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NASA NTRSDate not supplied

Open-source Numerical Modeling of Solidification Cracking Susceptibility: Application to Refractory Alloy Systems

Introduction. Alloys such as aluminum, nickel-base, and austenitic stainless steels are susceptible to solidification cracking during welding and 3D printing. Compositional optimization is one method used to effectively mitigate solidification cracking of those alloy systems. With the surge in hypersonic and in-space propulsion activities, refractory metals (Nb, Mo, Ta, W, and Re) and their alloy derivatives are increasing in importance due to their extreme high melting point and retention of high-temperature strength; however, their chemistry was most typically optimized to promote ductility during mechanical operations such as drawing and forming. Welding of such alloys has been a challenge due to a number of issues including solidification cracking, atmospheric contamination (O, C, and N), as well as a shift in ductile-to-brittle transition to higher temperature following grain growth induced by welding. Compositional optimization of refractory alloys for solidification cracking resistance in particular is desirable as their usage increases with the advent of advanced manufacturing methods such as 3D printing. This work evaluates the effect of compositional variation in refractory metal systems on the solidification cracking susceptibility with the goals of optimizing existing alloys and joining process techniques, and formulating new alloys with increased solidification cracking resistance. Experimental Procedures. A python code was developed in a Jupyter notebook environment (Michael and Sowards, 2023) to facilitate the calculation of crack susceptibility index proposed by Kou (2015). Composition is entered as a single point, or as a 1-D or 2-D array. The notebook calls pycalphad (Otis and Liu, 2017 and Bocklund et al, 2020) to calculate the evolution of fraction solid as a function of temperature (under either Scheil or equilibrium assumptions) and then evaluates steepness of the fraction solid curve near the terminal stage of solidification to predict solidification cracking resistance. Open source thermodynamic databases available at online repositories are used (van de Walle). The process is setup in an automated fashion to generate plots that show variation in solidification cracking susceptibility according to composition on 1-D line plots or 2-D contour plots. The Jupyter notebook and crack susceptibility algorithm was also integrated with a widely used commercial CALPHAD code for validation and alloy exploration. Results and Discussion. The crack susceptibility model was first validated against a series of refractory alloy compositions evaluated in past work which utilized a specialized Varestraint test built inside a vacuum chamber environment (Lessman and Gold, 1971). The alloys tested in the Varestraint apparatus included T-111 (Ta-8W-2Hf), ASTAR-811C (Ta-8W-1Re-0.7Hf-0.025C), FS-85 (Nb-27Ta-10W-1Zr), T-222 (Ta-9.6W-2.4Hf-0.01C), Ta-10W, B-66 (Nb-5Mo-5V-1Zr), and SCb-291 (Nb-10W-10Ta). The initial test of the model showed a strong correlation with empirical Varestraint data, i.e., a Spearman rank correlation between model predictions and hot cracking measurements was observed to be greater than 0.8. Following the validation, a set of refractory metal binary mixtures was investigated to evaluate sensitivity of Nb, Mo, W, and Ta to C, N, and O content. A series of plots were produced that suggest ppmw ranges of C, N, and O where solidification cracking increases significantly and reaches a maximum. Also comparative ranking of each primary refractory metal to each interstitial was produced. For example C produces greater cracking response in Mo whereas O produces greater cracking response in Ta and Nb. Such compositional values have utility in setting limits on pickup of these interstitial elements during welding and printing rather than using a one-size-fits-all approach. Furthermore, the results have use in determining additive powder recycling requirements, which is especially pertinent for refractory metal powders due to their high cost compared to conventional alloys. Another application created thousands of hypothetical alloys within the nominal specified composition range of two widely used refractory alloys C103 (Nb-10Hf-1Ti) and TZM (Mo-0.5Ti-0.1Zr). The cracking index was calculated for the alloys and results were fed into machine learning regression techniques including Multiple Linear Regression, Ridge Regression, and Lasso Regression to determine relative potency each alloying element had on computed solidification cracking index. A series of linear equations were produced that relate composition of C103 and TZM to solidification cracking index. The crack susceptibility of C103 for example is described by an equation of the form: cracking index ~ O + 0.667*C + 0.635*N + 0.00037*Ta – 0.0008*Hf (in wt.%) From that equation, it is clear that O has strong propensity to induce solidification cracking. Interestingly, Hf is shown to reduce calculated cracking response. Finally, realizing the potential of this method to discover new refractory alloy formulations across the period table that have low solidification cracking sensitivity, the code was applied to new untested alloy systems including W-Zr-C, W-Ta-C, and others. Conclusions. In summary, an open source numerical method has been developed using Python code to calculate Kou’s crack susceptibility index. The method was applied to refractory metals which are inherently difficult to study from a weldability testing standpoint since inert shielding gas is not sufficient and welding is typically done in vacuum, especially in light of findings presented here where oxygen has profound influence on solidification cracking. This work revealed the effect of compositional variations on a series of refractory metals and showed the framework defined here will be useful in 1) the development of new alloys that have improved weldability and 3D printability, 2) placing compositional limits on existing alloys, and 3) ensuring adequate controls of manufacturing processes such as 3D printing where powder reuse is critical. Keywords. pycalphad; Python; refractory metals; solidification cracking. References. B. Bocklund et. al. (2020) http://doi.org/10.5281/zenodo.3630657. S. Kou. (2015) https://doi.org/10.1016/j.actamat.2015.01.034. G.G. Lessmann and R.E. Gold. Welding Journal, issue 1, pp. 1-s – 8-s (1971). F.N. Michael and J.W. Sowards. NASA/TM-20230002218 (2023). R. Otis and Z.-K. Liu. (2017) http://doi.org/10.5334/jors.140. A. Van de Wallle et. al. (2018) https://doi.org/10.1016/j.calphad.2018.04.003.

