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NASA NTRS1994

Some metallographic results for brush bristles and brush segments of a shroud ring brush seal tested in a T-700 engine

Post-test investigation of a T-700 engine brush seal found regions void of bristles ('yanked out'), regions of bent-over bristles near the inlet, some 'snapped' bristles near the fence, and a more uniform smeared bristle interface between the first and last axial rows of bristles. Several bristles and four brush segments were cut from the brush seal, wax mounted, polished, and analyzed. Metallographic analysis of the bristle near the rub tip showed tungsten-rich phases uniformly distributed throughout the bristle, no apparent change within 1 mu m of the interface, and possibly a small amount of titanium, which would represent a transfer from the rotor. Analysis of the bristle wear face showed nonuniform tungsten, which is indicative of material resolidification. The cut end contained oxides and internal fractures; the worn end was covered with oxide scale. Material losses due to wear and elastoplastic deformation within the shear zone and third-body lubrication effects in the contact zone are discussed.

Hendricks, Robert C.↗
NASA NTRS1994

Physical and Tribological Characteristics of Ion-Implanted Diamond Films

Unidirectional sliding friction experiments were conducted with a natural, polished diamond pin in contact with both as-deposited and carbon-ion-implanted diamond films in ultrahigh vacuum. Diamond films were deposited on silicon, silicon carbide, and silicon nitride by microwave-plasma-assisted chemical vapor deposition. The as-deposited diamond films were impacted with carbon ions at an accelerating energy of 60 keV and a current density of 50 micron A/cm(exp 2) for approximately 6 min, resulting in a dose of 1.2 x 10(exp 17) carbon ions/cm(exp 2). The results indicate that the carbon ion implantation produced a thin surface layer of amorphous, nondiamond carbon. The nondiamond carbon greatly decreased both friction and wear of the diamond films. The coefficients of friction for the carbon-ion-implanted, fine-grain diamond films were less than 0.1, factors of 20 to 30 lower than those for the as-deposited, fine-grain diamond films. The coefficients of friction for the carbon-ion-implanted, coarse-grain diamond films were approximately 0.35, a factor of five lower than those for the as-deposited, coarse-grain diamond films. The wear rates for the carbon-ion-implanted, diamond films were on the order of 10(exp -6) mm(exp 3)/Nm, factors of 30 to 80 lower than that for the as-deposited diamond films, regardless of grain size. The friction of the carbon-ion-implanted diamond films was greatly reduced because the amorphous, nondiamond carbon, which had a low shear strength, was restricted to the surface layers (less than 0.1 micron thick) and because the underlying diamond materials retained their high hardness. In conclusion, the carbon-ion-implanted, fine-grain diamond films can be used effectively as wear resistant, self-lubricating coatings for ceramics, such as silicon nitride and silicon carbide, in ultrahigh vacuum.

Miyoshi, K.↗
NASA NTRS1994

Friction and Wear Properties of As-deposited and Carbon Ion-implanted Diamond Films

Recent work on the friction and wear properties of as-deposited and carbon ion-implanted diamond films was reviewed. Diamond films were produced by the microwave plasma chemical vapor deposition (CVD) technique. Diamond films with various grain sizes and surface roughnesses were implanted with carbon ions at 60 ke V ion energy, resulting in a dose of 1.2310(exp 17) carbon ions/cm(exp 2). Various analytical techniques, including Raman spectroscopy, proton recoil analysis, Rutherford backscattering, transmission and scanning electron microscopy, x-ray photoelectron spectroscopy, and x-ray diffraction, were utilized to characterize the diamond films. Sliding friction experiments were conducted with a polished natural diamond pin in contact with diamond films in the three environments: humid air (40 percent relative humidity), dry nitrogen (less than 1 percent relative humidity), and ultrahigh vacuum (10(exp -7) Pa). The CVD diamond films indeed have friction and were properties similar to those of natural diamond in the three environments. The as-deposited, fine-grain diamond films can be effectively used as self-lubricating, wear-resistant coatings that have low coefficients of friction (0.02 to 0.04) and low wear rates (10(exp -7) to 10(exp -8)mm(exp 3)/N-m) in both humid air and dry nitrogen. However, they have high coefficients of friction (1.5 to 1.7) and a high wear rate (10(exp -4)mm(exp 3/N-m) in ultrahigh vacuum. The carbon ion implanation produced a thin surficial layer (less than 0.1 micron thick) of amorphous, nondiamond carbon on the diamond films. In humid air and dry nitrogen, the ion-implanted, fine- and coarse-grain diamond films have a low coefficient of friction (around 0.1) and a low wear rate (10(exp -7)mm(exp 3/N-m). Even in ultrahigh vacuum, the presence of the nondiamond carbon layer reduced the coefficient of friction of fine-grain diamond films to 0.1 or lower and the wear rate to 10(exp -6)mm(exp 3)/N-m. Thus, the carbon ion-implanted, fine-grain diamond films can be effectively used as wear-resistant, self-lubricating coatings not only in air and dry nitrogen, but also in ultrahigh vacuum. The wear mechanism of diamond films is that of small fragments chipping off the surface. The size of wear particles is related to the extent of wear rates.

