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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1983

A review of the use of wear-resistant coatings in the cutting-tool industry

The main mechanisms involved in the wear of cutting tools are reviewed. Evaluation of the different coating properties required for the reduction of the different kinds of wear was also reviewed. The types of coatings and their ranges of applicability are presented and discussed in view of their properties. Various coating processes as well as their advantages and shortcomings are described. Potential future developments in the field of wear-resistant coatings are discussed.

Salik, J.↗
NASA NTRS1995

Convergent spray process for environmentally friendly coatings

Conventional spray application processes have poor transfer efficiencies, resulting in an exorbitant loss in materials, solvents, and time. Also, with ever tightening Environmental Protection Agency (EPA) regulations and Occupational Safety and Health Administration requirements, the low transfer efficiencies have a significant impact on the quantities of materials and solvents that are released into the environment. High solids spray processes are also limited by material viscosities, thus requiring many passes over the surface to achieve a thickness in the 0.125 -inch range. This results in high application costs and a negative impact on the environment. Until recently, requirements for a 100 percent solid sprayable, environmentally friendly, lightweight thermal protection system that can be applied in a thick (greater than 0.125 inch) single-pass operation exceeded the capability of existing systems. Such coatings must be applied by hand lay-up techniques, especially for thermal and/or fire protection systems. The current formulation of these coatings has presented many problems such as worker safety, environmental hazards, waste, high cost, and application constraints. A system which can apply coatings without using hazardous materials would alleviate many of these problems. Potential applications include the aerospace thermal protective specialty coatings, chemical and petroleum industries that require fire-protection coatings that resist impact, chemicals, and weather. These markets can be penetrated by offering customized coatings applied by automated processes that are environmentally friendly.

Scarpa, Jack↗
NASA NTRS1996

Interface Configuration Experiments (ICE) Explore the Effects of Microgravity on Fluids

The Interface Configuration Experiment (ICE) is actually a series of experiments that explore the striking behavior of liquid-vapor interfaces (i.e., fluid surfaces) in a low gravity environment under which major shifts in liquid position can arise from small changes in container shape or contact angle. Although these experiments are designed to test current mathematical theory, there are numerous practical applications that could result from these studies. When designing fluid management systems for space-based operations, it is important to be able to predict the locations and configurations that fluids will assume in containers under low-gravity conditions. The increased ability to predict, and hence control, fluid interfaces is vital to systems and/or processes where capillary forces play a significant role both in space and on the Earth. Some of these applications are in general coating processes (paints, pesticides, printing, etc.), fluid transport in porous media (ground water flows, oil recovery, etc.), liquid propellant systems in space (liquid fuel and oxygen), capillary-pumped loops and heat pipes, and space-based life-support systems. In space, almost every fluid system is affected, if not dominated, by capillarity. Knowledge of the liquid-vapor interface behavior, and in particular the interface shape from which any analysis must begin, is required as a foundation to predict how these fluids will react in microgravity and on Earth. With such knowledge, system designs can be optimized, thereby decreasing costs and complexity, while increasing performance and reliability. ICE has increased, and will continue to increase this knowledge, as it probes the specific peculiarities of current theory upon which our current understanding of these effects is based. Several versions of ICE were conducted in NASA Lewis Research Center's drop towers and on the space shuttle during the first and second United States Microgravity Laboratory missions (USML-1 and USML-2). Additional tests are planned for the space shuttle and for the Russian Mir space station. These studies will focus on interfacial problems concerning surface existence, uniqueness, configuration, stability, and flow characteristics.

