Search NASA⌕ Search

SEARCH · Search NASA

Results for “METAL FORMING”

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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1974

Method for making conductors for ferrite memory arrays

The ferrite memory arrays are made from pre-formed metal conductors for the ferrite arrays. The conductors are made by forming a thin sheet of a metallizing paste of metal alloy powder, drying the paste layer, bisque firing the dried sheet at a first temperature, and then punching the conductors from the fired sheet. During the bisque firing, the conductor sheet shrinks to 58 percent of its pre-fired volume and the alloy particles sinter together. The conductors are embedded in ferrite sheet material and finally fired at a second higher temperature during which firing the conductors shrink approximately the same degree as the ferrite material.

Heckler, C. H.↗
NASA NTRSDate not supplied

PRIME ISS Ground Prototype

In Additive Manufacturing (AM) with metal powders, layers of material are deposited and fused to form metal 3D parts. However, in most cases, remnant powder still must be removed from interior cavities and channels to fully clean the part before use. Ground demonstrations such as ultrasonic cleaning have been proven to work during ground testing at MSFC and Florida State University. However, manufacturing in the low gravity environment of space introduces challenges to this powder removal. Therefore, if this concept could be demonstrated in microgravity, the ability to clean AM parts or contaminated parts can bring new advancements to in-space manufacturing (ISM). The goal of this work was to make significant progress on developing an ISS payload using the ultrasonic technology called Powder Removal in Microgravity Environments (PRIME). This would also create new opportunities for in-space manufacturing (ISM) and the additive manufacturing community to develop new standards and practices for powder removal and the cleaning of contaminated parts in space.

Microgravity↗
NASA NTRS1995

Formation of Hydrocarbons in the Outflows from Red Giants

The formation of hydrocarbons in the oxygen-rich outflows from red giants was studied. The existence of organic molecules in such outflows has been known for several years; however, their surprisingly high abundances has been a mystery since all of the carbon had been thought to be irretrievably locked up in CO, the most strongly bound molecule. CO is the first molecule to form from the atoms present in the star's extended atmosphere, and as strong stellar winds drive a cooling outflow, dust grains condense out. In oxygen-rich outflows, the dust is thought to be composed mainly of silicates and other metal oxides. Perhaps the noble metals can condense out in metallic form, in particular the relatively abundant transition metals iron and nickel. We proposed that perhaps the carbon reservoir held as CO can be accessed through a catalytic process involving the chemisorption of CO and H2 onto grains rich in metallic iron. CO and H2 are the two most abundant molecules in circumstellar outflows, and they both are known to dissociate on transition metal surfaces at elevated temperatures, freeing carbon to form organic molecules such as methane. We believe methane is a precursor molecule to the organics observed in oxygen-rich red giants. We have developed a nonequilibrium numerical model of a surface chemical (catalytic) process. Based on this model, we believe that methane can be formed under the conditions present in circumstellar outflows. Although the methane formation rates are exceptionally low under these conditions, over dynamical timescales, a significant amount of CO can be converted to methane and driven further out in the envelope, explaining the presence of organics there.

Roberge, Wayne↗
NASA NTRS1968

Magnetic forming studies

Investigation of the tensile strength dependability on the characteristic time over which a pressure pulse is applied to a metal workpiece shows that the mechanical properties of these materials are functions of the rate at which the material is undergoing strain. These results and techniques are used in magnetomotive metal forming.

Furth, H. P.↗
NASA NTRS2008

Making a Back-Illuminated Imager with Back-Side Contact and Alignment Markers

A design modification and a fabrication process that implements the modification have been conceived to solve two problems encountered in the development of back-illuminated, back-sidethinned complementary metal oxide/ semiconductor (CMOS) image-detector integrated circuits. The two problems are (1) how to form metal electrical-contact pads on the back side that are electrically connected through the thickness in proper alignment with electrical contact points on the front side and (2) how to provide alignment keys on the back side to ensure proper registration of backside optical components (e.g., microlenses and/or color filters) with the front-side pixel pattern. The essence of the design modification is to add metal plugs that extend from the desired front-side locations through the thickness and protrude from the back side of the substrate. The plugs afford the required front-to-back electrical conduction, and the protrusions of the plugs serve as both the alignment keys and the bases upon which the back-side electrical-contact pads can be formed.

