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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 NTRS2017

Magnesium Alloys for Space Hardware Design

There have been advances in magnesium alloy development that NASA has not taken into consideration for space hardware because of a lack of test data. Magnesium alloys offer excellent weight reduction, specific strength, and deep space radiation mitigation. Traditionally, magnesium has been perceived as having too poor of a flammability resistance and corrosion resistance to be used for flight. Recent developments in magnesium alloying has led to the formation of two alloys, WE43 and Elektron 21, which are self-extinguishing and significantly less flammable because of their composition. Likewise, an anodizing process called Tagnite was formulated to deter any concern with galvanic and saltwater corrosion. The Materials Science Branch at Kennedy Space Center is currently researching these new alloys and treatments to better understand how they behave in the harsh environment of space. Successful completion of the proposed testing should result in a more thorough understanding of modern aerospace materials and processes, and possibly the permission to use magnesium alloys in future NASA designs.

microstructure↗
NASA NTRS2005

Heat Transfer and Thermal Stability Research for Advanced Hydrocarbon Fuel Technologies

In recent years there has been increased interest in the development of a new generation of high performance boost rocket engines. These efforts, which will represent a substantial advancement in boost engine technology over that developed for the Space Shuttle Main Engines in the early 1970s, are being pursued both at NASA and the United States Air Force. NASA, under its Space Launch Initiative s Next Generation Launch Technology Program, is investigating the feasibility of developing a highly reliable, long-life, liquid oxygen/kerosene (RP-1) rocket engine for launch vehicles. One of the top technical risks to any engine program employing hydrocarbon fuels is the potential for fuel thermal stability and material compatibility problems to occur under the high-pressure, high-temperature conditions required for regenerative fuel cooling of the engine combustion chamber and nozzle. Decreased heat transfer due to carbon deposits forming on wetted fuel components, corrosion of materials common in engine construction (copper based alloys), and corrosion induced pressure drop increases have all been observed in laboratory tests simulating rocket engine cooling channels. To mitigate these risks, the knowledge of how these fuels behave in high temperature environments must be obtained. Currently, due to the complexity of the physical and chemical process occurring, the only way to accomplish this is empirically. Heated tube testing is a well-established method of experimentally determining the thermal stability and heat transfer characteristics of hydrocarbon fuels. The popularity of this method stems from the low cost incurred in testing when compared to hot fire engine tests, the ability to have greater control over experimental conditions, and the accessibility of the test section, facilitating easy instrumentation. These benefits make heated tube testing the best alternative to hot fire engine testing for thermal stability and heat transfer research. This investigation used the Heated Tube Facility at the NASA Glenn Research Center to perform a thermal stability and heat transfer characterization of RP-1 in an environment simulating that of a high chamber pressure, regenerative cooled rocket engine. The first step in the research was to investigate the carbon deposition process of previous heated tube experiments by performing scanning electron microscopic analysis in conjunction with energy dispersive spectroscopy on the tube sections. This analysis gave insight into the carbon deposition process and the effect that test conditions played in the formation of deleterious coke. Furthermore, several different formations were observed and noted. One other crucial finding of this investigation was that in sulfur containing hydrocarbon fuels, the interaction of the sulfur components with copper based wall materials presented a significant corrosion problem. This problem in many cases was more life limiting than those posed by the carbon deposition process. The results of this microscopic analysis was detailed and presented at the December 2003 JANNAF Air-Breathing Propulsion Meeting as a Materials Compatibility and Thermal Stability Analysis of common Hydrocarbon Fuels (reference 1).

