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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 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

A Mission-Adaptive Variable Camber Flap Control System to Optimize High Lift and Cruise Lift-to-Drag Ratios of Future N+3 Transport Aircraft

Boeing and NASA are conducting a joint study program to design a wing flap system that will provide mission-adaptive lift and drag performance for future transport aircraft having light-weight, flexible wings. This Variable Camber Continuous Trailing Edge Flap (VCCTEF) system offers a lighter-weight lift control system having two performance objectives: (1) an efficient high lift capability for take-off and landing, and (2) reduction in cruise drag through control of the twist shape of the flexible wing. This control system during cruise will command varying flap settings along the span of the wing in order to establish an optimum wing twist for the current gross weight and cruise flight condition, and continue to change the wing twist as the aircraft changes gross weight and cruise conditions for each mission segment. Design weight of the flap control system is being minimized through use of light-weight shape memory alloy (SMA) actuation augmented with electric actuators. The VCCTEF program is developing better lift and drag performance of flexible wing transports with the further benefits of lighter-weight actuation and less drag using the variable camber shape of the flap.

Mission-Adaptive Wing↗
NASA NTRS2021

Utilizing local phase transformation strengthening for nickel-based superalloys

Almost 75 years of research has been devoted to producing superalloys capable of higher operating temperatures in jet turbine engines, and there is an ongoing need to increase operating temperature further. Here, a new disk Nickel-base superalloy is designed to take advantage of strengthening atomic-scale dynamic complexions. This local phase transformation strengthening provides the alloy with a three times improvement in creep strength over similar disk superalloys and comparable strength to a single crystal blade alloy at 760 °C. Ultra-high-resolution chemical mapping reveals that the improvement in creep strength is a result of atomic-scale η (D024) and χ (D019) formation along superlattice stacking faults. To understand these results, the energy differences between the L12 and competing D024 and D019 stacking fault structures and their dependence on composition are computed by density functional theory. This study can help guide researchers to further optimize local phase transformation strengthening mechanisms for alloy development.

Timothy M. Smith↗
NASA NTRS2000

Vacuum Plasma Spray of CuCrNb Alloy for Advanced Liquid - Fuel Combustion Chambers

The copper-8 atomic percent chromium-4 atomic percent niobium (CuCrNb) alloy was developed by Glenn Research Center (formally Lewis Research Center) as an improved alloy for combustion chamber liners. In comparison to NARloy-Z, the baseline (as in Space Shuttle Main Engine) alloy for such liners, CuCrNb demonstrates mechanical and thermophysical properties equivalent to NARloy-Z, but at temperatures 100 C to 150 C (180 F to 270 F) higher. Anticipated materials related benefits include decreasing the thrust cell liner weight 5% to 20%, increasing the service life at least two fold over current combustion chamber design, and increasing the safety margins available to designers. By adding an oxidation and thermal barrier coating to the liner, the combustion chamber can operate at even higher temperatures. For all these benefits, however, this alloy cannot be formed using conventional casting and forging methods because of the levels of chromium and niobium, which exceed their solubility limit in copper. Until recently, the only forming process that maintains the required microstructure of CrNb intermetallics is powder metallurgy formation of a billet from powder stock, followed by extrusion. This severely limits its usefulness in structural applications, particularly the complex shapes required for combustion chamber liners. Vacuum plasma spray (VPS) has been demonstrated as a method to form structural articles including small combustion chambers from the CuCrNb alloy. In addition, an oxidation and thermal barrier layer can be formed integrally on the hot wall of the liner that improve performance and extend service life. This paper discusses the metallurgy and thermomechanical properties of VPS formed CuCrNb versus the baseline powder metallurgy process, and the manufacturing of small combustion chamber liners at Marshall Space Flight Center using the VPS process. The benefits to advanced propulsion initiatives of using VPS to fabricate combustion chamber liners while maintaining the superior CuCrNb properties are also presented.

Zimmerman, Frank↗
NASA NTRS1976

Large-diameter fasteners of CRES alloy

Double-hex bolthead allows bolts of high strength corrosion-resistant steel (CRES) to be made in diameters up to 1-1/4 in. Design allows 12-point tension heads to be cold formed to retain required minimum tensile strength of 220,000 psi and to retain high fracture strength.

Charles, J. F.↗
NASA NTRS1983

Development and fabrication of an augmented power transistor

The development of device design and processing techniques for the fabrication of an augmented power transistor capable of fast switching and high voltage power conversion is discussed. The major device goals sustaining voltages in the range of 800 to 1000 V at 80 A and 50 A, respectively, at a gain of 14. The transistor switching rise and fall times were both to have been less than 0.5 microseconds. The development of a passivating glass technique to shield the device high voltage junction from moisture and ionic contaminants is discussed as well as the development of an isolated package that separates the thermal and electrical interfaces. A new method was found to alloy the transistors to the molybdenum disc at a relatively low temperature. The measured electrical performance compares well with the predicted optimum design specified in the original proposed design. A 40 mm diameter transistor was fabricated with seven times the emitter area of the earlier 23 mm diameter device.