Pain, Bedabrata↗
NASA NTRS2006

Optical Microscopy Techniques to Inspect for Metallic Whiskers

Metal surface finishes of tin, zinc and cadmium are often applied to electronic components, mechanical hardware and other structures. These finishes sometimes unpredictably may form metal whiskers over periods that can take from hours to months or even many years. The metal whiskers are crystalline structures commonly having uniform cross sectional area along their entire length. Typical whisker dimensions are nominally on the order of only a few microns (um) across while their lengths can extend from a few microns to several millimeters. Metal whiskers pose a reliability hazard to electronic systems primarily as an electrical shorting hazard. The extremely narrow dimensions of metal whiskers can make observation with optical techniques very challenging. The videos herein were compiled to demonstrate the complexities associated with optical microscope inspection of electronic and mechanical components and assemblies for the presence or absence of metal whiskers. The importance of magnification, light source and angle of illumination play critical roles in being able to detect metal whiskers when present. Furthermore, it is demonstrated how improper techniques can easily obscure detection. It is hoped that these videos will improve the probability of detecting metal whiskers with optical inspection techniques.

Brusse, Jay A.↗
NASA NTRS1978

Formation of metallic LiH

It is shown that a metallic form of LiH may be produced at the relatively low transition pressure of 1.1 mbar. LiH may thus be applied to studies of insulator-metal transition at high pressure. Experimental data is used to calculate LiH transition parameters: first, Herzfeld's criterion (1927) is used to determine the volume at which metallic behavior begins, and second, pressure-volume measurements for estimating the pressure at which this volume is achieved are extrapolated. For comparison, the same volume-pressure calculation is performed for H2, and it is found that the metallization of LiH should occur more easily than that of H2.

Vaisnys, J. R.↗
NASA NTRS2012

Internal Structure and Mineralogy of Differentiated Asteroids Assuming Chondritic Bulk Composition: The Case of Vesta

Bulk composition (including oxygen content) is a primary control on the internal structure and mineralogy of differentiated asteroids. For example, oxidation state will affect core size, as well as Mg# and pyroxene content of the silicate mantle. The Howardite-Eucrite-Diogenite class of meteorites (HED) provide an interesting test-case of this idea, in particular in light of results of the Dawn mission which provide information on the size, density and differentiation state of Vesta, the parent body of the HED's. In this work we explore plausible bulk compositions of Vesta and use mass-balance and geochemical modelling to predict possible internal structures and crust/mantle compositions and mineralogies. Models are constrained to be consistent with known HED samples, but the approach has the potential to extend predictions to thermodynamically plausible rock types that are not necessarily present in the HED collection. Nine chondritic bulk compositions are considered (CI, CV, CO, CM, H, L, LL, EH, EL). For each, relative proportions and densities of the core, mantle, and crust are quantified. Considering that the basaltic crust has the composition of the primitive eucrite Juvinas and assuming that this crust is in thermodynamic equilibrium with the residual mantle, it is possible to calculate how much iron is in metallic form (in the core) and how much in oxidized form (in the mantle and crust) for a given bulk composition. Of the nine bulk compositions tested, solutions corresponding to CI and LL groups predicted a negative metal fraction and were not considered further. Solutions for enstatite chondrites imply significant oxidation relative to the starting materials and these solutions too are considered unlikely. For the remaining bulk compositions, the relative proportion of crust to bulk silicate is typically in the range 15 to 20% corresponding to crustal thicknesses of 15 to 20 km for a porosity-free Vesta-sized body. The mantle is predicted to be largely dominated by olivine (>85%) for carbonaceous chondrites, but to be a roughly equal mixture of olivine and pyroxene for ordinary chondrite precursors. All bulk compositions have a significant core, but the relative proportions of metal and sulphide can be widely different. Using these data, total core size (metal+ sulphide) and average core densities can be calculated, providing a useful reference frame within which to consider geophysical/gravity data of the Dawn mission.