Miyoshi, Kazuhisa↗
NASA NTRS1993

Prediction of incidence and surface roughness effects on turbine performance

The results of a Navier-Stokes analysis for predicting the change in turbine efficiency due to a change in either incidence or surface roughness is discussed. It was experimentally determined by Boynton, Tabibzadeh, and Hudson that polishing the SSME high pressure fuel turbine blades improved turbine efficiency by about 2 points over a wide range of operating conditions. These conditions encompassed the range of incidence seen by the turbine blading during flight. It is also necessary to be able to predict turbine performance at various operating points for future rocket turbopump applications. The code RVCQ3D, developed by Rod Chima, was used to determine the effects of changes in incidence angle on turbine blade row efficiency. The midspan Navier-Stokes results were used in conjunction with an inviscid flow analysis code to predict the efficiency of the two stage SSME over a wide range of operating conditions for smooth and rough turbine blades. The use of the Navier-Stokes analysis to predict changes in turbine efficiency due to variation in incidence angles was found to be superior to other incidence loss correlations available in the literature. The sensitivity of the Navier-Stokes results to grid parameters is discussed. The effects of the surface roughness were accounted for using the Cebeci-Chang rough wall turbulence model. This model was implemented in the code RVCQ3D. The implementation of this model for predicting the change in efficiency is also discussed.

Boyle, R. J.↗
NASA NTRS1995

Hardware cleanliness methodology and certification

Inadequacy of mass loss cleanliness criteria for selection of materials for contamination sensitive uses, and processing of flight hardware for contamination sensitive instruments is discussed. Materials selection for flight hardware is usually based on mass loss (ASTM E-595). However, flight hardware cleanliness (MIL 1246A) is a surface cleanliness assessment. It is possible for materials (e.g. Sil-Pad 2000) to pass ASTM E-595 and fail MIL 1246A class A by orders of magnitude. Conversely, it is possible for small amounts of nonconforming material (Huma-Seal conformal coating) to not present significant cleanliness problems to an optical flight instrument. Effective cleaning (precleaning, precision cleaning, and ultra cleaning) and cleanliness verification are essential for contamination sensitive flight instruments. Polish cleaning of hardware, e.g. vacuum baking for vacuum applications, and storage of clean hardware, e.g. laser optics, is discussed. Silicone materials present special concerns for use in space because of the rapid conversion of the outgassed residues to glass by solar ultraviolet radiation and/or atomic oxygen. Non ozone depleting solvent cleaning and institutional support for cleaning and certification are also discussed.

