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NASA NTRS1991

Advances in high temperature components for AMTEC (Alkali Metal Thermal-to-Electric Converter)

The basic performance of Alkali Metal Thermal-to-Electric Converter (AMTEC) cells is well understood, and quantitative modeling of the electrode performance has been carried out. Tests have been carried out to evaluate the high temperature performance of critical AMTEC components. Progress made in understanding the relative performance of AMTEC components, such as electrodes, electrolytes, working fluids, and seals, as device operating temperature is varied is discussed. Most metallic components are especially subject to corrosion in hot liquid alkali metals containing dissolved oxides. Stability issues of AMTEC components may be addressed by life testing, accelerated testing, and modeling based on known kinetic and thermochemical data.

Williams, R. M.↗

NASA NTRS1973

Fatigue-test acceleration with flight-by-flight loading and heating to simulate supersonic-transport operation

Possibilities for reducing fatigue-test time for supersonic-transport materials and structures were studied in tests with simulated flight-by-flight loading. In order to determine whether short-time tests were feasible, the results of accelerated tests (2 sec per flight) were compared with the results of real-time tests (96 min per flight). The effects of design mean stress, the stress range for ground-air-ground cycles, simulated thermal stress, the number of stress cycles in each flight, and salt corrosion were studied. The flight-by-flight stress sequences were applied to notched sheet specimens of Ti-8Al-1Mo-1V and Ti-6Al-4V titanium alloys. A linear cumulative-damage analysis accounted for large changes in stress range of the simulated flights but did not account for the differences between real-time and accelerated tests. The fatigue lives from accelerated tests were generally within a factor of two of the lives from real-time tests; thus, within the scope of the investigation, accelerated testing seems feasible.

Imig, L. A.↗

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 NTRS1977

Ferrographic analysis of wear debris generated in accelerated rolling element fatigue tests

Ferrographic analysis was used to determine the types and quantities of wear particles generated during accelerated rolling contact fatigue tests. The NASA five-ball rolling contact fatigue tester was used. Ball specimens were made of AMS 5749, a corrosion-resistant high-temperature bearing steel. The lubricant was a super-refined naphthenic mineral oil. Conditions included a maximum Hertz stress of 5.52 billion Pa and a shaft speed of 10,000 rpm. Four types of wear particles were observed: normal rubbing wear particles, fatigue spall particles, spheres, and friction polymer.

Jones, W. R., Jr.↗

NASA NTRS2026

Evaluation of AMSOIL® -ANT PGW Coolant Formula Change and Super Space AMSOIL Development

AMSOIL ® Propylene Glycol Water (PGW), is the baselined internal thermal control fluid for multiple manned spacecraft including Gateway (HALO, IHAB, and ALM modules) and Orion. The use of AMSOIL-ANT PGW was originally validated through extensive NASA/Collins materials-compatibility testing (circa 2008–2015). However, in late 2019, AMSOIL implemented an unannounced change in its PG inhibitor package. Because of this reformulation, concerns around materials compatibility arose. Therefore, NASA initiated corrosion rate and coolant stability testing in 2024. Results showed that the reformulated AMSOIL PG produced substantially elevated corrosion rates in aluminum alloys (about two times when compared to the original AMSOIL PG formula) accompanied by visible surface degradation. Coolant stability testing indicated accelerated propylene-glycol breakdown as well, with glycolate levels about nine times higher than the original formulation. Based on these findings, NASA Materials & Processes and Thermal Control Systems groups have baselined the use of the original PGW chemistry for all spacecraft use. In response, AMSOIL produced a reformulated variant, “Super Space AMSOIL” (ANT-SSA), compliant with MPCV 70156.This paper documents the reformulation testing completed, details on the formulation change, and the development of Super Space AMSOIL.