Source record↗
NASA NTRS2005

Actuated Hybrid Mirror Telescope

The figure depicts the planned Actuated Hybrid Mirror Telescope (AHMT), which is intended to demonstrate a new approach to the design and construction of wide-aperture spaceborne telescopes for astronomy and Earth science. This technology is also appropriate for Earth-based telescopes. The new approach can be broadly summarized as using advanced lightweight mirrors that can be manufactured rapidly at relatively low cost. More specifically, it is planned to use precise replicated metallic nanolaminate mirrors to obtain the required high-quality optical finishes. Lightweight, dimensionally stable silicon carbide (SiC) structures will support the nanolaminate mirrors in the required surface figures. To enable diffraction- limited telescope performance, errors in surface figures will be corrected by use of mirror-shape-control actuators that will be energized, as needed, by a wave-front-sensing and control system. The concepts of nanolaminate materials and mirrors made from nanolaminate materials were discussed in several previous NASA Tech Briefs articles. Nanolaminates constitute a relatively new class of materials that can approach theoretical limits of stiffness and strength. Nanolaminate mirrors are synthesized by magnetron sputter deposition of metallic alloys and/or compounds on optically precise master surfaces to obtain optical-quality reflector surfaces backed by thin shell structures. As an integral part of the deposition process, a layer of gold that will constitute the reflective surface layer is deposited first, eliminating the need for a subsequent and separate reflective-coating process. The crystallographic textures of the nanolaminate will be controlled to optimize the performance of the mirror. The entire deposition process for making a nanolaminate mirror takes less than 100 hours, regardless of the mirror diameter. Each nanolaminate mirror will be bonded to its lightweight SiC supporting structure. The lightweight nanolaminate mirrors and SiC supporting structures will be fabricated from reusable master molds. The mirror-shape-control actuators will be low-power, high-capacitance lead magnesium niobate electrostrictive actuators that will be embedded in the SiC structures. The mode of operation of these actuators will be such that once power was applied, they will change in length and once power was removed, they will maintain dimensional stability to nanometer precision. This mode of operation will enable the use of low-power, minimally complex electronic control circuitry. The wave-front-sensing and control system will be designed and built according to a two-stage architecture. The first stage will be implemented by a Shack- Hartmann (SH) sensor subsystem, which will provide a large capture range. The second, higher-performance stage will be implemented by an image-based wave-front-sensing subsystem that will include a phase-retrieval camera (PRC), and will utilize phase retrieval and other techniques to measure wavefront error directly. Phase retrieval is a process in which multiple images of an unresolved object are iterated to estimate the phase of the optical system that acquired the images. The combination of SH and phase-retrieval sensors will afford the virtues of both a dynamic range of 105 and an accuracy of <10 nm.

Hickey, Gregory↗
NASA NTRS2004

Friction and Wear Characteristics of Cu-4Al Foil Bearing Coating at 25 and 650 degree C

The friction and wear performance of a Cu-4Al top foil coating has been investigated in Generation I foil air bearings. The copper alloy was applied by a novel deposition technique (ion diffusion) and the journal was coated with PS304, a plasma spray deposited high temperature composite solid lubricant coating. The ion diffusion coating process deposits a desirable smooth layer compared to other methods like cathodic arc deposition. The tribological performance of bearings with and without Cu-4Al foil coatings were evaluated through start-stop tests on an air bearing test rig at 25 and 650 C. The results indicate that the Cu-4Al assists during the initial break-in period, gives more stable friction performance with respect to temperature, and appears to prevent top foil wear at high temperature. The measured load capacity coefficient was 0.5, which was comparable to earlier testing of more advanced design Generation III bearings coated with standard cathodic arc deposited Cu-4Al. However, further studies are needed to determine if deeper penetration of the copper alloy into the foil would help make the transition in friction behavior from contact with the Cu-4Al coated foil to contact with the base foil material more gradual. Also, future work is recommended to assess the performance of ion diffusion coatings with different Cu-based alloy compositions and to investigate the effect the coating has on the elastic modulus of the foil material.

Stanford, Malcolm K.↗
NASA NTRS1994

The realuminizing of the 7-meter-diameter solar simulator collimating mirror

This paper describes the modification of a three-electron-beam (EB) gun system for vacuum depositing a highly reflective aluminum coating on a 7.01-m (23-ft) -diam nickel-plated aluminum collimating mirror. The mirror is part of the JPL 7.62-m space simulator that was recently modernized with a new high vacuum pumping system, solar lamp power supplies, solar optic lens system, and refurbished collimating mirror. The 7.01-m 12,700-kg (14-ton) spherical collimating mirror was removed from this facility for replating with 381 micron (0.015 in.) of electroless nickel and polished to a specular finish for realuminizing. The space chamber served as the vacuum coating vessel for the realuminizing coating process. The mirror is the primary reflector for the solar simulation system and the aluminized reflective surface is its most critical performance element. The uniformity of thickness and high reflectivity of the coating in visible and near-ultraviolet (UV) light governs the accuracy of the beam for solar testing. The uniformity of the thin-film thickness also controls the durability of the mirror over time. The mirror was polished to a 64-percent reflectivity with a uniformity of 1.5 percent. The performance goal for the aluminizing was 89 percent with +/- 0.5-percent variation over the mirror.