DeWitt, Kenneth↗
NASA NTRS2019

Molten Silicate Reactivity with Environmental Barrier Coating Materials for Gas Turbine Engine Applications

Rare earth (RE) disilicates are utilized in environmental barrier coatings (EBCs) to protect SiC-based ceramic matrix composites (CMCs) from destructive reactions with water vapor and other combustion species. These coating materials, however, degrade when exposed to molten silicate deposits primarily composed of calcium-magnesium aluminosilicates (CMAS). Coating materials are exposed to CMAS by engine ingestion of dust particulates from terrestrial sources during operation. Due to continual increases in engine operating temperature, it is important to understand the high temperature thermochemical mechanisms that drive corrosion of these materials. This work focuses on characterizing reaction products between disilicates and CMAS and optimizing coating chemistries to mitigate damage.

Stokes, Jamesa L.↗
NASA NTRS2009

NASA TEERM Hexavalent Chrome Alternatives Projects

This slide presentation reviews the NASA/DOD projects to select an alternative to hexavalent chrome in the aerospace industry. The Phase I process of the project performed: (1) Evaluation and testing of non-chromated coating systems as replacements for hexavalent chrome coatings in aircraft and aerospace applications. (2) Testing of coating systems to DoD and NASA specifications for corrosion resistance and adhesion. (3) Bare corrosion resistance and atmospheric exposure will be focus areas of Phase II Testing. The description includes a chart that summarizes the 3000 hour salt fog test results. The second phase of the project includes (1) Evaluation and testing of coating systems that do not contain hexavalent chrome as replacements for aerospace applications. (2) Evaluation of coatings at Beach Test Site and Launch Complex 39B (3) Evaluation of non-chrome coatings for electronic housings (bare corrosion resistance and electrical impedance) is a part of this round of testing. This project was performed for the Technology Evaluation for Environmental Risk Mitigation (TEERM)

Rothgeb, Matt↗
NASA NTRS2017

Technology Evaluation for Environmental Risk Mitigation Compendium

The Technology Evaluation for Environmental Risk Mitigation (TEERM) Principal Center and its predecessor organization the Acquisition Pollution Prevention Program (AP2) supported the National Aeronautics and Space Administration (NASA) in identifying technology solutions to risks and costs to NASA programs driven by environmental regulations and requirements. TEERM researched the commercial and government marketplace to locate viable and available technologies that met NASAs needs. TEERM focused on addressing environmentally-driven risks of direct concern to NASA programs and facilities, including hazardous materials in NASA operations and materials that became obsolescent because of environmental regulations. TEERM projects aimed to reduce cost; ensure the health and safety of people, assets, and the environment; promote efficiency; and minimize duplication. Major TEERM and AP2 projects focused on waste minimization and hazardous waste treatment, recycling, corrosion prevention and control, solvent and ozone depleting substances substitution, and aqueous based cleaners. In 2017, NASA made the decision to terminate the TEERM Principal Center. This Compendium Report documents TEERM and AP2 project successes. The Compendium Report traces the evolution of TEERM based on evolving risks and requirements for NASA and its relationship to the Space Shuttle Program, the United States Department of Defense, the European Space Agency, and other public and private stakeholders. This Compendium Report also documents project details from Project Summaries and Joint Test Plans and describes project stakeholders and collaborative effort results.

material obsolescent↗
NASA NTRS2020

Novel Environmental Barrier Coatings for the Protection of SiC Components

Greater gas turbine engine efficiency is a major goal in aeronautics research often pursued through increased engine operating temperatures. However, it is necessary to replace the current hot-stage alloy components with more thermally robust parts, such as Silicon-based ceramics and composites. Unfortunately, these materials are still susceptible to the effects of oxidation, water vapor, and (Calcium-Magnesium-Alumino-Silicate) CMAS interaction, among other issues at high temperature. To mitigate these effects, environmental barrier coating (EBC) materials are employed to help control the rate of degradation to the underlying composite, but must also survive the corrosive environment. The current study explores new design space in Mg-based EBC materials with respect to microstructure, high temperature phase stability, volatilization in water vapor, as well as structure-property relationships at high temperature.

