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Outline - New Technologies and New Materials meet Flight Program - Reactor Materials Selection - Material Radiation Resistance - Testing in four different radiation environments - Superalloy Creep Testing - Superalloy-Refractory Alloy Joining - Superalloy, Stainless Steel, Copper Brazing - Superalloy-Refractory Cross Contamination - Na and NaK Compatibility - Radiator Panel Materials Selection
High efficiency conversion, regulation, and filtering techniques are discussed for power using high conversion frequencies; i.e., in the order of 1 to 5 MHz for converters having total output power capability in the order of 20 watts and 200 to 500 KHz for converters having total output powers in excess of 200 watts. Work centered on areas of component selection, material selection, optimization of the various types of circuits required, and the selection of materials for and design of magnetic components. These techniques were then applied to the design of two sample converters, one a medium power instrument type converter and the second a high power converter representative of a primary spacecraft converter regulator. The configuration and performance of the two converters is reported and discussed.
The objective of the advanced concentrator program is to develop the technology that will lead to lightweight, highly reflective, accurate, scaleable, and long lived space solar dynamic concentrators. The advanced concentrator program encompasses new and innovative concepts, fabrication techniques, materials selection, and simulated space environmental testing. Fabrication techniques include methods of fabricating the substrates and coating substrate surfaces to produce high quality optical surfaces, acceptable for further coating with vapor deposited optical films. The selected materials to obtain a high quality optical surface include microsheet glass and Eccocoat EP-3 epoxy, with DC-93-500 selected as a candidate silicone adhesive and levelizing layer. The following procedures are defined: cutting, cleaning, forming, and bonding microsheet glass. Procedures are also defined for surface cleaning, and EP-3 epoxy application. The results and analyses from atomic oxygen and thermal cycling tests are used to determine the effects of orbital conditions in a space environment.
The objective of the advanced concentrator program is to develop the technology that will lead to lightweight, highly reflective, accurate, scaleable, and long lived space solar dynamic concentrators. The advanced concentrator program encompasses new and innovative concepts, fabrication techniques, materials selection, and simulated space environmental testing. Fabrication techniques include methods of fabricating the substrates and coating substrate surfaces to produce high-quality optical surfaces, acceptable for further coating with vapor deposited optical films. The selected materials to obtain a high quality optical surface include microsheet glass and Eccocoat EP-3 epoxy, with DC-93-500 selected as a candidate silicone adhesive and levelizing layer. The following procedures are defined: cutting, cleaning, forming, and bonding microsheet glass. Procedures are also defined for surface cleaning, and EP-3 epoxy application. The results and analyses from atomic oxygen and thermal cycling tests are used to determine the effects of orbital conditions in a space environment.
A literature search in the field of ultraviolet and charged particle irradiation of polymers was utilized in an experimental program aimed at the development of radiation stable materials for space applications. The rationale utilized for material selection and the synthesis, characterization and testing performed on several selected materials is described. Among the materials tested for ultraviolet stability in vacuum were: polyethyleneoxide, polyvinylnaphthalene, and the amino resin synthesized by the condensation of o-hydroxybenzoguanamine with formaldehyde. Particularly interesting was the radiation behavior of poly(ethyleneoxide), irradiation did not cause degradation of optical properties but rather an improvement in transparency as indicated by a decrease in solar absorptance with increasing exposure time.
The automotive Stirling engine now under development by DOE/NASA as an alternative to the internal combustion engine, imposes severe materials requirements for the hot portion of the engine. Materials selected must be low cost and contain a minimum of strategic elements so that availability is not a problem. Heater head tubes contain high pressure hydrogen on the inside and are exposed to hot combustion gases on the outside surface. The cylinders and regenerator housings must be readily castable into complex shapes having varying wall thicknesses and be amenable to brazing and welding operations. Also, high strength, oxidation resistance, resistance to hydrogen permeation, cyclic operation, and long-life are required. A research program conducted by NASA Lewis focused on alloy chemistry and microstructural control to achieve the desired properties over the life of the engine. Results of alloy selection, characterization, evaluation, and actual engine testing of selected materials are presented.
