Fatigue resistant carbon coatings for rolling/sliding contacts
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Singh, Harpal (ORCID:0000000287262876)↗
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Results for “optical profilometry”
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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Laser Processing of Metals and Polymers
A laser offers a unique set of opportunities for precise delivery of high quality coherent energy. This energy can be tailored to alter the properties of material allowing a very flexible adjustment of the interaction that can lead to melting, vaporization, or just surface modification. Nowadays laser systems can be found in nearly all branches of research and industry for numerous applications. Sufficient evidence exists in the literature to suggest that further advancements in the field of laser material processing will rely significantly on the development of new process schemes. As a result they can be applied in various applications starting from fundamental research on systems, materials and processes performed on a scientific and technical basis for the industrial needs. The interaction of intense laser radiation with solid surfaces has extensively been studied for many years, in part, for development of possible applications. In this thesis, I present several applications of laser processing of metals and polymers including polishing niobium surface, producing a superconducting phase niobium nitride and depositing thin films of niobium nitride and organic material (cyclic olefin copolymer). The treated materials were examined by scanning electron microscopy (SEM), electron probe microanalysis (EPMA), atomic force microscopy (AFM), high resolution optical microscopy, surface profilometry, Fourier transform infrared spectroscopy (FTIR) and x-ray diffraction (XRD). Power spectral density (PSD) spectra computed from AFM data gives further insight into the effect of laser melting on the topography of the treated niobium.
36 MATERIALS SCIENCE↗
Photovoltaic Cable Jackets: A Comparison of Representative Products Using Combined-Accelerated Stress Testing [Slides]
Photovoltaic (PV) cables facilitate the distribution of electricity collected from modules to the energy grid. Durable cabling enables continuous operation of PV installations, whereas cables with a lifetime less than the modules must be replaced - reducing electricity generation and adding to the operating expense. This study primarily focusses on the aging of the key cable types using the combined-accelerated stress testing (C-AST) protocol. Representative cables for utility, building, and control/auxiliary applications were examined. Cable jacket materials examined include: polyolefin, polyethylene, polyamide, poly(vinyl chloride), chlorinated polyethylene, thermoplastic elastomer, and ethylene propylene diene monomer rubber. Specimen characterizations applied include: optical microscopy, mechanical profilometry, instrumented indentation, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), Fourier-transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). A variety of performance and durability characteristics were observed, depending on the base material, polymer formulation, and jacket color. The results from C-AST are analyzed and discussed relative to a recent industry survey on electronic balance of system components in addition to a recent study where similar cables were aged using steady state ultraviolet weathering (International Electrotechnical Commission Technical Specification 62788-7-2). Recommendations are made for the screening, industry qualification, and service life prediction of PV cable jackets.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Magnetic Fluid Friction and Wear Behavior
The friction and wear properties of two groups of magnetic fluids, one developed at NASA Lewis Research Center and a commercial fluid, were evaluated for boundary lubrication. Friction and wear measurements were made using a pin-on-disk apparatus. Three different ball materials were evaluated, (1) 440C, (2) Al2O3, and (3) Si3N4 against 440C disks. The first class of magnetic fluids have a low vapor pressure hydrocarbon base oil and are suitable for space application. Four variations of this fluid were evaluated: (1) the base oil, (2) base oil with anti-wear additives, (3) a 100 Gauss strength magnetic fluid, and (4) a 400 gauss magnetic fluid. The commercial fluid base oil and four different magnetic particle concentration levels have been evaluated. A space qualified fluorinated lubricant was tested for base line comparison. Hardness, optical microscopy, surface profilometry, and surface analysis were used to characterize the test specimens. Friction was unaffected by the concentration of magnetic particles. Wear rates for magnetic fluids were slightly higher than the base oil. The low vapor pressure magnetic fluid has better wear characteristics than the space qualified fluorinated lubricant.