Kowalski, Benjamin A.↗
NASA NTRSDate not supplied

Space Shuttle Program Dual Docked Operations

Due to the ever-increasing visiting vehicle traffic to and from the International Space Station (ISS) during mated Orbiter/ISS missions, it became apparent to both the ISS Program (ISSP) and the Space Shuttle program (SSP) that there would arise occasions where a visiting vehicle docking and/or undocking could overlap when the Space Shuttle Orbiter was docked to the ISS, referred to as Dual Docked Operations (DDO). The primary concerns were that plumes from the visiting vehicles would cause contamination, corrosion, and erosion to Space Shuttle surfaces and present a toxicity hazard to ground personnel when processing the Space Shuttle after landing. This potential conflict provided the genesis for evaluating risk mitigations to gain maximum flexibility for managing potential visiting vehicle traffic to and from the ISS and to maximize launch and landing opportunities for all visiting vehicles. The overarching goal of this effort was to assess the viability and readiness of the SSP to protect for DDO on any given mission. To assess the viability of performing DDO, the ISSP delivered plume particle fluence (i.e., number of particles per unit area) and contamination deposition based on the visiting vehicle’s proximity operations to the SSP for evaluation. This paper summarizes the concept definition, studies, and analysis results generated by the SSP, ISSP, and Mission Operations Directorate (MOD) for implementing DDO involving the Orbiter and Russian vehicles (RVs). Discussion and results presented herein represent a generic assessment of the SSP and ISSP integrated safety and technical evaluations of DDO involving the Orbiter and RVs. Mission-specific analysis and operational impacts were conducted flight-by-flight as they arose.

Launch vehicles↗
NASA NTRS2010

QuEST: Qualifying Environmentally Sustainable Technologies, Volume 5

This edition of the QuEST newsletter contains brief articles that discuss the NASA Technology Evaluation for Environmental Risk Mitigation (TEERM) program, and the importance of collaboration, efforts in materials management and substitution for coatings for launch structures, Low volatile organic compound (VOC) Coatings Field Testing, Non-Chrome Coating Systems, Life Cycle Corrosion Testing, Lead-Free Electronics Testing and Corn Based Depainting and efforts in Pollution Control in the area of Hypergolic Propellant Destruction Evaluation, efforts in development of alternative energy in particular Hydrogen Sensors, Energy and Water Management, and efforts in remediation in the removal of Polychlorinated Biphenyl (PCB) contamination

Lewis, Pattie↗
NASA NTRS1987

Corrosion of a-Si cells and modules

The authors report on corrosion/erosion phonemena observed in exposing a-Si cells, modules, and specially designed test structures to natural and accelerated test environments. Relevant cell and module I-V curve data used for monitoring degradation are presented. The causes of the observed degradation, methods of mitigation, and consequences for fielded modules are discussed.

Mon, G. R.↗
NASA NTRS2017

Current EBC Development and Testing at NASA

SiC SiC Ceramic Matrix Composites (CMCs) are a game changer for advanced power generation equipment because of their high temperature capability, oxidation resistance, and light weight that translate to significant reduction in fuel consumption and emission. Limitations of SiC SiC CMCs include surface recession and component cracking and associated chemical and physical degradation in the CMC. The solution pursued to mitigate surface recession of SiC SiC CMCs is the incorporation of coating systems that provide surface protection, which has become known as an Environmental Barrier Coating (EBC). The development of EBCs for the protection of SiC SiC CMCs was a continuation of coating development work for corrosion protection of silicon-based monolithics. The first and second generation EBCs developed in mid 1990s-early 2000s laid the foundation for current EBCs. Environmental degradation that limits EBC life includes surface recession by steam, oxidation in steam environments, and CMAS-EBC reactions. Many engine tests have been conducted since late 1990s and a first CMC component entered into service in 2016 in a commercial engine. The introduction of CMCs represents significant challenges as failure of the EBC means rapid reduction in component life. A reliable lifing method and engine-relevant testing methods to validate life need to be developed. This paper will current activities on EBC development and testing at NASA.