The automotive Stirling engine now under development by DOE/NASA as an alternative to the internal combustion engine, imposes severe materials requirements for the hot portion of the engine. Materials selected must be low cost and contain a minimum of strategic elements so that availability is not a problem. Heater head tubes contain high pressure hydrogen on the inside and are exposed to hot combustion gases on the outside surface. The cylinders and regenerator housings must be readily castable into complex shapes having varying wall thicknesses and be amenable to brazing and welding operations. Also, high strength, oxidation resistance, resistance to hydrogen permeation, cyclic operation, and long-life are required. A research program conducted by NASA Lewis focused on alloy chemistry and microstructural control to achieve the desired properties over the life of the engine. Results of alloy selection, characterization, evaluation, and actual engine testing of selected materials are presented.
The objectives of the program were to: generate mechanical, thermal, and physical property test data for as-fabricated advanced materials; design and fabricate an accelerated thermal cycling chamber; and determine the effect of thermal cycling on thermomechanical properties and dimensional stability of composites. In the current program, extensive mechanical and thermophysical property tests of various organic matrix, metal matrix, glass matrix, and carbon-carbon composites were conducted, and a reliable database was constructed for spacecraft material selection. Material property results for the majority of the as-fabricated composites were consistent with the predicted values, providing a measure of consolidation integrity attained during fabrication. To determine the effect of thermal cycling on mechanical properties, microcracking, and thermal expansion behavior, approximately 500 composite specimens were exposed to 10,000 cycles between -150 and +150 F. These specimens were placed in a large (18 cu ft work space) thermal cycling chamber that was specially designed and fabricated to simulate one year low earth orbital (LEO) thermal cycling in 20 days. With this rate of thermal cycling, this is the largest thermal cycling unit in the country. Material property measurements of the thermal cycled organic matrix composite laminate specimens exhibited less than 24 percent decrease in strength, whereas, the remaining materials exhibited less than 8 percent decrease in strength. The thermal expansion response of each of the thermal cycled specimens revealed significant reduction in hysteresis and residual strain, and the average CTE values were close to the predicted values.
This report will discuss the design of a liquid hydrogen fuel tank constructed from composite materials. The focus of this report is to recommend a design for a fuel tank which will be able to withstand all static and dynamic forces during manned flight. Areas of study for the design include material selection, material structural analysis, heat transfer, thermal expansion, and liquid hydrogen diffusion. A structural analysis FORTRAN program was developed for analyzing the buckling and yield characteristics of the tank. A thermal analysis Excel spreadsheet was created to determine a specific material thickness which will minimize heat transfer through the wall of the tank. The total mass of the tank was determined by the combination of both structural and thermal analyses. The report concludes with the recommendation of a layered material tank construction. The designed system will include exterior insulation, combination of metal and organize composite matrices and honeycomb.
The performance of composite materials is dependent on the constituent materials selected, material structural geometry, and the fabrication process. Flaws can form in composite materials as a result of the fabrication process, handling in the manufacturing environment, and exposure in the service environment to anomalous activity. Often these flaws show no indication on the surface of the material while having the potential of substantially degrading the integrity of the composite structure. For this reason it is important to have available inspection techniques that can reliably detect sub-surface defects such as inter-ply disbonds, inter-ply cracks, porosity, and density changes caused by variations in fiber volume content. Many non-destructive evaluation techniques (NDE) are capable of detecting sub-surface flaws in composite materials. These include shearography, video image correlation, ultrasonic, acoustic emissions, and X-ray. The difficulty with most of these techniques is that they are time consuming and often difficult to apply to full scale structures. An NDE technique that appears to have the capability to quickly and easily detect flaws in composite structure is thermography. This technique uses heat to detect flaws. Heat is applied to the surface of a structure with the use of a heat lamp or heat gun. A thermographic camera is then pointed at the surface and records the surface temperature as the composite structure cools. Flaws in the material will cause the thermal-mechanical material response to change. Thus, the surface over an area where a flaw is present will cool differently than regions where flaws do not exist. This paper discusses the effort made to thermo-mechanically model the thermography process. First the material properties and physical parameters used in the model will be explained. This will be followed by a detailed discussion of the finite element model used. Finally, the result of the model will be summarized along with recommendations for future work.
