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At least 91 records · Page 5

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NASA NTRS1977

Susceptibility to hot corrosion of four nickel-base superalloys, NASA-TRW VIA, B-1900, 713C and IN-738

The susceptibility to hot corrosion of four nickel-base, cast superalloys has been studied at 900 and 1000 C. The test consisted of coating alloy samples with known amounts of Na2SO4 and oxidizing the coated samples isothermally in 1 atmosphere of slowly flowing oxygen, the weight-gain being monitored on a sensitive recording microbalance. Susceptibility to hot corrosion decreased in the order of decreasing molybdenum content of the alloys. Preoxidation of samples before hot-corrosion testing markedly increased the induction period observed prior to the inception of hot corrosion for all alloys tested. X-ray diffraction analyses of the oxide scales were made. All samples that underwent hot corrosion showed the presence of a (Ni,Co)MoO4 layer near the alloy-oxide interface. Several specimens displayed resistance to hot corrosion and these showed NaTaO3 as a prominent feature in their oxide scale. Our results may be interpreted as indicating that molybdenum in an alloy is detrimental, with respect to hot corrosion, while tantalum is beneficial.

Stearns, C. A.↗

NASA NTRS1980

Effect of sodium, potassium, magnesium, calcium, and chlorine on the high temperature corrosion of IN-100, U-700, IN-792, and Mar M-509

The effects of potential impurities such as Na, K, Mg, Ca, and Cl, in coal-derived liquid fuels on accelerated corrosion of IN-100, U-700, IN-792, and Mar M-509 were investigated using a Mach 0.3 burner rig for times to 200 hours in one hour cycles. These impurities were injected in combination as aqueous solutions into the combustor. Other variables were time, temperature, and fuel-to-air ratio. The experimental matrix was a central composite fractional fractorial design divided into blocks to allow modification of the design as data was gathered. The extent of corrosion was determined by metal consumption. The time exponent was near 1.0 for the least corrosion resistant alloys, U-700 and IN-100; near 0.8 for the moderately resistant IN-792; and close to Mar M-509, the most corrosion resistant alloy. As anticipated, corrosion rapidly increased with increasing temperature as well as Na and K concentrations, while corrosion decreased somewhat as the Ca concentration increased for all alloys. Mg was beneficial for the Ni-base alloys but had little effect on the Co-base alloy. Surprisingly, the effect of increasing Cl was to decrease the corrosion of all alloys. Little interaction among the dopants was noted.

Lowell, C. E.↗

NASA NTRS1981

Atmospheric corrosion model and monitor for low cost solar arrays

An atmospheric corrosion model and corrosion monitoring system has been developed for low cost solar arrays (LSA). The corrosion model predicts that corrosion rate is the product of the surface condensation probability of water vapor and the diffusion controlled corrosion current. This corrosion model is verified by simultaneous monitoring of weather conditions and corrosion rates at the solar array test site at Mead, Nebraska.

Kaelble, D. H.↗

NASA NTRS1984

Interaction of sulfuric acid corrosion and mechanical wear of iron

Friction and wear experiments were conducted with elemental iron sliding on aluminum oxide in aerated sulfuric acid at concentrations ranging from very dilute (0.00007 N; i.e., 4 ppm) to very concentrated (96 percent acid). Load and reciprocating sliding speed were kept constant. With the most dilute acid concentration of 0.00007 to 0.0002 N, a complex corrosion product formed that was friable and often increased friction and wear. At slightly higher concentrations of 0.001 N, metal losses were essentially by wear alone. Because no buildup of corrosion products occurred, this acid concentration became the standard from which to separate metal loss from direct corrosion and mechanical wear losses. When the acid concentration was increased to 5 percent (1 N), the well-established high corrosion rate of iron in sulfuric acid strongly dominated the total wear loss. This strong corrosion increased to 30 percent acid and decreased somewhat to 50 percent acid in accordance with expectations. However, the low corrosion of iron expected at acid concentrations of 65 to 96 percent was not observed in the wear area. It was apparent that the normal passivating film was being worn away and a galvanic cell established that rapidly attacked the wear area. Under the conditions where direct corrosion losses were highest, the coefficient of friction was the lowest.