Woody Beringer↗

NASA NTRSDate not supplied

Evaluation of AMSOIL ® -ANT PGW Coolant Formula Change and Super Space AMSOIL ® Development

David Brockett↗

NASA NTRS1978

Accelerated/abbreviated test methods for predicting life of solar cell encapsulants to Jet Propulsion Laboratory California Institute of Technology for the encapsulation task of the low-cost solar array project

An important principle is that encapsulants should be tested in a total array system allowing realistic interaction of components. Therefore, micromodule test specimens were fabricated with a variety of encapsulants, substrates, and types of circuitry. One common failure mode was corrosion of circuitry and solar cell metallization due to moisture penetration. Another was darkening and/or opacification of encapsulant. A test program plan was proposed. It includes multicondition accelerated exposure. Another method was hyperaccelerated photochemical exposure using a solar concentrator. It simulates 20 year of sunlight exposure in a short period of one to two weeks. The study was beneficial in identifying some cost effective encapsulants and array designs.

Kolyer, J. M.↗

NASA NTRS1983

Effect of the amount of Na2SO4 on the high temperature corrosion of Udimet-700

The corrosion of Udimet-700, coated with different doses of Na2SO4, was studied in an isothermal thermogravimetric test in the temperature range 900 to 950 C. The weight gain curve is characterized by five distinct stages: an initial period of linear corrosion; an induction period; a period of accelerated corrosion; a period of decelerating corrosion; and a period of parabolic oxidation. The time required for the failure of the alloy increases with an increase in the amount of Na2SO4, reaches a peak and then decreases with further increase in the amount of Na2SO4. For low and intermediate doses (0.3 to 2.0 mg/sq cm), the catastrophic failure of the material occurs by the formation of Na2MoO4 and interaction of the liquid Na2MoO4 with the alloy. For heavy doses, the degradation of the material is due to the formation of large amounts of sulfides.

Misra, A. K.↗

NASA NTRS1991

A system approach to archival storage

The introduction and viewgraphs of a discussion on a system approach to archival storage presented at the National Space Science Data Center (NSSDC) Mass Storage Workshop is included. The use of D-2 iron particles for archival storage is discussed along with how acceleration factors relating short-term tests to archival life times can be justified. Ampex Recording Systems is transferring D-2 video technology to data storage applications, and encountering concerns about corrosion. To protect the D-2 standard, Battelle tests were done on all four tapes in the Class 2 environment. Error rates were measured before and after the test on both exposed and control groups.

Corcoran, John W.↗

NASA NTRS2008

Nanophase Nickel-Zirconium Alloys for Fuel Cells

Nanophase nickel-zirconium alloys have been investigated for use as electrically conductive coatings and catalyst supports in fuel cells. Heretofore, noble metals have been used because they resist corrosion in the harsh, acidic fuel cell interior environments. However, the high cost of noble metals has prompted a search for less-costly substitutes. Nickel-zirconium alloys belong to a class of base metal alloys formed from transition elements of widely different d-electron configurations. These alloys generally exhibit unique physical, chemical, and metallurgical properties that can include corrosion resistance. Inasmuch as corrosion is accelerated by free-energy differences between bulk material and grain boundaries, it was conjectured that amorphous (glassy) and nanophase forms of these alloys could offer the desired corrosion resistance. For experiments to test the conjecture, thin alloy films containing various proportions of nickel and zirconium were deposited by magnetron and radiofrequency co-sputtering of nickel and zirconium. The results of x-ray diffraction studies of the deposited films suggested that the films had a nanophase and nearly amorphous character.

Narayanan, Sekharipuram↗

NASA NTRS2014

Film Cooled Recession of SiC/SiC Ceramic Matrix Composites: Test Development, CFD Modeling and Experimental Observations