pycalphad↗
NASA NTRS1998

New AFM Techniques for Investigating Molecular Growth Mechanisms of Protein Crystals

Atomic Force Microscopy (AFM) has emerged as a powerful technique for investigating protein crystal growth. Earlier AFM studies were among the first to demonstrate that these crystals grew by dislocation and 2D nucleation growth mechanisms [1]. These investigations were restricted to the micron range where only surface features, such as dislocation hillocks and 2D islands are visible. Most AFM instruments can scan at higher resolutions and have the potential to resolve individual protein molecules at nanometer ranges. Such scans are essential for determining the molecular packing arrangements on crystal faces and for probing the growth process at the molecular level. However, at this resolution the AFM tip influences the image produced, with the resulting image being a convolution of the tip shape and the surface morphology [2]. In most studies this problem is resolved by deconvoluting the image to obtain the true surface morphology. Although deconvolution routines work reasonably well for simple one- dimensional shapes, for complex surfaces this approach does not produce accurate results. In this study we devised a new approach which takes advantage of the precise molecular order of crystal surfaces, combined with the knowledge of individual molecular shapes from the crystallographic data of the protein and the AFM tip shape. This information is used to construct expected theoretical AFM images by convoluting the tip shape with the constructed crystal surface shape for a given surface packing arrangement. By comparing the images from actual AFM scans with the constructed ones for different possible surface packing arrangements, the correct packing arrangement can be conclusively determined. This approach was used in this study to determine the correct one from two possible packing arrangements on (I 10) faces of tetragonal lysozyme crystals. Another novel AFM technique was also devised to measure the dimension of individual growth units of the crystal faces. Measuring these units was not attempted before and most studies have assumed that the growth unit consisted of individual protein molecules. The linescan mode of AFM instruments allows the crystal surface to be scanned along a single line. By scanning across a growth step an image showing the motion of the step is obtained. Normally such an image shows a straight line for continuous and constant step velocity. In this study by increasing the scan rate and by decreasing the step velocity (by decreasing the supersaturation), we were able to capture images of individual growth events, shown by jump discontinuities in the step line. By suitable integration of the image the growth unit dimension in the scanned direction can be obtained. Since multiple units can be involved in the growth process it is necessary to collect a statistically relevant sample before drawing conclusions about the growth mechanism. This technique was successfully employed to obtain the dimensions of growth units for the (110) face, showing that they consisted of various aggregates corresponding to the 43 helices in the crystal structure.

Li, Huayu↗
NASA NTRS1922

Differential equations in airplane mechanics

In the following report, we will first draw some conclusions of purely theoretical interest, from the general equations of motion. At the end, we will consider the motion of an airplane, with the engine dead and with the assumption that the angle of attack remains constant. Thus we arrive at a simple result, which can be rendered practically utilizable for determining the trajectory of an airplane descending at a constant steering angle.

EQUATIONS, DIFFERENTIAL↗
NASA NTRS1972

Stage separation of parallel-staged shuttle vehicles, a capability assessment

The separation concept for stage separation of parallel staged space shuttle vehicles is discussed. The forward link separation concept is emphasized. The effects of aerodynamic interference and component mass are analyzed. Qualitative measurements used to perform a preliminary evaluation of various separation system concepts are presented. Line drawings are included to clarify the mechanisms and spacecraft structures used in stage separation.

Hurley, M. J.↗
NASA NTRS1978

The Partnership: a History of the Apollo-Soyuz Test Project

Correspondance, interviews, official documents, and other published materials were used to trace the evolution of the Apollo Soyuz Test Project from the initial proposal for international cooperation in space use and exploration until the successful completion of the joint Soviet-American mission. Conceptual drawings of proposed docking modules and mechanisms are presented and dicussed. Black and white photographs taken during mission planning and in-flight activities are included with color photographs of the earth taken during the mission. Joint meetings are summarized and the scientific experiments and launch vehicles are discussed in the appendices.