CMC↗
NASA NTRS2016

International Space Exploration Coordination Group Assessment of Technology Gaps for LOx/Methane Propulsion Systems for the Global Exploration Roadmap

As part of the Global Exploration Roadmap (GER), the International Space Exploration Coordination Group (ISECG) formed two technology gap assessment teams to evaluate topic discipline areas that had not been worked at an international level to date. The participating agencies were ASI, CNES, DLR, ESA, JAXA, and NASA. Accordingly, the ISECG Technology Working Group (TWG) recommended two discipline areas based on Critical Technology Needs reflected within the GER Technology Development Map (GTDM): Dust Mitigation and LOX/Methane Propulsion. LOx/Methane propulsion systems are enabling for future human missions Mars by significantly reducing the landed mass of the Mars ascent stage through the use of in-situ propellant production, for improving common fluids for life support, power and propulion thus allowing for diverse redundancy, for eliminating the corrosive and toxic propellants thereby improving surface operations and resusabilty, and for inceasing the performance of propulsion systems. The goals and objectives of the international team are to determine the gaps in technology that must be closed for LOx/Methane to be used in human exploration missions in cis-lunar, lunar, and Mars mission applications. An emphasis is placed on near term lunar lander applications with extensibility to Mars. Each agency provided a status of the substantial amount of Lox/Methane propulsion system development to date and their inputs on the gaps in the technology that are remaining. The gaps, which are now opportunities for collaboration, are then discussed.

Hurlbert, Eric A.↗
NASA NTRS2023

Shock- and Corrosion-Resistant Bearings for Space Mechanisms

Nickel-titanium (NiTi) alloys are an emerging class of materials for rolling element bearing applications that require superior corrosion resistance and/or high load capability. Certain space mechanisms fall into one or both of those categories. Often, due to size and mass considerations, space mechanism systems are limited in torque margin and necessarily require small, precision-instrument bearings with very little frictional drag (i.e., low torque). In addition, space mechanism bearings must survive launch conditions without suffering raceway dents known as brinnelling, which would increase operating torque and reduce overall smoothness. Consequently, a bearing material or design that reduces or eliminates brinnelling under high contact stress conditions would represent a beneficial technology advancement. One specific alloy, nickel-titanium-hafnium (NiTi-Hf), under development for several years at the NASA Glenn Research Center as a bearing material, has the potential to mitigate concerns about brinnelling under extreme load conditions due to its unusually high elastic strain capability. In the present work, a sample of small precision bearings produced with three different ball materials (steel, ceramic, and NiTi-Hf) is subjected to a range of load conditions sufficient to dent the races. The dent depth as a function of load is compared and demonstrates that NiTi-Hf has the potential to increase bearing load capacity from the perspective of brinnelling under severe load conditions; additional testing of full NiTi-Hf bearings demonstrates corrosion resistance superior to that of 440C bearings.

Bearings↗
NASA NTRS2004

Successful Surface Treatments for Reducing Instabilities in Advanced Nickel-base Superalloys for Turbine Blades

An optimized carburization treatment has been developed to mitigate instabilities that form in the microstructures of advanced turbine airfoil materials. Current turbine airfoils consist of a single crystal superalloy base that provides the mechanical performance of the airfoil, a thermal barrier coating (TBC) that reduces the temperature of the base superalloy, and a bondcoat between the superalloy and the TBC, that improves the oxidation and corrosion resistance of the base superalloy and the spallation resistance of the TBC. Advanced nickel-base superalloys containing high levels of refractory metals have been observed to develop an instability called secondary reaction zone (SRZ), which can form beneath diffusion aluminide bondcoats. This instability between the superalloy and the bondcoat has the potential of reducing the mechanical properties of thin-wall turbine airfoils. Controlled gas carburization treatments combined with a prior stress relief heat treatment and adequate surface preparation have been utilized effectively to minimize the formation of SRZ. These additional processing steps are employed before the aluminide bondcoat is deposited and are believed to change the local chemistry and local stresses of the surface of the superalloy. This paper presents the detailed processing steps used to reduce SRZ between platinum aluminide bondcoats and advanced single crystal superalloys.