SiCSiC ceramic matrix composites (CMCs) systems will play a crucial role in next generation turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. However, the environmental stability of Si-based ceramics in high pressure, high velocity turbine engine combustion environment is of major concern. The water vapor containing combustion gas leads to accelerated oxidation and corrosion of the SiC based ceramics due to the water vapor reactions with silica (SiO2) scales forming non-protective volatile hydroxide species, resulting in recession of the ceramic components. Although environmental barrier coatings are being developed to help protect the CMC components, there is a need to better understand the fundamental recession behavior of in more realistic cooled engine component environments.In this paper, we describe a comprehensive film cooled high pressure burner rig based testing approach, by using standardized film cooled SiCSiC disc test specimen configurations. The SiCSiC specimens were designed for implementing the burner rig testing in turbine engine relevant combustion environments, obtaining generic film cooled recession rate data under the combustion water vapor conditions, and helping developing the Computational Fluid Dynamics (CFD) film cooled models and performing model validation. Factors affecting the film cooled recession such as temperature, water vapor concentration, combustion gas velocity, and pressure are particularly investigated and modeled, and compared with impingement cooling only recession data in similar combustion flow environments. The experimental and modeling work will help predict the SiCSiC CMC recession behavior, and developing durable CMC systems in complex turbine engine operating conditions.

Recession↗

NASA NTRS1991

Microbial biofilm studies of the Environmental Control and Life Support System water recovery test for Space Station Freedom

Analysis of biofilm accumulation, studies of iodine disinfection of biofilm, and the potential for microbially influenced corrosion in the water recovery test (WRT) are presented. The analysis of WRT components showed the presence of biofilms and organic deposits in selected tubing. Water samples from the WRT contained sulfate-reducing and acid-producing organisms implicated in corrosion processes. Corrosion of an aluminum alloy was accelerated in the presence of these water samples, but stainless steel corrosion rates were not accelerated.

Obenhuber, D. C.↗

NASA NTRS2006

Methodology for Life Testing of Refractory Metal/Sodium Heat Pipes

The focus of this work was to establish an approach to generate carefully controlled data that can conclusively establish heat pipe operating life with material-fluid combinations capable of extended operation. To accomplish this goal acceleration is required to compress 10 years of operational life into 3 years of laboratory testing through a combination of increased temperature and mass fluence. Specific test series have been identi3ed, based on American Society for Testing and Materials (ASTM) specifications, to investigate long term corrosion rates. The refractory metal selected for demonstration purposes is a Molybdenum-44.5%Rhenium alloy formed by powder metallurgy. The heat pipe makes use of an annular crescent wick design formed by hot isostatic pressing of Molybdenum-Rhenium wire mesh. The heat pipes are filled using vacuum distillation and purity sampling is considered. Testing of these units is round-the-clock with 6-month destructive and non-destructive inspection intervals to identify the onset and level of corrosion. Non-contact techniques are employed for providing power to the evaporator (radio frequency induction heating at I to 5 kW per unit) and calorimetry at the condenser (static gas gap coupled water cooled calorimeter). The planned operating temperature range would extend from 1123 to 1323 K. Accomplishments prior to project cancellation included successful demonstration of the heat pipe wick fabrication technique, establishment of all engineering designs, baselined operational test requirements and procurement/assembly of supporting test hardware systems.

Martin, James J.↗

NASA NTRS1981

Investigation of test methods, material properties, and processes for solar cell encapsulants

Encapsulant materials and processes for the production of cost-effective, long-life solar cell modules were investigated. The following areas were explored: (1) soil resistant surface treatment; (2) corrosion protecting coatings from mild steel substrates; (3) primers for bonding module interfaces; and (4) RS/4 accelerated aging of candidate encapsulation compounds

Willis, P. B.↗

NASA NTRS2013

Closeout Report for the Refractory Metal Accelerated Heat Pipe Life Test Activity