Geisler, M. J.↗
NASA NTRS1994

Magnetic properties and magnetic hardening mechansim of Pt-Co-B alloys

The intrinsic coercivity is found to be maximized in the Pt42Co45B13 ternary alloy which is undercooled and rapidly solidified (quenched using a 70 m/s wheel speed after undercooling), and then annealed (800 C for 2400 min). The same alloy, processed at slower cooling rates and annealed in the same way, has a much larger scale microstructure and a much lower resulting magnetic coercivity. The microstructure which would optimize the coercitvity of this coercivity of this ternary alloy is a completely ordered L1(sub zero) Pt-Co matrix with a submicron magnetic single-domion Co-boride precipitate. The L1(sub zero) phase is highly anistropic magnetically while the Co-boride precipate is somewhat less so. Annealing treatments designed to produced single-domain Co-boride precipitates enhance the coercivity. This suggests that the refined microstructures is responsible for the high coercivities found in the rapidly solidified and annealed alloy. The magnetic domain wall thickness for a Co-boride precipitate is determined from both experimental observation and theoretical calculation in order to evaluate its influence on the coercivity of the alloy. The effects of the pinning of domain walls and the barrier to the nucleation of reverse domains on the coercivity are discussed. Both microstrucutral analysis and theoretical calculation indicate that the high coercivities in the Pt42Co45B13 alloy are due to the difficult nucleation of reverse magnetic domains.

Qiu, Ning↗
NASA NTRS2014

Design and Test of a Deployable Radiation Cover for the REgolith X-Ray Imaging Spectrometer

The REgolith X-ray Imaging Spectrometer (REXIS) instrument contains a one-time deployable radiation cover that is opened using a shape memory alloy actuator (a "Frangibolt") from TiNi Aerospace and two torsion springs. The door will be held closed by the bolt for several years in cold storage during travel to the target asteroid, Bennu, and it is imperative to gain confidence that the door will open at predicted operational temperatures. This paper briefly covers the main design features of the radiation cover and measures taken to mitigate risks to cover deployment. As the chosen FD04 model Frangibolt actuator has minimal flight heritage, the main focus of this paper is the testing, results and conclusions with the FD04 while discussing key lessons learned with respect to the use of the FD04 actuator in this application.

Carte, David B.↗
NASA NTRS1981

Performance of a Haynes 188 metallic standoff thermal protection system at Mach 7

A flight weight, metallic thermal protection system (TPS) model applicable to reentry and hypersonic vehicles was subjected to multiple cycles of both radiant and aerothermal heating to evaluate its aerothermal performance and structural integrity. The TPS was designed for a maximum operating temperature of 1255 K and featured a shingled, corrugation stiffened corrugated skin heat shield of Haynes 188, a cobalt base alloy. The model was subjected to 3 radiant preheat/aerothermal tests for a total of 67 seconds and to 15 radiant heating tests for a total of 85.9 minutes at 1255 K. The TPS limited the primary structure to temperatures below 430 K in all tests. No catastrophic failures occurred in the heat shields, supports, or insulation system. The TPS continued to function even after exposure to a differential temperature 4 times the design value produced thermal buckles in the outer skin. The shingled thermal expansion joint effectively allowed for thermal expansion of the heat shield without allowing any appreciable hot gas flow into the model cavity, even though the overlap gap between shields increased after several thermal cycles.

Avery, D. E.↗
NASA NTRS2018

Development and Qualification of the Primary Structure of the Orion European Service Module

This paper presents an overview of the development and qualification test campaign for the primary structure of the European Service Module of ORION, the NASA spacecraft which will serve the future human exploration missions to the Moon, Mars and beyond. Under an agreement between NASA and ESA, the ORION will be powered by a European Service Module (ESM), providing also water and oxygen for astronauts' life sustainability. The development and qualification of the European Service Module (ESM) is under ESA responsibility with Airbus Defense and Space as the prime contractor. Thales Alenia Space Italia is responsible for design development, manufacturing, assembly and qualification of the Structure subsystem. The European Service Module, installed onto the launch adapter, shall support the crew module with its adapter and a launch abort system. It shall sustain: - A combination of global and local launch loads during lift off and ascent phases, - On orbit loads induced by engine firing for orbital transfers and attitude control. The ESM structure is based on a core made of Composite Fiber Reinforced Polymer (CFRP) sandwich panels complemented by aluminum alloy platforms, longerons and secondary structures. A development campaign has been implemented in order to define and validate composite parts' strength allowable values for design: coupon tests at material level, test at component level up to breadboards tests performed on main structural components (composite to metallic joints, and at panels' discontinuities). An incremental approach as defined in [1] has been followed. A qualification static test campaign at primary structure assembly level has been implemented in order to validate the design against static stiffness and ultimate strength as well as to correlate the structural Finite Element Model (FEM) used for sizing and confirm the margins of safety. The tests have been performed successfully by Thales Alenia Space Italia (TAS-I) on two flight representative structural models (STA1, STA2), in Turin facilities (Italy) between August 2015 and March 2017, with engineering support of technical representatives from Airbus, ESA, NASA and LMCO. The main development and qualification test activities and associated results are presented and discussed in the paper