Harvey, Gale A.↗
NASA NTRS1995

Image analysis used to count and measure etched tracks from ionizing radiation

We have developed techniques to use digitized scanning electron micrographs and computer image analysis programs to measure track densities in lunar soil grains and plastic dosimeters. Tracks in lunar samples are formed by highly ionizing solar energetic particles and cosmic rays during near surface exposure on the Moon. The track densities are related to the exposure conditions (depth and time). Distributions of the number of grains as a function of their track densities can reveal the modality of soil maturation. We worked on two samples identified for a consortium study of lunar weathering effects, 61221 and 67701. They were prepared by the lunar curator's staff as polished grain mounts that were etched in boiling 1 N NaOH for 6 h to reveal tracks. We determined that backscattered electron images taken at 10 percent contrast and approximately 50 percent brightness produced suitable high contrast images for analysis. We used the NIH Image program to cut out areas that were unsuitable for measurement such as edges, cracks, etc. We ascertained a gray-scale threshold of 25 to separate tracks from background. We used the computer to count everything that was two pixels or greater in size and to measure the area to obtain track densities. We found an excellent correlation with manual measurements for track densities below 1 x 10(exp 8) cm(exp -2). For track densities between 1 x 10(exp 8) cm(exp -2) to 1 x 10(exp 9) cm(exp -2) we found that a regression formula using the percentage area covered by tracks gave good agreement with manual measurements. We determined the track density distributions for 61221 and 67701. Sample 61221 is an immature sample, but not pristine. Sample 67701 is a submature sample that is very close to being fully mature. Because only 10 percent of the grains have track densities less than 10(exp 9) cm(exp -2), it is difficulty to determine whether the sample matured in situ or is a mixture of a mature and a submature soil. Although our analysis of plastic dosimeters is at an early stage of development, results are encouraging. The dosimeter was etched in 6.25 N NaOH at 70 deg C for 16 h. We took 200x secondary electron images of the sample and used the NIH Image software to count and measure major and minor diameters of the etched tracks. We calculated the relative track etch rate from a formula that relates it to the major and minor diameters. We made a histogram of the number of tracks versus their relative etch rate. The relative track etching rate is proportional to the linear energy transfer of the particle. With appropriate calibration experiments, the histogram could be used to calculate the radiation dose.

Blanford, George E.↗
NASA NTRS1995

Spontaneous dewetting of a perfluoropolyether

Eight different production lots of a commercial perfluoropolyether (PFPE) based on hexafluoropropene oxide (HFPO) were applied to polished metal surfaces by spinning. One of the lots repeatedly dewetted from a clean 440C steel surface, forming droplets on the surface, whereas the other seven did not dewet. This dewetting phenomenon also repeatedly occurred on 2024 aluminum and 1018 steel, but not on copper or gold. Fourier transform infrared microspectroscopy (mu-FTIR) was used to determine thickness and uniformity of the PFPE films. The dewetting lot was found to dewet from 440C steel at a film thickness greater than 520 A. A portion of the dewetting lot was heated at 316 C for 12 days in the presence of oxygen and M-50 steel. This fluid did not dewet. Sequentially, samples of the dewetting lot were filtered either with an alumina or a silica cartridge which can remove polar impurities. Neither of the filtered samples dewetted from 440C steel. It was concluded that an unknown impurity, both thermally labile and polar, present at very low concentration and undetected by our analytical techniques (FTIR, proton NMR, or F-19 NMR), was responsible for the dewetting phenomenon.

Shogrin, Bradley↗
NASA NTRS1994

Phosphate microaggregates in Archean sediments

Light microscopy conducted on samples of Archean sediments reveals phosphate microaggregates which are suggestive of a biotic origin (Arrhenius et al., 1993). These aggregates, typically 15 micrometers wide and 50 micrometers long, are thought to be the mineral remains of colonies of microorganisms that lived during the late Archean Eon (greater than or equal to 2.5 Ga). Confocal microscopy was used to study the structures of these microaggregates in three dimensions. Samples used in this study are from the lowermost section of drill core taken from the Dales Gorge Member of the Brockman Iron-Formation (Hamersley Basin) in Western Australia. These sediments are well-preserved and escaped extensive metamorphism typically experienced by older rocks of this type. Two types of samples were prepared for study under the microscope: thin sections (30 micrometers) for transmitted light microscopy to study the general rock texture and to locate the grains of interest, and thick sections (3mm) for confocal microscopy to determine the 3-D structure of the aggregates in situ. The samples have been carefully polished so that they may be directly placed on the oil-immersion lens without the use of a cover slip. No chemical treatments of the surfaces have been performed. The aggregates often form clusters, although isolated aggregates have also been found. The clusters tend to distribute along microbands in the rocks. Electron microprobe analyses show that the phosphate grains and their inclusions, besides calcium and phosphorus, contain no major elements heavier than sodium. The proportions of calcium to phosphorus, the absence of stoichiometric amounts of other cations such as magnesium and iron, as well as optical properties suggest apatite as the mineral form.