With the selection of a gas-cooled reactor, this heat pipe accelerated life test activity was closed out and its resources redirected. The scope of this project was to establish the long-term aging effects on Mo-44.5%Re sodium heat pipes when subjected to space reactor temperature and mass fluences. To date, investigators have demonstrated heat pipe life tests of alkali metal systems up to .50,000 hours. Unfortunately, resources have not been available to examine the effect of temperature, mass fluence, or impurity level on corrosion or to conduct post-test forensic examination of heat pipes. The key objective of this effort was to establish a cost/time effective method to systematically test alkali metal heat pipes with both practical and theoretical benefits. During execution of the project, a heat pipe design was established, a majority of the laboratory test equipment systems specified, and operating and test procedures developed. Procurements for the heat pipe units and all major test components were underway at the time the stop work order was issued. An extremely important outcome was the successful fabrication of an annular wick from Mo-5%Re screen (the single, most difficult component to manufacture) using a hot isostatic pressing technique. This Technical Publication (TP) includes specifics regarding the heat pipe calorimeter water-cooling system, vendor design for the radio frequency heating system, possible alternative calorimeter designs, and progress on the vanadium equilibration technique. The methods provided in this TP and preceding project documentation would serve as a good starting point to rapidly implement an accelerated life test. Relevant test data can become available within months, not years, and destructive examination of the first life test heat pipe might begin within 6 months of test initiation. Final conclusions could be drawn in less than a quarter of the mission duration for a long-lived, fission-powered, deep space probe.

Martin, J.↗

NASA NTRS1980

Improved PFB operations: 400-hour turbine test results

A pressurized fluidized bed (PFB) coal-burning reactor was used to provide hot effluent gases for operation of a small gas turbine. Preliminary tests determined the optimum operating conditions that would result in minimum bed particle carryover in the combustion gases. Solids were removed from the gases before they could be transported into the test turbine by use of a modified two stage cyclone separator. Design changes and refined operation procedures resulted in a significant decrease in particle carryover, from 2800 to 93 ppm (1.5 to 0.05 grains/std cu ft), with minimal drop in gas temperature and pressure. The achievement of stable burn conditions and low solids loadings made possible a 400 hr test of small superalloy rotor, 15 cm (6 in.) in diameter, operating in the effluent. Blades removed and examined metallographically after 200 hr exhibited accelerated oxidation over most of the blade surface, with subsurface alumina penetration to 20 micron m. After 400 hours, average erosion loss was about 25 micron m (1 mil). Sulfide particles, indicating hot corrosion, were present in depletion zones, and their presence corresponded in general to the areas of adherent solids deposit. Sulfidation appears to be a materials problem equal in importance to erosion.

Rollbuhler, R. J.↗

NASA NTRS1985

Gamma radiation effects on the dynamic fatigue measurements of glass discs

Circular specimens of low iron soda lime silicate glass were blasted with grit after having a circular notch etched into their centers. After separation into two groups, one group was exposed to gamma radiation. The fracture strengths of all samples were then tested by the biaxial technique, i.e., specimens were balanced on three balls and loaded in the center by a piston. The irradiated samples had received a 140,000 Gy dose from a Co-60 source. An enhanced interaction between the ambient moisture and the grit-blasted central notch was observed in the irradiated samples, which displayed accelerated corrosion.

Ananaba, T. O. J.↗

NASA NTRS1973

Evaluation of Stress Corrosion Cracking Susceptibility Using Fracture Mechanics Techniques, Part 1

Stress corrosion cracking (SSC) tests were performed on 13 aluminum alloys, 13 precipitation hardening stainless steels, and two titanium 6Al-4V alloy forgings to compare fracture mechanics techniques with the conventional smooth specimen procedures. Commercially fabricated plate and rolled or forged bars 2 to 2.5-in. thick were tested. Exposures were conducted outdoors in a seacoast atmosphere and in an inland industrial atmosphere to relate the accelerated tests with service type environments. With the fracture mechanics technique tests were made chiefly on bolt loaded fatigue precracked compact tension specimens of the type used for plane-strain fracture toughness tests. Additional tests of the aluminum alloy were performed on ring loaded compact tension specimens and on bolt loaded double cantilever beams. For the smooth specimen procedure 0.125-in. dia. tensile specimens were loaded axially in constant deformation type frames. For both aluminum and steel alloys comparative SCC growth rates obtained from tests of precracked specimens provide an additional useful characterization of the SCC behavior of an alloy.

Sprowls, D. O.↗