Toplis, M. J.↗
NASA NTRS2005

The Effect of Metal Composition on Fe-Ni Partition Behavior between Olivine and FeNi-Metal, FeNi-Carbide, FeNi-Sulfide at Elevated Pressure

Metal-olivine Fe-Ni exchange distribution coefficients were determined at 1500 C over the pressure range of 1 to 9 GPa for solid and liquid alloy compositions. The metal alloy composition was varied with respect to the Fe/Ni ratio and the amount of dissolved carbon and sulfur. The Fe/Ni ratio of the metal phase exercises an important control on the abundance of Ni in the olivine. The Ni abundance in the olivine decreases as the Fe/Ni ratio of the coexisting metal increases. The presence of carbon (up to approx. 3.5 wt.%) and sulfur (up to approx. 7.5 wt.%) in solution in the liquid Fe-Ni-metal phase has a minor effect on the partitioning of Fe and Ni between metal and olivine phases. No pressure dependence of the Fe-Ni-metal-olivine exchange behavior in carbon- and sulfur-free and carbon- and sulfur-containing systems was found within the investigated pressure range. To match the Ni abundance in terrestrial mantle olivine, assuming an equilibrium metal-olivine distribution, a sub-chondritic Fe/Ni-metal ratio that is a factor of 17 to 27 lower than the Fe/Ni ratios in estimated Earth core compositions would be required, implying higher Fe concentrations in the core forming metal phase. A simple metal-olivine equilibrium distribution does not seem to be feasible to explain the Ni abundances in the Earth's mantle. An equilibrium between metal and olivine does not exercise a control on the problem of Ni overabundance in the Earth's mantle. The experimental results do not contradict the presence of a magma ocean at the time of terrestrial core formation, if olivine was present in only minor amounts at the time of metal segregation.

Holzheid, Astrid↗
NASA NTRS1993

Cheaper Fabrication Of Tube-Wall Components

Relatively inexpensive method of forming metal tubes into wall component devised. One initially selects ordinary, imprecisely dimensioned tubes having passed both pressure test and inspections for wall thickness and surface imperfections, and tubes bonded to each other in shorter, simpler procedure. Eliminates need for progressive die forming and attendant inspections after forming steps. Also applicable in fabrication of heat exchangers and other unitary assemblies of tubes.

Bales, Daniel A.↗
NASA NTRS2014

Humic Acid Complexation of Th, Hf and Zr in Ligand Competition Experiments: Metal Loading and Ph Effects

The mobility of metals in soils and subsurface aquifers is strongly affected by sorption and complexation with dissolved organic matter, oxyhydroxides, clay minerals, and inorganic ligands. Humic substances (HS) are organic macromolecules with functional groups that have a strong affinity for binding metals, such as actinides. Thorium, often studied as an analog for tetravalent actinides, has also been shown to strongly associate with dissolved and colloidal HS in natural waters. The effects of HS on the mobilization dynamics of actinides are of particular interest in risk assessment of nuclear waste repositories. Here, we present conditional equilibrium binding constants (Kc, MHA) of thorium, hafnium, and zirconium-humic acid complexes from ligand competition experiments using capillary electrophoresis coupled with ICP-MS (CE- ICP-MS). Equilibrium dialysis ligand exchange (EDLE) experiments using size exclusion via a 1000 Damembrane were also performed to validate the CE-ICP-MS analysis. Experiments were performed at pH 3.5-7 with solutions containing one tetravalent metal (Th, Hf, or Zr), Elliot soil humic acid (EHA) or Pahokee peat humic acid (PHA), and EDTA. CE-ICP-MS and EDLE experiments yielded nearly identical binding constants for the metal- humic acid complexes, indicating that both methods are appropriate for examining metal speciation at conditions lower than neutral pH. We find that tetravalent metals form strong complexes with humic acids, with Kc, MHA several orders of magnitude above REE-humic complexes. Experiments were conducted at a range of dissolved HA concentrations to examine the effect of [HA]/[Th] molar ratio on Kc, MHA. At low metal loading conditions (i.e. elevated [HA]/[Th] ratios) the ThHA binding constant reached values that were not affected by the relative abundance of humic acid and thorium. The importance of [HA]/[Th] molar ratios on constraining the equilibrium of MHA complexation is apparent when our estimated Kc, MHA values attained at very low metal loading conditions are compared to existing literature data. Overall, experimental data suggest that the tetravalent transition metal/-actinide-humic acid complexation is important over a wide range of pH values, including mildly acidic conditions, and thus, these complexes should be included in speciation models.