Noller, E. W.↗
NASA NTRS2005

Low Earth Orbit Environmental Effects on Space Tether Materials

Atomic oxygen (AO) and ultraviolet (UV) radiation erode and embrittle most polymeric materials. This research was designed to test several different materials and coatings under consideration for their application to space tethers, for resistance to these effects. The samples were vacuum dehydrated, weighed and then exposed to various levels of AO or UV radiation at the NASA Marshall Space Flight Center. They were then re-weighed to determine mass loss due to atomic oxygen erosion, inspected for damage and tensile tested to determine strength loss. The experiments determined that the Photosil coating process, while affording some protection, damaged the tether materials worse than the AO exposure. TOR-LM also failed to fully protect the materials, especially from UV radiation. The POSS and nickel coatings did provide some protection to the tethers, which survived the entire test regime. M5 was tested, uncoated, and survived AO exposure, though its brittleness prevented any tensile testing.

Finckernor, Miria M.↗
NASA NTRS1953

Relative Importance of Various Sources of Defect-Producing Hydrogen Introduced into Steel During Application of Vitreous Coatings

When porcelain enamels or vitreous-type ceramic coatings are applied to ferrous metals, there is believed to be an evolution of hydrogen gas both during and after the firing operation. At elevated temperatures rapid evolution may result in blistering while if hydrogen becomes trapped in the steel during the rapid cooling following the firing operation gas pressures may be generated at the coating-metal interface and flakes of the coating literally blown off the metal. To determine experimentally the relative importance of the principal sources of the hydrogen causing the defects, a procedure was devised in which heavy hydrogen (deuterium) was substituted in turn for regular hydrogen in each of five possible hydrogen-producing operations in the coating process. The findings of the study were as follows: (1) the principal source of the defect-producing hydrogen was the dissolved water present in the enamel frit that was incorporated into the coating. (2) the acid pickling, the milling water, the chemically combined water in the clay, and the quenching water were all minor sources of defect-producing hydrogen under the test conditions used. Confirming experiments showed that fishscaling could be eliminated by using a water-free coating.

Moore, Dwight G↗
NASA NTRS2012

Development of YAG:Dy Thermographic Phosphor Coatings for Turbine Engine Applications

The selection and development of thermographic phosphor coatings were pursued to meet the objective of demonstrating luminescence-decay-based temperature measurements up to 1300C on the surface of a vane in an operating demonstrator turbine engine. To meet this objective, YAG:Dy was selected based on the desirable luminescence performance observed for YAG:Dy powder: (1) excellent temperature sensitivity and intensity at operating turbine engine temperatures, (2) an emission peak at the relatively short wavelength of 456 nm, where the interference from background blackbody radiation is fairly low, and (3) its nearly single exponential decay which makes for a simple, reliable temperature calibration. However, implementation of YAG:Dy for surface temperature measurements required application of YAG:Dy as a coating onto the surface of a superalloy component with a preexisting yttria-stabilized zirconia (YSZ) thermal barrier coating (TBC). An inherent dilemma in producing a YAG:Dy coating is that coating processing is constrained to be performed at temperatures below (less than 1200C) what is considered safe for the superalloy component, much lower than temperatures used to produce the high quality crystalline powder. Therefore, YAG:Dy coatings tend to exhibit lower luminescence performance compared to well prepared YAG:Dy powder, and the luminescence performance of the coating will depend on the method of coating deposition. In this presentation, the luminescence performance of YAG:Dy coatings prepared by the different methods of (1) application of a binder-based YAG:Dy-containing paint, (2) solution precursor plasma spray (SPPS), and (3) electron-beam physical vapor deposition (EB-PVD) and the effect of post-deposition heat treatments will be discussed.