Rengstorff, G. W. P.↗

NASA NTRS1986

Interaction of sulfuric acid corrosion and mechanical wear of iron

Friction and wear experiment were conducted with elemental iron sliding on aluminum oxide in aerated sulfuric acid at concentrations ranging from very dilute (0.00007 N; i.e., 4 ppm) to very concentrated (96 percent acid). Load and reciprocating sliding speed were kept constant. With the most dilute acid concentration of 0.00007 to 0.0002 N, a complex corrosion product formed that was friable and often increased friction and wear. At slightly higher concentrations of 0.001 N, metal losses were essentially by wear alone. Because no buildup of corrosion products occurred, this acid concentration became the standard from which to separate metal loss from direct corrosion and mechanical wear losses. When the acid concentration was increased to 5 percent (1 N), the well-established high corrosion rate of iron in sulfuric acid strongly dominated the total wear loss. This strong corrosion increased to 30 percent acid and decreased somewhat to 50 percent acid in accordance with expectations. However, the low corrosion of iron expected at acid concentrations of 65 to 96 percent was not observed in the wear area. It was apparent that the normal passivating film was being worn away and a galvanic cell established that rapidly attacked the wear area. Under the conditions where direct corrosion losses were highest, the coefficient of friction was the lowest.

Rengstorff, G. W. P.↗

NASA NTRS1985

Na2SO4 induced corrosion of nickel at high temperature

Sodium sulfate-induced corrosion of nickel was studied at 900 C as a function of oxygen partial pressure. For high O2 partial pressures, accelerated corrosion during the first few minutes occurred by rapid penetration of the melt along the metal grain boundaries. A mechanism is proposed to explain this phenomenon. Repetitive scale metal detachment was observed for corrosion in lower O2 partial pressures and during the later period of corrosion in higher O2 partial pressures. The effect of preoxidation on the hot corrosion has also been studied. An induction period is observed before the onset of rapid corrosion for the preoxidized samples; the onset of rapid corrosion is associated with sudden cracking of the scale. The length of the induction period for the preoxidized samples is a function of the length of preoxidation, and appears to be related to the structure of the oxide scale after the preoxidation treatment.

Misra, A. K.↗

NASA NTRS1987

Sodium sulfate-induced corrosion of pure nickel and superalloy Udimet 700 in a high velocity burner rig at 900 C

Sodium sulfate-induced corrosion of pure nickel and a commercial nickel-base superalloy, Udimet 700 (U-700), were studied at 900 C in a Mach 0.3 burner rig with different Na levels in the combustor. The corrosion rate of Ni was independent of the Na level in the combustor and considerably lower than that measured in laboratory salt spray tests. The lower rates are associated with the deposition of only a small amount of Na2SO4 on the surface of the NiO scale. Corrosion of U-700 was observed to occur in two stages. During the first stage, the corrosion proceeds by reaction of Cr2O3 scale with the Na2SO4 and evaporation of the Na2CrO4 reaction product from the surface of the corroding sample. Cr depletion in the alloy occurs and small sulfide particles are formed in the Cr depletion zone. Extensive sulfidation occurs during the second state of corrosion, and a thick scale forms. The relationship between the corrosion rate of U-700 and the Na level in the combustor gives a good correlation in the range of 0.3 to 1.5 ppm by weight Na. Very low levels of Na in the combustor cause accelerated oxidation of U-700 without producing the typical hot corrosion morphology.

Misra, A. K.↗

NASA NTRS1991

Localized corrosion of high performance metal alloys in an acid/salt environment

Various vacuum jacketed cryogenic supply lines at the Space Shuttle launch site at Kennedy Space Center use convoluted flexible expansion joints. The atmosphere at the launch site has a very high salt content, and during a launch, fuel combustion products include hydrochloric acid. This extremely corrosive environment has caused pitting corrosion failure in the thin walled 304L stainless steel flex hoses. A search was done to find a more corrosion resistant replacement material. The study focussed on 19 metal alloys. Tests which were performed include electrochemical corrosion testing, accelerated corrosion testing in a salt fog chamber, and long term exposure at a beach corrosion testing site. Based on the results of these tests, several nickel based alloys were found to have very high resistance to this corrosive environment. Also, there was excellent agreement between the electrochemical tests and the actual beach exposure tests. This suggests that electrochemical testing may be useful for narrowing the field of potential candidate alloys before subjecting samples to long term beach exposure.