Structural Testing↗
NASA NTRS1985

An experimental investigation of rubbing interaction in labyrinth seals at cryogenic temperature

An experimental program was carried out to address issues related to the observed cracking of the titanium knife edges on the labyrinth seals of the high pressure fuel pump (HPFP) in the Space Shuttle main engine (SSME). Thermal shock experiments were carried out using a jet specimen with geometry similar to the knife edge geometry. These tests demonstrate that cracking of the titanium alloy is possible in a situation involving repeated thermal cycles over a wide temperature range, as might be realized during a rub in the liquid hydrogen fuel pump. High speed rub interaction tests were conducted using a representative knife edge and seal geometry over a broad range of interaction rates. Alternative materials were also experimentally evaluated. These tests provide information which can be used to design improved labyrinth seals for the HPFP of the SSME. In particular, plasma-sprayed aluminum-graphite was found to be significantly better than aluminum alloy seals used at present from the standpoint of rub performance. Ion nitriding of the titanium alloy knife edges was also found to improve rub performance compared with the untreated baseline knife edge material.

Dolan, F. X.↗
NASA NTRS1985

Development of powder metallurgy 2XXX series Al alloy plate and sheet materials for high temperature aircraft structural applications, FY 1983/1984

The objective of this investigation is to fabricate and evaluate PM 2124 Al alloy plate and sheet materials according to NASA program goals for damage tolerance and fatigue resistance. Previous research has indicated the outstanding strength-toughness relationship available with PM 2124 Al-Zr modified alloy compositions in extruded product forms. The range of processing conditions was explored in the fabrication of plate and sheet gage materials, as well as the resultant mechanical and metallurgical properties. The PM composition based on Al-3.70 Cu-1.85 Mg-0.20 Mn with 0.60 wt. pct. Zr was selected. Flat rolled material consisting of 0.250 in. thick plate was fabricated using selected thermal mechanical treatments (TMT). The schedule of TMT operations was designed to yield the extreme conditions of grain structure normally encountered in the fabrication of flat rolled products, specifically recrystallized and unrecrystallized. The PM Al alloy plate and sheet materials exhibited improved strength properties at thin gages compared to IM Al alloys, as a consequence of their enhanced ability to inhibit recrystallization and grain growth. In addition, the PM 2124 Al alloys offer much better combinations of strength and toughnessover equivalent IM Al. The alloy microstructures were examined by optical metallographic texture techniques in order to establish the metallurgical basis for these significant property improvements.

Chellman, D. J.↗
NASA NTRS1998

The Effect of Alloying on Topologically Close Packed Phase Instability in Advanced Nickel-Based Superalloy Rene N6

An investigation was conducted to describe topologically close packed (TCP) phase instability as a function of composition in the advanced Ni-base superalloy Rene N6. TCP phases are detrimental to overall high-temperature performance of Ni-base superalloys because of their brittle nature and because they deplete the Ni-rich matrix of potent solid solution strengthening elements. Thirty-four variations of polycrystalline Rene N6 determined from a design-of-experiments approach were cast and homogenized at 1315"C for 80 hours followed by exposure at 10930C for 400 hours to promote TCP formation. The alloys had the following composition ranges in atomic percent: Co 10.61 to 16.73%, Mo 0.32 to 1.34%, W 1.85 to 2.52%, Re 1.80 to 2.1 1 %, Ta 2.36 to 3.02%, Al 11.90 to 14.75%, and Cr 3.57 to 6.23%. Physical and chemical characteristics of all n-ticrostructures obtained were described using various analytical techniques. From these observations, a mathematical description of TCP occurrence (omega and P phase) was generated for polycrystalline Rene N6.