Locci, Ivan E.↗
NASA NTRS2011

NASA TEERM Hexavalent Chrome Alternatives Projects

This slide presentation reviews the NASA project to select an alternative to hexavalent chrome in the aerospace industry. Included is a recent historic testing and research that the Agency has performed on (1) the external tank, (2) the shuttle orbiter, (3) the Shuttle Rocket Booster, and (4) the Space Shuttle Main Engine. Other related Technology Evaluation for Environmental Risk Mitigation (TEERM) projects are reviewed. The Phase I process of the project performed testing of alternatives the results are shown in a chart for different coating systems. International collaboration was also reviewed. Phase II involves further testing of pretreatment and primers for 6 and 12 months of exposure to conditions at Launch Pad and the beach. Further test were performed to characterize the life cycle corrosion of the space vehicles. A new task is described as a joint project with the Department of Defense to identify a Hex Chrome Free Coatings for Electronics.

Kessel, Kurt↗
NASA NTRS2016

NASA and ESA Collaboration on Alternative to Nitric Acid Passivation: Parameter Optimization of Citric Acid Passivation for Stainless Steel Alloys

National Aeronautics and Space Administration (NASA) Headquarters chartered the Technology Evaluation for Environmental Risk Mitigation Principal Center (TEERM) to coordinate agency activities affecting pollution prevention issues identified during system and component acquisition and sustainment processes. The primary objectives of NASA TEERM are to: Reduce or eliminate the use of hazardous materials or hazardous processes at manufacturing, remanufacturing, and sustainment locations. Avoid duplication of effort in actions required to reduce or eliminate hazardous materials through joint center cooperation and technology sharing. Corrosion is an extensive problem that affects the National Aeronautics and Space Administration (NASA) and the European Space Agency (ESA). The damaging effects of corrosion result in steep costs, asset downtime affecting mission readiness, and safety risks to personnel. Consequently, it is vital to reduce corrosion costs and risks in a sustainable manner. NASA and ESA have numerous structures and equipment that are fabricated from stainless steel. The standard practice for protection of stainless steel is a process called passivation. Passivation is defined by The American Heritage Dictionary of the English Language as to treat or coat (a metal) in order to reduce the chemical reactivity of its surface. Passivation works by forming a shielding outer (metal oxide) layer that reduces the impact of destructive environmental factors such as air or water. Consequently, this process necessitates a final product that is very clean and free of iron and other contaminants. Typical passivation procedures call for the use of nitric acid; however, there are a number of environmental, worker safety, and operational issues associated with its use. Citric acid is an alternative to nitric acid for the passivation of stainless steels. Citric acid offers a variety of benefits including increased safety for personnel, reduced environmental impact, and reduced operational cost. The primary objective of this effort is to qualify citric acid as an environmentally-preferable alternative to nitric acid for the passivation of stainless steel alloys. While citric acid use has become more prominent in industry, there is little evidence that citric acid is a technically sound passivation agent, especially for the unique and critical applications encountered by NASA and ESA.

citric acid passivation↗
NASA NTRS2009

Refractory Materials for Flame Deflector Protection System Corrosion Control: Coatings Systems Literature Survey

When space vehicles are launched, extreme heat, exhaust, and chemicals are produced and these form a very aggressive exposure environment at the launch complex. The facilities in the launch complex are exposed to this aggressive environment. The vehicle exhaust directly impacts the flame deflectors, making these systems very susceptible to high wear and potential failure. A project was formulated to develop or identify new materials or systems such that the wear and/or damage to the flame deflector system, as a result of the severe environmental exposure conditions during launches, can be mitigated. This report provides a survey of potential protective coatings for the refractory concrete lining on the steel base structure on the flame deflectors at Kennedy Space Center (KSC).