Macdowell, L. G.↗

NASA NTRS1991

Development of an Accelerated Test Method for the Determination of Susceptibility to Atmospheric Corrosion

The theoretical rationale is presented for use of a repetitive cyclic current reversal voltammetric technique for characterization of localized corrosion processes, including atmospheric corrosion. Applicability of this proposed experimental protocol is applied to characterization of susceptibility to crevice and pitting corrosion, atmospheric corrosion and stress corrosion cracking. Criteria upon which relative susceptibility is based were determined and tested using two iron based alloys commonly in use at NASA-Kennedy; A36 (a low carbon steel) and 4130 (a low alloy steel). Practicality of the procedure was demonstrated by measuring changes in anodic polarization behavior during high frequency current reversal cycles of 25 cycles per second with 1 mA/sq cm current density amplitude in solutions containing Cl anions. The results demonstrated that, due to excessive polarization which affects conductivity of barrier corrosion product layers, A36 was less resistant to atmospheric corrosion than its 4130 counterpart; behavior which was also demonstrated during exposure tests.

Ambrose, John R.↗

NASA NTRS2007

Experimental Design for the Evaluation of Detection Techniques of Hidden Corrosion Beneath the Thermal Protective System of the Space Shuttle Orbiter

The detection of corrosion beneath Space Shuttle Orbiter thermal protective system is traditionally accomplished by removing the Reusable Surface Insulation tiles and performing a visual inspection of the aluminum substrate and corrosion protection system. This process is time consuming and has the potential to damage high cost tiles. To evaluate non-intrusive NDE methods, a Proof of Concept (PoC) experiment was designed and test panels were manufactured. The objective of the test plan was three-fold: establish the ability to detect corrosion hidden from view by tiles; determine the key factor affecting detectability; roughly quantify the detection threshold. The plan consisted of artificially inducing dimensionally controlled corrosion spots in two panels and rebonding tile over the spots to model the thermal protective system of the orbiter. The corrosion spot diameter ranged from 0.100" to 0.600" inches and the depth ranged from 0.003" to 0.020". One panel consisted of a complete factorial array of corrosion spots with and without tile coverage. The second panel consisted of randomized factorial points replicated and hidden by tile. Conventional methods such as ultrasonics, infrared, eddy current and microwave methods have shortcomings. Ultrasonics and IR cannot sufficiently penetrate the tiles, while eddy current and microwaves have inadequate resolution. As such, the panels were interrogated using Backscatter Radiography and Terahertz Imaging. The terahertz system successfully detected artificially induced corrosion spots under orbiter tile and functional testing is in-work in preparation for implementation.

Kemmerer, Catherine C.↗

NASA NTRS2019

Electrochemical, Polarization, and Crevice Corrosion Testing of Inconel X750: A Supplement to the Environmental Control and Life Support System Sustaining Metal Materials Compatibility Study