Ritzert, Frank↗
NASA NTRS1999

Evaluation of Pressurization Fatigue Life of 1441 Al-li Fuselage Panel

A study was conducted to evaluate the pressurization fatigue life of fuselage panels with skins fabricated from 1441 Al-Li, an attractive new Russian alloy. The study indicated that 1441 Al-Li has several advantages over conventional aluminum fuselage skin alloy with respect to fatigue behavior. Smooth 1441 Al-Li sheet specimens exhibited a fatigue endurance limit similar to that for 1163 Al (Russian version of 2024 Al) sheet. Notched 1441 Al-Li sheet specimens exhibited greater fatigue strength and longer fatigue life than 1163 Al. In addition, Tu-204 fuselage panels fabricated by Tupolev Design Bureau using Al-Li skin and ring frames with riveted 7000-series aluminum stiffeners had longer pressurization fatigue lives than did panels constructed from conventional aluminum alloys. Taking into account the lower density of this alloy, the results suggest that 1441 Al-Li has the potential to improve fuselage performance while decreasing structural weight.

Bird, R. Keith↗
NASA NTRS2016

Testing and Analysis of a Composite Non-Cylindrical Aircraft Fuselage Structure: Ultimate Design Loads - Part 1

The Environmentally Responsible Aviation Project aimed to develop aircraft technologies enabling significant fuel burn and community noise reductions. Small incremental changes to the conventional metallic alloy-based 'tube and wing' configuration were not sufficient to achieve the desired metrics. One airframe concept identified by the project as having the potential to dramatically improve aircraft performance was a composite-based hybrid wing body configuration. Such a concept, however, presented inherent challenges stemming from, among other factors, the necessity to transfer wing loads through the entire center fuselage section which accommodates a pressurized cabin confined by flat or nearly flat panels. This paper discusses finite element analysis and testing of a large-scale hybrid wing body center section structure developed and constructed to demonstrate that the Pultruded Rod Stitched Efficient Unitized Structure concept can meet these challenging demands of the next generation airframes. Part I of the paper considers the five most critical load conditions, which are internal pressure only and positive and negative g-loads with and without internal pressure. Analysis results are compared with measurements acquired during testing. Performance of the test article is found to be closely aligned with predictions and, consequently, able to support the hybrid wing body design loads in pristine and barely visible impact damage conditions.

Przekop, Adam↗
NASA NTRS1979

Low-cost directionally-solidified turbine blades, volume 1

A low cost process of manufacturing high stress rupture strength directionally-solidified high pressure turbine blades was successfully developed for the TFE731-3 Turbofan Engine. The basic processing parameters were established using MAR-M 247 and employing the exothermic directional-solidification process in trial castings of turbine blades. Nickel-based alloys were evaluated as directionally-solidified cast blades. A new turbine blade, disk, and associated components were then designed using previously determined material properties. Engine tests were run and the results were analyzed and compared to the originally established goals. The results showed that the stress rupture strength of exothermically heated, directionally-solidified MAR-M 247 turbine blades exceeded program objectives and that the performance and cost reduction goals were achieved.

Sink, L. W.↗
NASA NTRS1981

Gas-turbine critical research and advanced technology support project

A technology data base for utility gas turbine systems capable of burning coal derived fuels was developed. The following areas are investigated: combustion; materials; and system studies. A two stage test rig is designed to study the conversion of fuel bound nitrogen to NOx. The feasibility of using heavy fuels in catalytic combustors is evaluated. A statistically designed series of hot corrosion burner rig tests was conducted to measure the corrosion rates of typical gas turbine alloys with several fuel contaminants. Fuel additives and several advanced thermal barrier coatings are tested. Thermal barrier coatings used in conjunction with low critical alloys and those used in a combined cycle system in which the stack temperature was maintained above the acid corrosion temperature are also studied.

Clark, J. S.↗
NASA NTRS1985

Elevated temperature crack growth

The purpose is to determine the ability of currently available P-I integrals to correlate fatigue crack propagation under conditions that simulate the turbojet engine combustor liner environment. The utility of advanced fracture mechanics measurements will also be evaluated during the course of the program. To date, an appropriate specimen design, a crack displacement measurement method, and boundary condition simulation in the computational model of the specimen were achieved. Alloy 718 was selected as an analog material based on its ability to simulate high temperature behavior at lower temperatures. Tensile and cyclic tests were run at several strain rates so that an appropriate constitutive model could be developed. Suitable P-I integrals were programmed into a finite element post-processor for eventual comparison with experimental data.

Malik, S. N.↗
NASA NTRS1992

Fastening apparatus having shape memory alloy actuator

A releasable fastening apparatus is presented. The device includes a connecting member and a housing. The housing supports a gripping mechanism that is adapted to engage the connecting member. A triggering member is movable within the housing between a first position in which it constrains the gripping mechanism in locked engagement with the connecting member, and a second position in which the gripping mechanism is disengaged from the connecting member. A shaped memory alloy actuator is employed for translating the triggering member from its first to its second position. The actuator is designed to expand longitudinally when transitioned from a martensitic to an austenitic state.

Mckinnis, Darin N.↗