Keith, Theo G., Jr.↗
Influence of Surface Properties and Impact Conditions on Adhesion of Insect Residues
Insect residues can cause premature transition to turbulent flow on laminar flow airfoils. Engineered surfaces that mitigate the adhesion of insect residues provide, therefore, a route to more efficient aerodynamics and reduced fuel burn rates. Areal coverage and heights of residues depend not only on surface properties, but also on impact conditions. We report high speed photography of fruit fly impacts at different angles of inclination on a rigid aluminum surface, optical microscopy and profilometry, and contact angle goniometry to support the design of engineered surfaces. For the polyurethane and epoxy coatings studied, some of which exhibited superhydrophobicity, it was determined that impact angle and surface compositions play critical roles in the efficacy of these surfaces to reduce insect residue adhesion.
Wohl, Christopher J.↗
Experimental Investigation of Friction and Wear Behavior of 304L Stainless Steel Sliding Against Different Counterface in Dry Contact
In this study, friction and wear behavior of 304L stainless steel sliding against different ball counterface under dry contact was investigated. Tests were conducted using a ball-on-flat contact configuration in reciprocating sliding with 440C stainless steel, Al alloy (2017) and bronze ball counterfaces under different loads. Detailed surface analysis was also done using 3-D profilometry technique and optical microscopy in order to determine wear mechanism and dimension. All the pairs exhibited initial rapid increase in coefficient of friction after which a variety of friction behavior, depending on the ball counterface, was observed. The flat and the ball counterface in 304L stainless steel-440C stainless steel pair showed wear that was proportional to applied load. In both 304L stainless steel-Al alloy (2017) and 304L stainless steel-bronze pairs, ball samples showed severe wear that was proportional to the applied load while material transfer from the different balls occurred in the flat. The study concluded that friction and wear were not material properties but a kind of responses that characterize a pair of surfaces in contact undergoing relative motion.
Olofinjana, Bolutife↗
Vapor transport growth of organic solids in microgravity and unit gravity: some comparisons and results to date
Thin films of an organic nonlinear optical (NLO) material, N, N-dimethyl-p-(2,2-dicyanovinyl) aniline (DCVA), have been grown in space and on the ground by physical vapor transport in an effusive ampoule arrangement. The thin film growth technique developed on the ground is a direct result of information gleaned from experiments in microgravity. This paper covers the results of our experimental investigations for establishing "ideal" terrestrial conditions for deposition of a DCVA film. The active control during the deposition process was exercised by three deposition variables: the material source temperature, the background pressure external to the growth ampoule and the substrate temperature. Successful growth occurred when the difference in temperature between the source material and the copper substrate was 14 degrees C and the background nitrogen pressure was such that the transport was either diffusive or convective. A qualitative diffusion limited boundary was estimated to occur at a pressure of approximately 20 torr. We have probed the DCVA thin films with visible-near infrared reflection absorption spectroscopy, polarized Fourier transform infrared spectrometry, differential interference contrast optical microscopy, and stylus profilometry.
short duration↗
Near infrared laser annealing of CdTe and in-situ measurement of the evolution of structural and optical properties
The high performance of polycrystalline CdTe thin film solar cells is enabled by annealing in the presence of Cl. This process is typically carried out for tens of minutes resulting in reduction of defect states within the bandgap among other beneficial effects. In this work, we investigate laser annealing as a means of rapidly annealing CdTe using a continuous wave sub-bandgap 1064 nm laser. The partial transmission of the beam allows us to monitor the annealing process in-situ and in real time. We find that optoelectronic and structural changes occur through two distinct kinetic processes resulting in the removal of deep defects and twinned regions, respectively. A multilayer optical model including surface roughness is used to interpret both the in-situ transmission as well as ex-situ reflectivity measurements. These experiments demonstrate beneficial material changes resulting from sub-bandgap laser-driven CdCl{sub 2} treatment of CdTe in minutes, which is an important step towards accelerating the processing of the CdTe absorber layer.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Resonant infrared pulsed laser deposition of cyclic olefin copolymer films
Barrier materials on thin-film organic optoelectronic devices inhibit the uptake of water, oxygen, or environmental contaminants, and fabricating them is a major challenge. By definition, these barrier layers must be insoluble, so the usual routes to polymer- or organic-film deposition by spin coating are not problematic. In this paper, we report comparative studies of pulsed laser deposition of cyclic olefin copolymer (COC), an excellent moisture barrier and a model system for a larger class of protective materials that are potentially useful in organic electronic devices, such as organic light-emitting diodes (OLEDs). Thin films of COC were deposited by resonant and nonresonant infrared pulsed laser ablation of solid COC targets, using a free-electron laser tuned to the 3.43 μm C–H stretch of the COC, and a high-intensity nanosecond Q-switched laser operated at 1064 nm. The ablation craters and deposited films were characterized by scanning-electron microscopy, Fourier-transform infrared spectrometry, atomic-force microscopy, high-resolution optical microscopy, and surface profilometry. Thermal-diffusion calculations were performed to determine the temperature rise induced in the film at the C–H resonant wavelength. The results show that resonant infrared pulsed laser deposition (RIR-PLD) is an effective, low-temperature thin-film deposition technique that leads to evaporation and deposition of intact molecules in homogeneous, smooth films. Nonresonant PLD, on the other hand, leads to photothermal damage, degradation of the COC polymers, and to the deposition only of particulates.