In previous studies, electrochemical test results were experimentally acquired and then presented for several noble alloys in two specific solutions representative of waste liquids generated or present within the Environmental Control and Life Support System (ECLSS) aboard the International Space Station (ISS). Subsequently, another metal candidate, Inconel X750, has been submitted and was subjected to the same test routines in the same solutions and evaluated with the same statistical/analytical methodologies as those utilized in the earlier studies. Previous studies included three titanium grades, (Commercially Pure, 6Al-4V alloy, and 6Al-4V Low Interstitial alloy), two nickel-chromium alloys (Inconel® 625 and Hastelloy® C276), one high tier stainless steel (Cronidur® 30), and a nickel-titanium alloy (Nitinol 60). Thus far, all candidate alloys have exhibited excellent corrosion protection and galvanic compatibility attributes and have been deemed qualified materials for application within the ECLSS facility. Inconel X750 now joins that group. The titanium alloys gave the best results of all the metal candidates by demonstrating superior nobility and galvanic protection properties. It is worth noting that the corrosion performance properties for the three titanium alloys were essentially indistinguishable. As such and for expediency, this study and all future evaluations will refer only to the comparative properties already documented for Titanium 6Al-4V as this alloy is representative of all three alloys and considered to be more mainstream. Now the measured corrosion properties for Inconel X750 were very similar to those determined previously for Inconel 625 and Hastelloy C276 which were also determined to be very high performers. For the current effort, the results have clearly shown that Inconel X750 possesses exceptional anti-corrosion attributes comparable to metals in the highest tier of the galvanic series. Overall, one can conclude that Inconel X750 is quite noble, highly corrosion resistant and galvanically compatible with the other metal groups from both an electrochemical perspective and a long-term exposure scenario. This was clearly demonstrated after utilizing the same techniques as those applied in previous studies which included linear, Tafel and cyclic polarization, galvanic coupling with each of the other metal candidates, and pitting/crevicing assessments after one full year of immersion in the subject test solutions. Attributes defining the nobility and anti-corrosion capabilities for X750 appear to be on par with all the other candidates thus far and this alloy can now be classified as ‘excellent’ exhibiting very high resistance toward general, localized, and galvanic corrosion in the subject test media.

Lee, R. E.↗

NASA NTRS2014

Characterization of Encapsulated Corrosion Inhibitors for Environmentally Friendly Smart Coatings

Research efforts are under way to replace current corrosion inhibitors with more environmentally friendly alternatives. However, problems with corrosion inhibition efficiency, coating compatibility and solubility have hindered the use of many of these materials as simple pigment additives.This paper will present technical details on how the Corrosion Technology Lab at NASAs Kennedy Space Center (KSC) has addressed these issues by encapsulating environmentally friendly inhibitors into organic and inorganic microparticles and microcapsules. The synthetic process for polymer particles was characterized and post-synthesis analysis was performed to determine the interactions between the inhibitors and the encapsulation material. The pH-controlled release of inhibitors from various particle formulations in aqueous base was monitored and compared to both electrochemical and salt immersion accelerated corrosion experiment. Furthermore, synergistic corrosion inhibition effects observed during the corrosion testing of several inhibitor combinations will be presented.

Environmentally Friendly↗

NASA NTRS2012

Environmentally Friendly Corrosion Preventative Compounds

The objective of the Ground Systems Development and Operations Program Environmentally Friendly Corrosion Protective Coatings and Corrosion Preventive Compounds (CPCs) project is to identify, test, and develop qualification criteria for the use of environmentally friendly corrosion protective coatings and CPCs for flight hardware and ground support equipment. This document is the Final Report for Phase I evaluations, which included physical property, corrosion resistance, and NASA spaceport environment compatibility testing and analysis of fifteen CPC types. The CPCs consisted of ten different oily film CPCs and five different wax or grease CPC types. Physical property testing encompassed measuring various properties of the bulk CPCs, while corrosion resistance testing directly measured the ability of each CPC material to protect various metals against corrosion. The NASA spaceport environment compatibility testing included common tests required by NASA-STD-6001, "Flammability, Odor, Offgassing, and Compatibility Requirements and Test Procedures for Materials in Environments that Support Combustion". At the end of Phase I, CPC materials were down-selected for inclusion in the next test phases. This final report includes all data and analysis of results obtained by following the experimental test plan that was developed as part of the project. Highlights of the results are summarized by test criteria type.