Ezell, E. C.↗
NASA NTRS1984

Computer models and output, Spartan REM: Appendix B

A computer model of the Spartan Release Engagement Mechanism (REM) is presented in a series of numerical charts and engineering drawings. A crack growth analysis code is used to predict the fracture mechanics of critical components.

Marlowe, D. S.↗
NASA NTRS1992

Toxicological implications of extended space flights

This paper draws attention to the needs and mechanisms for shielding crewmembers on long-duration space flights from hazards related to chemical toxicants. Specific attention is given to existing data on sources of impaired performance, namely, neurotoxicants, respiratory infections, pulmonary function. The behavioral effects associated with long-term exposure to volatile organic solvents can impair crucial functional parameters of space flight and mission objectives. Respiratory infections contribute to performance decrements of up to 20 percent, and pulmonary function can be impaired by contaminants such as ozone leading to reduced performance. It is concluded that these and other sources of toxicologically induced performance reductions be studied since they impinge on vehicle design and mission objectives.

Weiss, Bernard↗
NASA NTRS1993

Meso-Beta scale numerical simulation studies of terrain-induced jet streak mass/momentum perturbations

The Control-B simulation experiment was designed to improve on the Control-A experiment performed with the GMASS model. This experiment addressed several inadequacies with the first smooth terrain numerical simulation by including: (1) increased nested-grid resolution to better define the simulated gravity waves, (2) increased horizontal diffusion to remove outflow boundary condition noise, and (3) the use of reanalyzed rawinsonde data and surface observations in the initial state to increase the definition of the observed jet streak as well as other low-level features. A smoothed-terrain dry simulation with the nested-grid GMASS model has revealed many important aspects of the processes which resulted in the generation of gravity waves in the region and time when and where they were observed. However, the vertical structure, number, and characteristics of the waves are still quite different from observed waves as diagnosed thus necessitating future improved simulations. However, this control simulation has produced substantial insight into processes which occur on many spatial scales over a 30 hour time period thus allowing one to draw promising inferences as to the mechanisms for the complex process which occurred in nature during the CCOPE case study. The theoretical aspects of the project have focus on understanding the nature of the ageostrophic circulations which are produced in idealized models of the atmosphere in which the troposphere is modeled in one of two ways. The first model assumes that the lower atmosphere can be represented as a single layer of homogeneous fluid whose upper surface is free to exhibit vertical displacement. Two-dimensional internal convergence (divergence) occurring during the adjustment to an asymptotic equilibrium state from an ageostrophic initial state whose momentum structure is representative of a midlatitude localized zonal wind anomaly will cause the free upper surface of the homogeneous atmosphere to rise (fall), and therefore the response can be viewed as being physically three-dimensional. The second model assumes that the troposphere can be represented by an unbounded continuously stratified Boussinesq fluid of constant Brunt-Vaisala frequency N, where the vertical gradient of the basic state potential temperature profile allows for the existence of vertically propagating internal inertia-gravity waves.

Lin, Yuh-Lang↗
NASA NTRS1986

Shutter Mechanism for Calibration of the Cryogenic Diffused Infrared Background Experiment (DIRBE) Instrument

This paper describes the design requirements, the design, the assembly and alignment, and the test program for a shutter mechanism which must operate at cryogenic temperature and draw less than 1.0 milliwatt. The design solution to meet these requirements is a device that positions a mirror with repeated accuracy, has no wearing surfaces and operates at 2.0 K. The unique feature of this device is the simplicity of the mechanism, thus obtaining high reliability.

Tyler, Allen↗
NASA NTRS1986

Shutter mechanism for calibration of the cryogenic diffused infrared background experiment (DIRBE) instrument

The design requirements, the design, the assembly and alignment, and the test program for a shutter mechanism which must operate at cryogenic temperature and draw less than 1.0 milliwatt are discussed. The design solution to meet these requirements is a device that positions a mirror with repeated accuracy, has no wearing surfaces, and operates at 2.0 K. The unique feature of this device is the simplicity of the mechanism, thus obtaining high reliability.

Tyler, Allen↗
NASA NTRS1985

New analysis of nuclear interaction observed by Mt. Kanbara emulsion chamber experiment

To date the analysis of the air cascade family has been performed using a full Monte Carlo simulation. It is difficult to draw a definite conclusion about the interaction mechanism by using only this kind of simulation. On the other hand, attempts to reproduce the original gamma ray at the interaction point, for example decascading, have also been made. This method makes it possible to observe the interaction directly and to analyze the data from various angles. All of these methods, however, assume a constant ER in the cascade shower, where E is energy and R is the distance from the center of the cascade shower. It is impossible to reproduce the exact interaction height and energy by these methods. A relative method in separating one cascade shower from others is adopted. This method makes it possible to estimate the interaction height and energy by using information about the lateral spread of the cascade shower.