Mojzsis, S.↗
NASA NTRS1994

A phyllosilicate-sulfide vein in Kaidun

A fragment of a carbonaceous chondrite (#53.12, maximal dimension about 2 mm) containing a phyllosilicate-sulfide vein was found during an inspection of small pieces of the Kaidun meteorite. Phyllosilicate veins are apparently rare in carbonaceous chondrites and have so far only been reported from the Y82162 CI chondrite. In hand sample the vein was visible on two perpendicular faces. The polished section prepared from one side displays a complex structure. A single vein, 150 microns in width, bifurcates, and each branch narrows toward a large rounded object (RO). The section contains abundant ROs, most of them less than or equal to 100 microns in diameter. The vein has sharp contacts to the surrounding matrix, whereas the RO contacts are diffuse. The phyllosilicate in the main vein has a massive texture along the contact, which becomes platy toward the vein center where the crystals protrude into an open space. The texture of the largest RO resembles that of a barred olivine (BO) chondrule. Some of the smaller ROs also texturally resemble chondrules. The BO chondrule contains rounded sulfide-silicate objects and small metal grains covered by oxides. Phyllosilicates of the main vein consist mainly of serpentine. The phyllosilicate near the contact with the matrix has low contents of minor elements and a high Mg/Fe ratio. The composition changes in a regular manner toward the center: Al, Na, Ca, Ni, and S increase, indicating increasing amounts of sulfates admixed. The phyllosilicate vein could only have formed after a substantial rock was formed. Mechanical stress probably opened a crack that was subsequently filled by phyllosilicate, pyrrhotite, and finally by a (Fe,Mg)-sulfate. The source of the matter mobilized to form the vein could have been within the rock itself or outside. No compositional or mineralogical zoning is apparent at the vein-rock contacts. The nature of the transporting agent (liquid H2O or vapor) must also remain an enigma. M. Zolensky has recently observed similar phyllosilicate-filled veins in dark, wet clasts in the Al Rais CR chondrite.

Ivanov, A. V.↗
NASA NTRS1994

Measuring glass abundances in lunar agglutinates

The purpose of this study is to develop a standard method for measuring modal abundances of glass in single agglutinates in the lunar regolith. Not only does agglutinitic glass increase in single agglutinates as clasts of older agglutinates get incorporated into newer agglutinates with increasing maturity, but it is in this glassy phase that nanophase superparamagnetic Fe metal originates as a result of reduction reactions during the agglutination process. We report the results of two sets of independent measurements using two different methods to determine the proportion of glass in single agglutinates. We have used polished grain mounts (PGM) of five hand-picked single agglutinates from Apollo 16 soil 61181. The ISI Scanning Electron Microscope (SEM) fitted with a high-resolution Backscattered Electron (BSE) detector was used to collect high-contrast BSE images of the agglutinates. Several images were collected to represent each single agglutinate. The contrast, brightness, and focus were adjusted to optimize each image collected. Histograms of the grayscale range for all images produced four 'peaks' corresponding to epoxy, glass, crystalline phases, and metal grains. We analyzed every grid point for 12 elements with a less than 1 micron electron beam using a CAMECA SX-50 electron probe microanalyzer (EPM). If any analysis was not within about 10% of the stoichiometry of a known lunar mineral, we considered that point to be nonmineralic. Our results show that there is a remarkable correspondence in the glass percentages obtained by the two methods. The EPM method may overestimate glass because secondary fluorescence from dusty clasts in agglutinitic glass can give the appearance of nonmineralic targets. The BSE method may underestimate glass because the diversity of compositions of agglutinitic glass may not be contained under one grayscale 'peak' during image analysis.