36 MATERIALS SCIENCE↗
Friction and wear behavior of nitrogen-doped ZnO thin films deposited via MOCVD under dry contact
Most researches on doped ZnO thin films are tilted toward their applications in optoelectronics and semiconductor devices. Research on their tribological properties is still unfolding. In this work, nitrogen-doped ZnO thin films were deposited on 304 L stainless steel substrate from a combination of zinc acetate and ammonium acetate precursor by MOCVD technique. Compositional and structural studies of the films were done using Rutherford Backscattering Spectroscopy (RBS) and X-ray Diffraction (XRD). The frictional behavior of the thin film coatings was evaluated using a ball-on-flat configuration in reciprocating sliding under dry contact condition. After friction test, the flat and ball counter-face surfaces were examined to assess the wear dimension and failure mechanism. In conclusion, both friction behavior and wear (in the ball counter-face) were observed to be dependent on the crystallinity and thickness of the thin film coatings.
36 MATERIALS SCIENCE↗
Lubricating and wear mechanisms for a hemisphere sliding on polyimide-bonded graphite fluoride film
Friction, wear life, rider wear, and film wear for a 440 C high-temperature-stainless-steel, hemispherically tipped rider sliding against polyimide-bonded graphite fluoride films were evaluated in a moist-air atmosphere at 25 C. Optical microscope and surface profilometry observations were made at various sliding intervals to determine how film thickness affected the lubricating and failure mechanisms of the films. Two lubrication regimes operated for the same load. In the first, the film supported the load and the lubricating mechanism consisted of the shear (plastic flow) of a thin layer of the lubricant between the metallic rider and the film surface. In the second, the film did not support the load (it was worn away) and the lubricating mechanism consisted of the shear of very thin lubricant films between flat areas generated on the rider and on sandblasted metallic asperities in the film wear track. Lubricant was supplied from the valleys between the asperities or from the sides of the wear track. With thicker films, wear life increased since a greater lubricant supply was available from the sides of the wear track.
Fusaro, R. L.↗
Radial Profilometry
Radial profilometry is combination of optical and electronic techniques for measurement of inner surfaces of cylindrical or nearly cylindrical cavities. Profilometer inserted in pipe or other cavity to measure its shape optically. Illumination supplied through optical fiber, and image of inspected area of cavity transmitted through bundle of optical fibers. Applications include inspection of pipes, tubes, boreholes, and possibly measurements of contours in blood vessels or other internal organs.