Crewed spacecraft trace contaminant control employs both passive and active methods to achieve acceptable cabin atmospheric quality. Passive methods include carefully selecting materials of construction, employing clean manufacturing practices, and minimizing systems and payload operational impacts to the cabin environment. Materials selection and manufacturing processes constitute the first level of equipment offgassing control. An element-level equipment offgassing test provides preflight verification that passive controls have been successful. Offgassing test results from multiple International Space Station (ISS) habitable elements and cargo vehicles are summarized and implications for active contamination control equipment design are discussed
The process for selecting materials for use in oxygen or oxygen-enriched environments is one that continues to be investigated by many industries due to the importance to those industries of oxygen systems. There are several excellent resources available to assist oxygen systems design engineers and end-users, with the most comprehensive being ASTM MNL-36, Safe Use of Oxygen and Oxygen Systems: Handbook for Design, Operation and Maintenance, 2nd Edition. ASTM also makes available several standards for oxygen systems. However, the ASTM publications are extremely detailed, and typically designed for professionals who already possess a working knowledge of oxygen systems. No notable resource exists, whether an ASTM or other organizational publication, which can be used to educate engineers or technicians who have no prior knowledge of the nuances of oxygen system design and safety. This paper will fill the void for information needed by organizations that design or operate oxygen systems. The information in this paper is not new information, but is a concise and easily understood summary of selecting materials for oxygen systems. This paper will serve well as an employee s first introduction to oxygen system materials selection, and probably the employee s first introduction to ASTM.
Selected fire-retardant materials for possible application to commercial aircraft are described. The results of flammability screening tests and information on the physical and chemical properties of both original and newly installed materials after extended use are presented in tabular form, with emphasis on wear properties, strength, puncture and tear resistances, and cleanability.
Selection of spacecraft construction materials for optimum performance in various space environments
The contamination character of selected materials used in space technology testing is presented. Many of these materials contain components that become volatile in a space environment. Most previous data were limited to weight loss or vapor pressure. However, these parameters are not necessarily a direct measure of the contamination character of these materials. Selected materials were exposed to a thermal-vacuum environment, and the degree of contamination was measured by collecting the outgases from these materials on a cold test mirror surface. The degradation of reflectivity of the mirror was measured over a spectral range from 1100 A to 2.5 microns. Half the mirror's surface was also exposed to UV irradiation to determine its effects on the contaminative character of the depositing outgases. The amount of deposit per unit area was measured by microbalances mounted near the mirror; the sensor of one microbalance was UV irradiated. A quadrupole mass spectrometer was used to determine the composition of the outgases.
The key High Speed Civil Transport (HSCT) features which control the materials selection are discussed. Materials are selected based on weight and production economics. The top-down and bottoms-up approaches to material selection are compared for the Mach 2.4 study baseline aircraft. The key materials and structures related tasks which remain to be accomplished prior to proceeding with the building of the HSCT aircraft are examined.
Summary data on investigation of magnetic properties of selected spacecraft materials
We investigate the optical properties of new "selective emitter" materials for possible use in high-efficiency thermophotovoltaic power systems. These are systems which directly convert heat to radiation at a wavelength closely matched to the bandgap energy of the solar cell. Candidate materials which have strong absorption lines fairly close to the bandgap of good solar-cell materials were chosen for study. Their emittance was measured as a function of wavelength to evaluate their promise as selective TPV emitters. Useful and informative results were obtained. Some of these results were presented at a January 1996 solar energy conference of the American Institute of Aeronautics and Astronautics.