Strait, M. M.↗
NASA NTRS1994

Carbonates in the Kaidun chondrite

Kaidun is a remarkable chondrite breccia fall containing lithic clasts that span a wide range of chondrite groups including C and E chondrites, as well as having clasts with characteristics not yet found in existing chondrite samples. The dominant lithology in Kaidun appears to be CR chondritic, consonant with recent O isotope data. The carbonates in Kaidun are presented as one mineralogical basis for comparing it to the other hydrated chondrites and to better understand its relative alteration history. The four polished thin sections of Kaidun studied contained a variety of lithologies that we classified into four groups -- CR, E, CM-like, and dark inclusions (DIs). DIs contain sulfide and magnetite morphologies that superficially resemble CI chondrites, and some of the previously reported CI lithologies in Kaidun may be what we term DIs. Carbonates were found in all lithologies studied. Carbonates in Kaidun are similar in composition to those in CR chondrites. Some of the DIs in Kaidun, previously characterized as CI, have carbonates similar to those in CR chondrites and are unlike those in CI or CM chondrites. Most carbonates in Kaidun and CR chondrites are calcites, some of which formed at temperatures above 250 C. Dolomite is less common and some may be metastable. Alteration temperatures in the Renazzo CR chondrite were estimated to be approximately 300 C, based on O isotope fractionation between phyllosilicates and magnetite. Temperatures of up to 450 C were proposed for the alteration of a CR-like dark inclusion in Kaidun, based on the presence of hydrothermal pentlandite veins. The alteration temperatures for Kaidun and the other CR chondrites are considerably higher than those suggested for CI or CM parent bodies.

Weisberg, M. K.↗
NASA NTRS1995

Impact damage resistance of carbon/epoxy composite tubes for the DC-XA liquid hydrogen feedline

Low-velocity impacts were inflicted upon two elbow sections of carbon/epoxy feedline that are to be a part of the Delta Clipper-XA flight vehicle. A soap-based liquid leak detector solution was used to inspect the impact sites for leaks of pressurized gas that was pumped into the tube. Visual surface damage was noted and recorded for each impact site. After impact testing of each of the two sections of tubes was completed, the damage zones were disected from the tube and cross sectioned through the impact site. These specimens were polished after potting them in epoxy and were examined for microcracking using a fluorescent dye penetrant technique. The results showed that nonvisible damage could cause microcracking, thereby resulting in leaks through the tube wall.

Nettles, A. T.↗
NASA NTRS1994

Replicate Wolter-I x-ray mirrors

Cylindrical (hyperbolic - parabolic Wolter I) mirrors have been electroformed from nickel over an electroless nickel-phosphorous (NiP) plated aluminum mandrel in support of the NASA AXAF-S x-ray spectrometer program. The electroless nickel was diamond turned and polished to achieve a surface finish of 10 angstroms rms or better. Gold was then plated on the nickel alloy after an electrochemical passivation step. Next a heavy layer of pure nickel was plated one millimeter thick with controlled stress at zero using a commercial PID program to form the actual mirror. This shell was removed from the NiP alloy coated mandrel by cryogenic cooling and contraction of the aluminum to release the mirror. It is required that the gold not adhere well to the NiP but all other plated coatings must exhibit good adherence. Four mirrors were fabricated from two mandrels prepared by this method. The area of each part is 0.7 square meters (7.5 square feet).

Engelhaupt, D. E.↗
NASA NTRS1995

Diamond and diamondlike carbon as wear-resistant, self-lubricating coatings for silicon nitride

Recent work on the friction and wear properties of as-deposited fine-grain diamond, polished coarse-grain diamond, and as-deposited diamondlike carbon (DLC) films in humid air at a relative humidity of approximately 40 percent and in dry nitrogen is reviewed. Two types of chemical vapor deposition (CVD) processes are used to deposit diamond films on silicon nitride (Si3N4) substrates: microwave-plasma and hot-filament. Ion beams are used to deposit DLC films of Si3N4 substrates. The diamond and DLC films in sliding contact with hemispherical bare Si3N4 pins have low steady-state coefficients of friction (less than 0.2) and low wear rates (less than 10(exp -7) mm(exp 2)/N-m), and thus, can be used effectively as wear-resistant, self-lubricating coatings for Si3N4 in the aforementioned two environments.