Gilbert, J. A.↗
Detached Bridgman Growth of Germanium and Germanium-Silicon Alloy Crystals
Earth based experiments on the science of detached crystal growth are being conducted on germanium and germanium-silicon alloys (2 at% Si average composition) in preparation for a series of experiments aboard the International Space Station (ISS). The purpose of the microgravity experiments includes differentiating among proposed mechanisms contributing to detachment, and confirming or refining our understanding of the detachment mechanism. Because large contact angle are critical to detachment, sessile drop measurements were used to determine the contact angles as a function of temperature and composition for a large number of substrates made of potential ampoule materials. Growth experiments have used pyrolytic boron nitride (pBN) and fused silica ampoules with the majority of the detached results occurring predictably in the pBN. The contact angles were 173 deg (Ge) and 165 deg (GeSi) for pBN. For fused silica, the contact angle decreases from 150 deg to an equilibrium value of 117 deg (Ge) or from 129 deg to an equilibrium value of 100 deg (GeSi) over the duration of the experiment. The nature and extent of detachment is determined by using profilometry in conjunction with optical and electron microscopy. The stability of detachment has been analyzed, and an empirical model for the conditions necessary to achieve sufficient stability to maintain detached growth for extended periods has been developed. Results in this presentation will show that we have established the effects on detachment of ampoule material, pressure difference above and below the melt, and silicon concentration; samples that are nearly completely detached can be grown repeatedly in pBN.
Szofran, F. R.↗
Reduction of Defects in Germanium-Silicon
Crystals grown without contact with a container have far superior quality to otherwise similar crystals grown in direct contact with a container. In addition to float-zone processing, detached- Bridgman growth is a promising tool to improve crystal quality, without the limitations of float zoning or the defects introduced by normal Bridgman growth. Goals of this project include the development of the detached Bridgman process to be reproducible and well understood and to quantitatively compare the defect and impurity levels in crystals grown by these three methods. Germanium (Ge) and germanium-silicon (Ge-Si) alloys are being used. At MSFC, we are responsible for the detached Bridgman experiments intended to differentiate among proposed mechanisms of detachment, and to confirm or refine our understanding of detachment. Because the contact angle is critical to determining the conditions for detachment, the sessile drop method was used to measure the contact angles as a function of temperature and composition for a large number of substrates made of potential ampoule materials. Growth experiments have used pyrolytic boron nitride (pBN) and fused silica ampoules with the majority of the detached results occurring predictably in the pBN. Etch pit density (EPD) measurements of normal and detached Bridgman-grown Ge samples show a two order of magnitude improvement in the detached-grown samples. The nature and extent of detachment is determined by using profilometry in conjunction with optical and electron microscopy. The stability of detachment has been analyzed, and an empirical model for the conditions necessary to achieve sufficient stability to maintain detached growth for extended periods has been developed. We have investigated the effects on detachment of ampoule material, pressure difference above and below the melt, and Si concentration; samples that are nearly completely detached can be grown repeatedly in pBN. Current work is concentrated on developing a method to make in situ pressure measurements in the growth ampoules.
Source record↗
New Technology-Large-Area Three- Dimensional Surface Profiling Using Only Focused Air-Coupled Ultrasound-Given 1999 R&D 100 Award
Surface topography, which significantly affects the performance of many industrial components, is normally measured with diamond-tip profilometry over small areas or with optical scattering methods over larger areas. To develop air-coupled surface profilometry, the NASA Glenn Research Center at Lewis Field initiated a Space Act Agreement with Sonix, Inc., through two Glenn programs, the Advanced High Temperature Engine Materials Program (HITEMP) and COMMTECH. The work resulted in quantitative surface topography profiles obtained using only high-frequency, focused ultrasonic pulses in air. The method is nondestructive, noninvasive, and noncontact, and it does not require light-reflective surfaces. Air surface profiling may be desirable when diamond-tip or laserbased methods are impractical, such as over large areas, when a significant depth range is required, or for curved surfaces. When the configuration is optimized, the method is reasonably rapid and all the quantitative analysis facilities are online, including two- and three-dimensional visualization, extreme value filtering (for faulty data), and leveling.