Calle, Luz M.↗
NASA NTRS1996

Chemical Characterization and Reactivity Testing of Fuel-Oxidizer Reaction Product (Test Report)

The product of incomplete reaction of monomethylhydrazine (MMH) and nitrogen tetroxide (NTO) propellants, or fuel-oxidizer reaction product (FORP), has been hypothesized as a contributory cause of an anomaly which occurred in the chamber pressure (PC) transducer tube on the Reaction Control Subsystem (RCS) aft thruster 467 on flight STS-51. A small hole was found in the titanium-alloy PC tube at the first bend below the pressure transducer. It was surmised that the hole may have been caused by heat and pressure resulting from ignition of FORP. The NASA Johnson Space Center (JSC) White Sands Test Facility (WSTF) was requested to define the chemical characteristics of FORP, characterize its reactivity, and simulate the events in a controlled environment which may have lead to the Pc-tube failure. Samples of FORP were obtained from the gas-phase reaction of MMH with NTO under laboratory conditions, the pulsed firings of RCS thrusters with modified PC tubes using varied oxidizer or fuel lead times, and the nominal RCS thruster firings at WSTF and Kaiser-Marquardt. Fourier transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), accelerating rate calorimetry (ARC), ion chromatography (IC), inductively coupled plasma (ICP) spectrometry, thermogravimetric analysis (TGA) coupled to FTIR (TGA/FTIR), and mechanical impact testing were used to qualitatively and quantitatively characterize the chemical, thermal, and ignition properties of FORP. These studies showed that the composition of FORP is variable but falls within a limited range of compositions that depends on the fuel loxidizer ratio at the time of formation, composition of the post-formation atmosphere (reducing or oxidizing), and reaction or postreaction temperature. A typical composition contains methylhydrazinium nitrate (MMHN), ammonium nitrate (AN), methylammonium nitrate (MAN), and trace amounts of hydrazinium nitrate and 1,1-dimethylhydrazinium nitrate. The thermal decomposition reactions of FORP compositions used in this study were unremarkable, Neither the various compositions of FORP, the pure major components of FORP, nor mixtures of FORP with propellant-system corrosion products showed any unusual thermal activity when decomposed under laboratory conditions. Off-limit thruster operations were simulated by rapid mixing of liquid MMH and liquid NTO in a confined space. The test hardware was constructed with pressure- and temperature-measurement devices to determine if the expected fuel oxidizer reaction would result in increased energy release when FORP, FORP constituents, or propellant-system corrosion products were present. These tests demonstrated that FORP, MMHN, AN, or Inconel corrosion products can induce a mixture of MMH and NTO to produce component-damaging energies. The simulation-test program was not extensive enough to provide statistical probabilities for these events but did show that such events can occur. Damaging events required FORP or metal salts to be present at the initial mixing of MMH and NTO. Based on the results of these studies, it is suggested that removal or mitigation of a buildup of these materials may decrease the incidence of these high-energy, potentially damaging events.

Source record↗
NASA NTRS1983

A survey of gas-side fouling in industrial heat-transfer equipment

Gas-side fouling and corrosion problems occur in all of the energy intensive industries including the chemical, petroleum, primary metals, pulp and paper, glass, cement, foodstuffs, and textile industries. Topics of major interest include: (1) heat exchanger design procedures for gas-side fouling service; (2) gas-side fouling factors which are presently available; (3) startup and shutdown procedures used to minimize the effects of gas-side fouling; (4) gas-side fouling prevention, mitigation, and accommodation techniques; (5) economic impact of gas-side fouling on capital costs, maintenance costs, loss of production, and energy losses; and (6) miscellaneous considerations related to gas-side fouling. The present state-of-the-art for industrial gas-side fouling is summarized by a list of recommendations for further work in this area.

Marner, W. J.↗