Miyoshi, Kazuhisa↗
NASA NTRS1995

Preliminary Evaluation of PS300: A New Self-Lubricating High Temperature Composite Coating for Use to 800 C

This paper introduces PS300, a plasma sprayed, self-lubricating composite coating for use in sliding contacts at temperatures to 800 C. PS300 is a metal bonded chrome oxide coating with silver and BaF2/CaF2 eutectic solid lubricant additives. PS300 is similar to PS200, a chromium carbide based coating, which is currently being investigated for a variety of tribological applications. In pin-on-disk testing up to 650 C, PS300 exhibited comparable friction and wear properties to PS200. The PS300 matrix, which is predominantly chromium oxide rather than chromium carbide, does not require diamond grinding and polishes readily with silicon carbide abrasives greatly reducing manufacturing costs compared to PS200. It is anticipated that PS300 has potential for sliding bearing and seal applications in both aerospace and general industry.

Dellacorte, C.↗
NASA NTRS1993

Characterization of precipitates in CdTe and Cd(1-x)Zn(x)Te grown by vertical Bridgman-Stockbarger technique

Different polishing solutions were tested for exposing precipitates in CdTe and Cd(0.96)Zn(0.04) single crystals grown by vertical Bridgman-Stockbarger technique. A solution of 5-7% Br2 in methanol and E-solution were both effective. High resolution scanning electron microscopy with energy dispersive spectroscopy (SEM/EDS) was employed to characterize those exposed precipitates. Most of the polyhedral-shaped Te precipitates with a size range from 3 to 20 microns had voids inside. Partially dissolved Te precipitates were observed in CdTe samples that had been annealed in Cd vapor at 700 C for 10 min. Isolated areas mis-oriented from the matrix were observed in CdTe and Cd(0.96)Zn(0.04)Te that had been annealed in Cd vapor at 700 C for 20 and 50 h, respectively. Te precipitate images were recorded with EDS. By SEM/EDS, Cd-rich precipitates were observed in some Cd-annealed CdTe. C and Na impurities were detected in some Te precipitates.

Shen, J.↗
NASA NTRS1996

A Fundamental Study of Nucleate Pool Boiling Under Microgravity

An experimental study of incipient boiling in short-term microgravity and with a/g = +/- 1 for pool boiling was performed. Calibrated thin gold films sputtered on a smoothly polished quartz surface were used simultaneously for thermal-resistance measurements and heating of the boiling surface. The gold films were used for both transient and quasi-steady heating surface temperature measurements. Two test vessels were constructed for precise measurement and control of fluid temperature and pressure: a laboratory pool boiling vessel for the a/g = +/- 1 experiments and a pool boiling vessel designed for the 131 m free-fall in the NASA Lewis Research Center Microgravity Research Facility for the microgravity tests. Measurements included the heater surface temperature, the pressure near the heating surface, the bulk liquid temperatures. High speed photography (up to 1,000 frames per second) was used in the experiments. With high quality microgravity and the measured initial temperature of the quiescent test fluid, R113, the temperature distribution in the liquid at the moment of boiling inception resulting from an imposed step in heat flux is known with a certainty not possible previously. The types of boiling propagation across the large flat heating surface, some observed here for the first time, are categorized; the conditions necessary for their occurrence are described. Explosive boiling propagation with a striking pattern of small scale protuberances over the entire vapor mass periphery not observed previously at low heat flux levels (on the order of 5 W/cm(exp 2)) is described. For the heater surface with a/g = -1, a step in the heater surface temperature of short duration was imposed. The resulting liquid temperature distribution at the moment of boiling inception was different from that obtained with a step in heat flux.

Ervin, Jamie S.↗
NASA NTRS1996

Control of Unstable Waves in Three Dimensional Boundary Layers

Stability experiments are conducted in the Arizona State University Unsteady Wind Tunnel on a 45 deg. swept airfoil. The pressure gradient is designed to provide purely crossflow-dominated transition; that is, the boundary layer is subcritical to Tollmien- Schlichting (T-S) disturbances. The airfoil surface is hand polished to a 0.25 micron rms finish. Under these conditions, stationary crossflow disturbances grow to nonuniform amplitude due to submicron surface irregularities near the leading edge. Spectral de-compositions isolate single-mode growth rates for the fundamental and harmonic disturbances. The measurements show early nonlinear growth causing amplitude saturation well before transition. Comparisons with nonlinear PSE calculations show excellent agreement in both the amplitude saturation and the disturbance mode shape.

Saric, William S.↗