humic acid↗
NASA NTRS1993

Microscopic iron metal on glass and minerals - A tool for studying regolith maturity

A novel method of producing mixtures of glass or minerals with iron metal is presented. A portion of the Fe(2+) in basaltic glass and minerals can be reduced to metal in a few hours at 1100 C and an oxygen fugacity well below the iron-wustite buffer. Part of the iron metals forms rounded submicrometer blebs on the surfaces and in some cases within the grains. A concentration of such blebs equivalent to 20-30 percent of a grain's surface area can totally dominate the reflectance spectra of basaltic glass, pyroxene, and olivine. The production of optically opaque iron metal blebs, combined with the decline in Fe(2+), affects the glass and mineral reflectance spectra in three ways: by lowering the overall reflectivity, reducing the spectral contrast of absorption features, and producing a continuum with a general rise in reflectivity toward longer wavelengths.

Allen, C. C.↗
NASA NTRS1999

Interaction of Porosity with an Advancing Solid/Liquid Interface: a Real-Time Investigation

Problems associated with formation of porosity during solidification continue to have a daily impact on the metal forming industry. Several past investigations have dealt with the nucleation and growth aspects of porosity. However, investigations related to the interaction of porosity with that of a solidification front has been limited mostly to organic analogues. In this paper we report on real time experimental observations of such interactions in metal alloys. Using a state of the art X-Ray Transmission Microscope (XTM) we have been able to observe and record the dynamics of the interaction. This includes distortion of the solid/liquid interface near a poro.sity, solute segr,egation patterns surrounding a porosity and the change in shape of the porosity during interaction with an advancing solid/liquid interface. Results will be presented for different Al alloys and growth conditions. The experimental data will be compared to theory using a recently developed 2D numerical model. The model employs a finite difference approach where the solid/liquid interface is defined through the points at which the interface intersects the grid lines. The transport variables are calculated at these points and the motion of the solidification front is determined by the magnitude of the transport variables. The model accounts for the interplay of the thermal and solutal field and the influence of capilarity to predict the shape of the solid/liquid interface with time in the vicinity of porosity. One can further calculate the perturbation of the solutal field by the presence of porosity in the melt.

Sen, S.↗
NASA NTRS1992

Iron and alloys of iron

All lunar soil contains iron in the metallic form, mostly as an iron-nickel alloy in concentrations of a few tenths of 1 percent. Some of this free iron can be easily separated by magnetic means. It is estimated that the magnetic separation of 100,000 tons of lunar soil would yield 150-200 tons of iron. Agglutinates contain metallic iron which could be extracted by melting and made into powder metallurgy products. The characteristics and potential uses of the pure-iron and iron-alloy lunar products are discussed. Processes for working iron that might be used in a nonterrestrial facility are also addressed.

Sastri, Sankar↗
NASA NTRS2006

Electron Beam Brazing of Titanium for Construction in Space

An extended presence of humans in space requires an in-situ capability to construct various permanent structures to support scientific research, power generation, communication, radiation shielding and other functions. Electron Beam (EB) vacuum brazing has been identified as one of the best joining processes for in-space joining, particular for making a large quantity of permanent joints as required for construction of the sizeable truss structures. Thin wall titanium tubes are perhaps the best choice because of their high stiffness, excellent strength-to-weight ratio and great metal forming and joining ability. An innovative EB vacuum spot brazing process is being developed at Goddard Space Flight Center to be used for robotic as well as human-assisted construction in space. This paper describes experimental results obtained during the initial effort of EB brazing of titanium tubes with the special emphasis on low temperature aluminum filler metals.