Eldridge, J. I.↗
NASA NTRS1993

High-Emittance, Low-Absorbance Thermal-Control Coating

Modified process for anodizing 5657 aluminum alloy results in Al2O3 surfaces with infrared emissivities as great as 0.92 and solar absorptivities as small as 0.2. Coating enables fabrication of radiators requiring less surface, and hence less weight: radiators with coating weigh approximately 7 percent less than thermally equivalent radiators made with older anodizing processes. Coating applied easily and economically, and retains all of desirable properties of standard anodized coatings.

Le, Huong G.↗
NASA NTRS1979

Automated aray assembly, phase 2

A manufacturing process suitable for the large-scale production of silicon solar array modules at a cost of less than $500/peak kW is described. Factors which control the efficiency of ion implanted silicon solar cells, screen-printed thick film metallization, spray-on antireflection coating process, and panel assembly are discussed. Conclusions regarding technological readiness or cost effectiveness of individual process steps are presented.

Daiello, R. V.↗
NASA NTRS1988

Polymer powder prepregging: Scoping study

Early on, it was found that NEAT LARC-TPI thermoplastic polyimide powder behaved elastoplastically at pressures to 20 ksi and temperatures to 260 degrees celcius (below MP). At high resin assay, resin powder could be continuously cold-flowed around individual carbon fibers in a metal rolling mill. At low resin assay (2:1, C:TPI), fiber breakage was prohibitive. Thus, although processing of TPI below MP would be quite unique, it appears that the polymer must be melted and flowed to produce low resin assay prepreg. Fiber tow was spread to 75 mm using a venturi slot tunnel. This allowed intimate powder/fiber interaction. Two techniques were examined for getting room temperature powder onto the room temperature fiber surface. Electrostatic powder coating allows the charged powder to cling tenaciously to the fiber, even while heated with a hot air gun to above its melt temperature. A variant of the wet slurry coating process was also explored. The carbon fibers are first wetted with water. Then dry powder is sprinkled onto the wet tow and doctor-rolled between the fibers. The wet structure is then taken onto a heated roll, with hot air guns drying and sinter-melting the powder onto the fiber surfaces. In both cases SEM shows individual fibers coated with powder particles that have melted in place and flowed along the fiber surface via surface tension.

Throne, James L.↗
NASA NTRS1985

Manufacturing and producibility technology

Activities of the manufacturing/producibility working group within the Advanced High-Pressure O2/H2 Technology Program are summarized. The objectives of the M/P working group are: to develop and evaluate process and manufacturing techniques for advanced propulsion hardware design and selected materials; and to optimize the producibility of (SSME) components and assemblies by improved performance, increased life, greater reliability, and/or reduced cost. The technologies being developed include: plasma arc, laser, and inertia welding; combustion chamber and turbine blade coatings; coating processes; high performance alloy electroforming; and process control technology.

Hankins, J. D.↗
NASA NTRS2012

Spinoff 2011

Topics include: Bioreactors Drive Advances in Tissue Engineering; Tooling Techniques Enhance Medical Imaging; Ventilator Technologies Sustain Critically Injured Patients; Protein Innovations Advance Drug Treatments, Skin Care; Mass Analyzers Facilitate Research on Addiction; Frameworks Coordinate Scientific Data Management; Cameras Improve Navigation for Pilots, Drivers; Integrated Design Tools Reduce Risk, Cost; Advisory Systems Save Time, Fuel for Airlines; Modeling Programs Increase Aircraft Design Safety; Fly-by-Wire Systems Enable Safer, More Efficient Flight; Modified Fittings Enhance Industrial Safety; Simulation Tools Model Icing for Aircraft Design; Information Systems Coordinate Emergency Management; Imaging Systems Provide Maps for U.S. Soldiers; High-Pressure Systems Suppress Fires in Seconds; Alloy-Enhanced Fans Maintain Fresh Air in Tunnels; Control Algorithms Charge Batteries Faster; Software Programs Derive Measurements from Photographs; Retrofits Convert Gas Vehicles into Hybrids; NASA Missions Inspire Online Video Games; Monitors Track Vital Signs for Fitness and Safety; Thermal Components Boost Performance of HVAC Systems; World Wind Tools Reveal Environmental Change; Analyzers Measure Greenhouse Gasses, Airborne Pollutants; Remediation Technologies Eliminate Contaminants; Receivers Gather Data for Climate, Weather Prediction; Coating Processes Boost Performance of Solar Cells; Analyzers Provide Water Security in Space and on Earth; Catalyst Substrates Remove Contaminants, Produce Fuel; Rocket Engine Innovations Advance Clean Energy; Technologies Render Views of Earth for Virtual Navigation; Content Platforms Meet Data Storage, Retrieval Needs; Tools Ensure Reliability of Critical Software; Electronic Handbooks Simplify Process Management; Software Innovations Speed Scientific Computing; Controller Chips Preserve Microprocessor Function; Nanotube Production Devices Expand Research Capabilities; Custom Machines Advance Composite Manufacturing; Polyimide Foams Offer Superior Insulation; Beam Steering Devices Reduce Payload Weight; Models Support Energy-Saving Microwave Technologies; Materials Advance Chemical Propulsion Technology; and High-Temperature Coatings Offer Energy Savings.