Roth, Don J.↗
MAB Phase Ceramics for Lunar Applications
During the ten-week internship my work focused on designing characterization protocol for 3D printed MAB phase ceramics on steel and Tiplates. I was mentored by Dr. Samuel Hocker of NASA and advised by Dr. Gupta from University of North Dakota. I also collaborated with Mackenzie Short from the University of North Dakota. The characterization protocol was divided into following steps; initially, we performed visual inspection of the plates. During this process, the coatings which spalled or delaminated were discarded for further evaluation. During the next step, we performed optical microscopy to discern and document surface features and porosities of the samples. We also noted some decomposition under the optical microscope as well. Thereafter, profilometry analysis was performed to understand the effect of power density on the surface roughness. Due to the deposited powder over the samples, the profilometry was inconclusive. We then cleaned the samples on the steel plate using ethanol and cotton swabs to wipe up the loose powder covering the samples. Detailed SEM analysis was then performed on the cleaned specimens. In parallel, the 3D printed samples on the Tiplate were cleaned by using an ultrasonic bath for 1h. Optical imaging showed that this cleaning process was more effective for cleaning except that small cracks propagated through the layered ceramics. The profilometry data gathered on the titanium plate after cleaning was more conclusive. The SEM data on the steel plate showed that there is decomposition at all wattages although at 100 W the extent of decomposition was lower. We are planning to characterize the steel samples after cleaning in ultrasonic bath for 5-10 min to minimize cracking during the cleaning process. In addition, we are also planning to study the fractured surface by SEM analysis.
Additive Manufacturing, Laser Powder Bed Fusion, S↗
Thin film processing of photorefractive BaTiO3
During the period covered by this report, October 11, 1991 through October 10, 1992, the research has progressed in a number of different areas. The sol-gel technique was initially studied and experimentally evaluated for depositing films of BaTiO3. The difficulties with the precursors and the poor quality of the films deposited lead to the investigation of pulsed laser deposition as an alternative approach. The development of the pulsed laser deposition technique has resulted in continuous improvements to the quality of deposited films of BaTiO3. The initial depositions of BaTiO3 resulted in amorphous films, however, as the pulsed laser deposition technique continued to evolve, films were deposited in the polycrystalline state, then the textured polycrystalline state, and most recently heteroepitaxial films have also been successfully deposited on cubic (100) oriented SrTiO3 substrates. A technique for poling samples at room temperature and in air is also undergoing development with some very preliminary but positive results. The analytical techniques, which include x-ray diffraction, ferroelectric analysis, UV-Vis spectrophotometry, scanning electron microscopy with x-ray compositional analysis, optical and polarized light microscopy, and surface profilometry have been enhanced to allow for more detailed evaluation of the samples. In the area of optical characterization, a pulsed Nd:YAG laser has been incorporated into the experimental configuration. Now data can also be acquired within various temporal domains resulting in more detailed information on the optical response of the samples and on their photorefractive sensitivity. The recent establishment of collaborative efforts with two departments at Johns Hopkins University and the Army Research Lab at Fort Belvoir has also produced preliminary results using the metallo-organic decomposition technique as an alternative method for thin film processing of BaTiO3. RF and DC sputtering is another film deposition approach that should be initiated in the near future. Other techniques for optical characterization, which may even allow for intragrannular (within single grains) investigations, are also being considered.
Schuster, Paul R.↗
Accelerated Aging of PV Cables - The Development of Methods Towards Combined-Accelerated Stress Testing
PV cables allow the collection and distribution of electricity from modules to the energy grid. Durable cabling allows continuous operation of PV installations. Cables with a life less than that of the modules must be replaced - reducing electricity generation and adding to the system operating expense. We have examined the durability of a variety of representative cable samples using artificial UV weathering (IEC TS 62788-7-2) and combined accelerated stress testing (C-AST). Jackets in this study include PV-rated (polyolefin), building wire (PVC/PA), and multi-conductor (rubber, as in PV trackers), with some examples of black and red cables. Characterizations at read points include appearance (camera and optical microscope), surface roughness (linear profilometry), instrumented indentation, surface morphology (SEM), chemical composition (EDS), thermal decomposition (TGA), phase transition (DSC), crystalline structure (WAXS), and polymer chemical structure (FTIR). Complimentary examinations confirm damage to the external and interior layer(s) of less durable samples, including changes in morphology (e.g., cracking), chemistry (e.g., oxidation), structure, and mechanical performance (e.g., through-thickness modulus and hardness). The results may be generally compared to other examples from the field (PV installations) or after accelerated testing (IEC 61215). The methods in this study are presently being applied in a follow-on C-AST study, incorporating both dynamic and kinematic fixtures.
balance of systems↗