Nanjo, H.↗
NASA NTRS1993

Numerical simulation of steady and unsteady viscous flow in turbomachinery using pressure based algorithm

The objective of this research is to simulate steady and unsteady viscous flows, including rotor/stator interaction and tip clearance effects in turbomachinery. The numerical formulation for steady flow developed here includes an efficient grid generation scheme, particularly suited to computational grids for the analysis of turbulent turbomachinery flows and tip clearance flows, and a semi-implicit, pressure-based computational fluid dynamics scheme that directly includes artificial dissipation, and is applicable to both viscous and inviscid flows. The values of these artificial dissipation is optimized to achieve accuracy and convergency in the solution. The numerical model is used to investigate the structure of tip clearance flows in a turbine nozzle. The structure of leakage flow is captured accurately, including blade-to-blade variation of all three velocity components, pitch and yaw angles, losses and blade static pressures in the tip clearance region. The simulation also includes evaluation of such quantities of leakage mass flow, vortex strength, losses, dominant leakage flow regions and the spanwise extent affected by the leakage flow. It is demonstrated, through optimization of grid size and artificial dissipation, that the tip clearance flow field can be captured accurately. The above numerical formulation was modified to incorporate time accurate solutions. An inner loop iteration scheme is used at each time step to account for the non-linear effects. The computation of unsteady flow through a flat plate cascade subjected to a transverse gust reveals that the choice of grid spacing and the amount of artificial dissipation is critical for accurate prediction of unsteady phenomena. The rotor-stator interaction problem is simulated by starting the computation upstream of the stator, and the upstream rotor wake is specified from the experimental data. The results show that the stator potential effects have appreciable influence on the upstream rotor wake. The predicted unsteady wake profiles are compared with the available experimental data and the agreement is good. The numerical results are interpreted to draw conclusions on the unsteady wake transport mechanism in the blade passage.

Lakshminarayana, B.↗
NASA NTRS2012

Pandora Operation and Analysis Software

Pandora Operation and Analysis Software controls the Pandora Sun- and sky-pointing optical head and built-in filter wheels (neutral density, UV bandpass, polarization filters, and opaque). The software also controls the attached spectrometer exposure time and thermoelectric cooler to maintain the spectrometer temperature to within 1 C. All functions are available through a GUI so as to be easily accessible by the user. The data are automatically stored on a miniature computer (netbook) for automatic download to a designated server at user defined intervals (once per day, once per week, etc.), or to a USB external device. An additional software component reduces the raw data (spectrometer counts) to preliminary scientific products for quick-view purposes. The Pandora systems are built from off-the-shelf commercial parts and from mechanical parts machined using electronic machine shop drawings. The Pandora spectrometer system is designed to look at the Sun (tracking to within 0.1 ), or to look at the sky at any zenith or azimuth angle, to gather information about the amount of trace gases or aerosols that are present.

Herman, Jay↗
NASA NTRS1996

Effect of Temperature and Deformation Rate on the Tensile Mechanical Properties of Polyimide Films

In order to study the structure-property relationships of different processed oriented polyimide films, the mechanical properties will be identified by using tensile tester Instron 4505 and structural information such as the 3-dimensional birefringence molecular symmetry axis and 3-dimensional refractive indices will be determined by using wave guide coupling techniques. The monoaxial drawing techniques utilized in this research are very useful for improving the tensile mechanical properties of aromatic polyimide films. In order to obtain high modulus/high strength polyimide films the following two techniques have been employed, cold drawing in which polyimide films are drawn at room temperature at different cross head speeds and hot drawing in which polyimide films are drawn at different temperatures and cross head speeds. In the hot drawing process the polyimide films are drawn at different temperatures until the glass transition temperature (Tg) is reached by using the environmental chamber. All of the mechanical and optical property parameters will be identified for each sample processed by both cold and hot drawing techniques.

Moghazy, Samir F.↗
NASA NTRS1982

Discovery of an Io-correlated energy source for Io's hot plasma torus

Energy flowing into Io's hot plasma torus from a local-time correlated source and from an Io-related source are discussed, and a correlation of the brightness of the ansae of the torus with the apparent orbital phase of Io is reported. It is shown that the energy flows cause an azimuthal modulation of the brightness of the torus that is correlated with the position of Io, and the plasma downstream from Io is shown to be brighter in S III 685-A emission, which indicates a higher electron temperature. Differences in electron temperature inferred from spectral analyses account for all observed differences in brightness, implying that no change in the composition or density of the hot plasma occurs. The mechanism regulating the Io-related source is clearly distinct from the mechanism driving the local time source, although both draw on the same pool of energy, and the combination of the two sources is easily capable of supplying all the energy radiated by the torus.

Sandel, B. R.↗