Source record↗
NASA NTRS1995

Graphite fiber textile preform/copper matrix composites

Graphite fiber reinforced/copper matrix composites have sufficiently high thermal conduction to make them candidate materials for critical heat transmitting and rejection components. The term textile composites arises because the preform is braided from fiber tows, conferring three-dimensional reinforcement and near net shape. The principal issues investigated in the past two years have centered on developing methods to characterize the preform and fabricated composite and on braidability. It is necessary to have an analytic structural description for both processing and final property modeling. The structure of the true 3-D braids used is complex and has required considerable effort to model. A structural mapping has been developed as a foundation for analytic models for thermal conduction and mechanical properties. The conductivity has contributions both from the copper and the reinforcement. The latter is accomplished by graphitization of the fibers, the higher the amount of graphitization the greater the conduction. This is accompanied by an increase in the fiber modulus, which is desirable from a stiffness point of view but decreases the braidability; the highest conductivity fibers are simply too brittle to be braided. Considerable effort has been expended on determining the optimal braidability--conductivity region. While a number of preforms have been fabricated, one other complication intervenes; graphite and copper are immiscible, resulting in a poor mechanical bond and difficulties in infiltration by molten copper. The approach taken is to utilize a proprietary fiber coating process developed by TRA, of Salt Lake City, Utah, which forms an itermediary bond. A number of preforms have been fabricated from a variety of fiber types and two sets of these have been infiltrated with OFHC copper, one with the TRA coating and one without. Mechanical tests have been performed using a small-scale specimen method and show the coated specimens to have superior mechanical properties. Final batches of preforms, including a finned, near net shape tube, are being fabricated and will be infiltrated before summer.

Gilatovs, G. J.↗
NASA NTRS1976

Ablative performance of uncoated silicone-modified and shuttle baseline reinforced carbon composites

The relative ablative performance of uncoated silicone-modified reinforced carbon composite (RCC) and uncoated shuttle baseline RCC substrates was investigated. The test specimens were 13 plies (5.3 to 5.8 millimeters) thick and had a 25-millimeter-diameter test face. Prior to arc tunnel testing, all specimens were subjected to a heat treatment simulating the RCC coating process. During arc tunnel testing, the specimens were exposed to cold wall heating rates of 178 to 529 kilowatts/sq m and stagnation pressures ranging from 0.015 to 0.046 atmosphere at Mach 4.6 in air, with and without preheating in nitrogen. The results show that the ablative performance of uncoated silicone-modified RCC substrates is significantly superior to that of uncoated shuttle baseline RCC substrates over the range of heating conditions used. These results indicate that the silicone-modified RCC substrate would yield a substantially greater safety margin in the event of complete coating loss on the shuttle orbiter.

Dicus, D. L.↗
NASA NTRS2016

Advanced Environmental Barrier Coating Development for SiC-SiC Ceramic Matrix Composite Components

This presentation reviews the NASA advanced environmental barrier coating (EBC) system development for SiCSiC Ceramic Matrix Composite (CMC) components for next generation turbine engines. The emphasis has been placed on the current design challenges of the 2700F environmental barrier coatings; coating processing and integration with SiCSiC CMCs and component systems; and performance evaluation and demonstration of EBC-CMC systems. This presentation also highlights the EBC-CMC system temperature capability and durability improvements through advanced compositions and architecture designs, as shown in recent simulated engine high heat flux, combustion environment, in conjunction with mechanical creep and fatigue loading testing conditions.

Simulated Engine Test↗