Preventative Compounds↗

NASA NTRS2017

Materials Science Corrosion Internship Overview

The overarching purpose of this semester-long internship at the National Aeronautics and Space Administration's (NASA) John F. Kennedy Space Center (KSC) was to study the impacts of corrosion regarding the development of ground support equipment (GSE), launch support structures, and flight hardware in aid of the Space Launch System (SLS) and Orion program. Environmental corrosion is known as one of the largest material degradation issues for any structure comprised of metal on the Space Coast and requires the initiation of special protective measures for proper corrosion mitigation. The four (4) projects to be described were conducted with NASA Civil Servants and NASA Contractors who provided necessary resources to ensure the highest quality of data acquisition and knowledge transfer. The main objective shared between all four (4) of the following projects was to assess the modes by which corrosion takes place in multiple environments as well as the methods by which these modes of corrosion can be reduced for the enhancement of the mechanical, structural, and chemical compatibility of those respective environments with different candidate metals. A multitude of test methods were performed over the duration of this internship to assess the corrosive properties of these different candidate metals.

Ground Systems Development and Operations↗

NASA NTRSDate not supplied

Evaluation Of Corrosion-Resistant Alloys for Use in Acidic and Marine Launch Environments at NASA Kennedy Space Center: 20-Year Study

After the completion of an initial three-year study to qualify corrosion-resistant stainless steel tubing for use in NASA Kennedy Space Center’s acidic and marine launch environment, test specimens remained exposed at the KSC Beachside Atmospheric Corrosion Test Site for long-term exposure. NASA KSC’s lifetime requirement for most ground support equipment is twenty years. After twenty-one years of marine exposure, NASA KSC took the unique opportunity to reevaluate the tubing after long-term exposure to better understand the corrosion resistance of these alloys as they reached their expected lifetime requirement. Metallurgical and corrosion analysis was performed on the CRES tubing components and the alloys were rated on performance. A summary of CRES alloy tubing corrosion-related performance after 20 years of exposure in a marine launch environment is presented in this work.

NASA KSC↗

NASA NTRS1972

Ion and laser microprobes applied to the measurement of corrosion produced hydrogen on a microscopic scale.

Use of an ion microprobe and a laser microprobe to measure concentrations of corrosion-produced hydrogen on a microscopic scale. Hydrogen concentrations of several thousand ppm were measured by both analytical techniques below corroded and fracture surfaces of hot salt stress corroded titanium alloy specimens. This extremely high concentration compares with only about 100 ppm hydrogen determined by standard vacuum fusion chemical analyses of bulk samples. Both the ion and laser microprobes were used to measure hydrogen concentration profiles in stepped intervals to substantial depths below the original corroded and fracture surfaces. For the ion microprobe, the area of local analysis was 22 microns in diameter and for the laser microprobe, the area of local analysis was about 300 microns in diameter. The segregation of hydrogen below fracture surfaces supports a previously proposed theory that corrosion-produced hydrogen is responsible for hot salt stress corrosion embrittlement and cracking of titanium alloys. These advanced analytical techniques suggest great potential for many areas of stress corrosion and hydrogen embrittlement research, quality control, and field inspection of corrosion problems. For example, it appears possible that a contour map of hydrogen distribution at notch roots and crack tips could be quantitatively determined. Such information would be useful in substantiating current theories of stress corrosion and hydrogen embrittlement.

Gray, H. R.↗

NASA NTRS1973

Wear: Corrosion and erosion

The various forms of corrosion are discussed and the role of localized electrochemical reactions in the wear of sliding surfaces are considered. It is stated that there is evidence that fretting corrosion, stress corrosion cracking, corrosion fatigue, and erosion corrosion have as a common basis the localized electrochemical reactions caused by a combination of the induced homogeneity of the surfaces and the corrosive environment. Several processes leading to erosive wear are discussed.

Rowe, C. N.↗

NASA NTRS1975

Corrosion and fatigue of surgical implants

Implants for the treatment of femoral fractures, mechanisms leading to the failure or degradation of such structures, and current perspectives on surgical implants are discussed. Under the first heading, general usage, materials and procedures, environmental conditions, and laboratory analyses of implants after service are considered. Corrosion, crevice corrosion, stress corrosion cracking, intergranular corrosion, pitting corrosion, fatigue, and corrosion fatigue are the principal degradation mechanisms described. The need for improvement in the reliability of implants is emphasized.

Lisagor, W. B.↗