Flom, Yury↗
NASA NTRS2012

Chondritic Models of 4 Vesta: Comparison of Data from the Dawn Mission with Predicted Internal Structure and Surface Composition/Mineralogy

While the HEDs provide an extremely useful basis for interpreting data from the Dawn mission, there is no guarantee that they provide a complete vision of all possible crustal (and possibly mantle) lithologies that are exposed at the surface of Vesta. With this in mind, an alternative approach is to identify plausible bulk compositions and use mass-balance and geochemical modelling to predict possible internal structures and crust/mantle compositions and mineralogies. While such models must be consistent with known HED samples, this approach has the potential to extend predictions to thermodynamically plausible rock types that are not necessarily present in the HED collection. Nine chondritic bulk compositions are considered (CI, CV, CO, CM, H, L, LL, EH, EL). For each, relative proportions and densities of the core, mantle, and crust are quantified. This calculation is complicated by the fact that iron may occur in metallic form (in the core) and/or in oxidized form (in the mantle and crust). However, considering that the basaltic crust has the composition of Juvinas and assuming that this crust is in thermodynamic equilibrium with the residual mantle, it is possible to calculate a single solution to this problem for a given bulk composition. Of the nine bulk compositions tested, solutions corresponding to CI and LL groups predicted a negative metal fraction and were not considered further. Solutions for enstatite chondrites imply significant oxidation relative to the starting materials and these solutions too are considered unlikely. For the remaining bulk compositions, the relative proportion of crust to bulk silicate is typically in the range 15 to 20% corresponding to crustal thicknesses of 15 to 20 km for a porosity-free Vesta-sized body. The mantle is predicted to be largely dominated by olivine (greater than 85%) for carbonaceous chondrites, but to be a roughly equal mixture of olivine and pyroxene for ordinary chondrite precursors. All bulk compositions have a significant core, but the relative proportions of metal and sulphide can be widely different. Using these data, total core size (metal+ sulphide) and average core densities can be calculated, providing a useful reference frame within which to consider geophysical/gravity data of the Dawn mission. Further to these mass-balance calculations, the MELTS thermodynamic calculator has been used to assess to what extent chondritic bulk compositions can produce Juvinas-like liquids at relevant degrees of partial melting/crystallization. This work will refine acceptable bulk compositions and predict the mineralogy and composition of the associated solid and liquid products over wide ranges of partial melting and crystallization, providing a useful and self-consistent reference frame for interpretation of the data from the VIR and GRaND instruments onboard the Dawn spacecraft.

Toplis, M. J.↗
NASA NTRS2013

Ultrasonic Low-Friction Containment Plate for Thermal and Ultrasonic Stir Weld Processes

The thermal stir welding (TSW) process is finding applications in fabrication of space vehicles. In this process, workpieces to be joined by TSW are drawn, by heavy forces, between "containment plates," past the TSW tool that then causes joining of the separate plates. It is believed that the TSW process would be significantly improved by reducing the draw force, and that this could be achieved by reducing the friction forces between the workpieces and containment plates. Based on use of high-power ultrasonics in metal forming processes, where friction reduction in drawing dies has been achieved, it is believed that ultrasonic vibrations of the containment plates could achieve similar friction reduction in the TSW process. By applying ultrasonic vibrations to the containment plates in a longitudinal vibration mode, as well as by mounting and holding the containment plates in a specific manner such as to permit the plates to acoustically float, friction between the metal parts and the containment plates is greatly reduced, and so is the drawing force. The concept was to bring in the ultrasonics from the sides of the plates, permitting the ultrasonic hardware to be placed to the side, away from the equipment that contains the thermal stir tooling and that applies clamping forces to the plates. Tests demonstrated that one of the major objectives of applying ultrasonics to the thermal stir system, that of reducing draw force friction, should be achievable on a scaled-up system.

Graff, Karl↗
NASA NTRS1977

Reactions between NO/+/ and metal atoms using magnetically confined afterglows

A new method of studying thermal energy ion-neutral collision processes involving nongaseous neutral atoms is described. A long magnetic field produced by a solenoid in a vacuum chamber confines a thermal-energy plasma generated by photoionization of gas at very low pressure. As the plasma moves toward the end of the field, it is crossed by a metal atom beam. Ionic products of ion-atom reactions are trapped by the field and both the reactant and product ions move to the end of the magnetic field where they are detected by a quadrupole mass filter. The cross sections for charge transfer between NO(+) and Na, Mg, Ca, and Sr and that for rearrangement between NO(+) and Ca have been obtained. The charge-transfer reaction is found strongly dominant over the rearrangement reaction that forms metallic oxide ions.

Lo, H. H.↗