts on Silicone Elastomer Seals and Mating Aluminum Surfaces

While in space silicone based elastomer seals planned for use on NASA's Crew Exploration Vehicle (CEV) are exposed to threats from micrometeoroids and orbital debris (MMOD). An understanding of these threats is required to assess risks to the crew, the CEV orbiter, and missions. An Earth based campaign of hypervelocity impacts on small scale seal rings has been done to help estimate MMOD threats to the primary docking seal being developed for the Low Impact Docking System (LIDS). LIDS is being developed to enable the CEV to dock to the ISS (International Space Station) or to Altair (NASA's next lunar lander). The silicone seal on LIDS seals against aluminum alloy flanges on ISS or Altair. Since the integrity of a seal depends on both sealing surfaces, aluminum targets were also impacted. The variables considered in this study included projectile mass, density, speed, incidence angle, seal materials, and target surface treatments and coatings. Most of the impacts used a velocity near 8 km/s and spherical aluminum projectiles (density = 2.7 g/cubic centimeter), however, a few tests were done near 5.6 km/s. Tests were also performed using projectile densities of 7.7, 2.79, 2.5 or 1.14 g/cubic centimeter. Projectile incidence angles examined included 0 degrees, 45 degrees , and 60 degrees from normal to the plane of the target. Elastomer compounds impacted include Parker's S0383-70 and Esterline's ELA-SA-401 in the as received condition, or after an atomic oxygen treatment. Bare, anodized and nickel coated aluminum targets were tested simulating the candidate mating seal surface materials. After impact, seals and aluminum plates were leak tested: damaged seals were tested against an undamaged aluminum plate; and undamaged seals were placed at various locations over craters in aluminum plates. It has been shown that silicone elastomer seals can withstand an impressive level of damage before leaking beyond allowable limits. In general on the tests performed to date, the diameter of the crater in either the elastomer, or the aluminum, must be at least as big as 80% to 90% of width of the bulb of the seal before significant leakage occurs.

deGroh, Henry C., III↗