Stress-corrosion cracking of cold-reduced austenitic stainless steels.
Stress corrosion cracking of cold reduced austenitic stainless steels noting effects of marine atmosphere exposure, cold working, welding, etc
STRESS CORROSION↗
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Corrosion of metals and alloys in sulfate melts at 750 C
The corrosion of Ni, Co, Ni-10Cr, Co-21Cr, and IN738 was studied at 750 C in the presence of molten sulfate mixtures (Na2SO4-Li2SO4 and Na2SO4-CoSO4) and in an atmosphere consisting of O2 + 0.12 percent SO2-SO3. The corrosion was observed to be similar for both Na2SO4-Li2SO4 and Na2SO4-CoSO4 melts. The corrosion of Ni and Co took place by the formation of a mixed oxide plus sulfide scale, very similar to the corrosion in SO2 or SO3 alone. The initial stage for the corrosion of Ni-10Cr involved the formation of a thick NiO + Ni3S2 duplex scale, and Cr sulfide was formed during the later stages. A pitting type of morphology was observed for both Co-21Cr and IN738. The pit was Cr sulfide at the beginning, and subsequently the sulfides oxidized to Cr2O3. A base-metal oxide layer was present above the pit, and this was observed to be formed very early in the corrosion process. A mechanism is proposed to explain this. In general, the formation of sulfides appears to be the primary mode of degradation in mixed sulfide melts.
Misra, A. K.↗
Seacoast stress corrosion cracking of aluminum alloys
The stress corrosion cracking resistance of high strength, wrought aluminum alloys in a seacoast atmosphere was investigated and the results were compared with those obtained in laboratory tests. Round tensile specimens taken from the short transverse grain direction of aluminum plate and stressed up to 100 percent of their yield strengths were exposed to the seacoast and to alternate immersion in salt water and synthetic seawater. Maximum exposure periods of one year at the seacoast, 0.3 or 0.7 of a month for alternate immersion in salt water, and three months for synthetic seawater were indicated for aluminum alloys to avoid false indications of stress corrosion cracking failure resulting from pitting. Correlation of the results was very good among the three test media using the selected exposure periods. It is concluded that either of the laboratory test media is suitable for evaluating the stress corrosion cracking performance of aluminum alloys in seacoast atmosphere.
Humphries, T. S.↗
Oxidation-chlorination of binary Ni-Cr alloys in flowing Ar-O2-Cl2 gas mixtures at 1200 K
Nickel-chromium alloys are resistant to oxidation because of the selective oxidation of chromium to form a protective Cr2O3 scale. In chlorine-containing environments, volatile corrosion products can also be formed. The mixed oxidation-chlorination of Ni-4.5Cr, Ni-13.8Cr, and Ni-26.5Cr (by weight) alloys in Ar-O2-Cl2 gas mixtures is investigated using thermogravimetric analysis and atmospheric-pressure-sampling mass spectrometry, followed by examination of the corrosion products using scanning electron microscopy and X-ray diffraction analysis. The overall kinetics of the corrosion are affected by the relative amounts of oxides and chlorides formed and the composition of the oxide corrosion products.
Mcnallan, M. J.↗
Performance Of Perfluoropolyalkylether Lubricant System
Perfluoro-polyalkylethers (PFPAE) constitute class of fluids having characteristics of high thermal oxidative stability, good vicosity-temperature characteristics, good elastohydrodynamic film-forming capabilities, low volatility, and non-flammability. One unfortunate drawback PFPAE causes severe metal corrosion and fluid degradation when used in oxidizing atmosphere. Reports of interest deal with synthesis of PFPAE-type liquids and development of additive to reduce oxidizing atmosphere degradation. Properties and molecular structures reported in detail. Also lubricant performance over range of conditions.
Paciorek, K.↗
In Situ Electrosynthesis of Polymethyl Methacrylate Within Ceramic Launch Pad Materials
Electrokinetic deposition of methylmethacrylate is used to mitigate corrosion in reinforced concrete. The methylmethacrylate (MMA) monomer deposits in the pores in the concrete where it is converted into its polymer, polymethylmethacrylate, thus creating a barrier that also enhances the mechanical properties of the concrete. Previous to the MMA treatment an Electrokinetic deposition is used to transport calcium, sodium and potassium hydroxide particles through the capillary pores of concrete directly to the concrete reinforcement. The intent is to use these compounds as a sacrificial electrode layer during the electrokinetic deposition of methylmethacrylate monomer. Cylindrical reinforced concrete specimens were subjected to electrokinetic treatment and the specimens were tested to characterize porosity reduction and tensile splitting strength showing an increase in the tensile strength. In addition, nine specimens treated electro-kinetically and in long-term atmospheric exposure testing at NASA's Kennedy Space Center, seaside atmospheric exposure test site were tested to determine their corrosion rate.
Acevedo, Raul↗
Long Life Molten Salt Battery for NASA Venus Application
A development program is being conducted at Advanced Thermal Batteries (ATB) to create a low discharge rate, long life, molten salt battery for a NASA Venus surface probe. Battery goals are 60 days continuous operation at +25V +0/-6 volts and -25V +6/-0 Volts under severe environments of 465°C, 92 atm pressure, and corrosive sulfur dioxide in a super critical carbon dioxide atmosphere. Conveniently, molten salt thermal battery electrochemistry starts to operate efficiently at 330°C. However, a major barrier to direct application of existing thermal battery technology is the high self-discharge rate, resulting in lifetimes in only minutes, not days. The best performance to date, which meets the required voltage regulation, has been a lithium silicon (LiSi) alloy anode discharging through all three voltage plateau versus an iron monosulfide (FeS) cathode. In order to perform reproducibly, additional engineering controls within the battery design are required to limit cell–to–cell parasitic discharge mechanisms. Results of these trials have improved the efficiency and manufacturability of the design.
Thermal Battery↗
Electrochemical Impedance Spectroscopy of Alloys in a Simulated Space Shuttle Launch Environment
Corrosion studies began at NASA/Kennedy Space Center in 1966 during the Gemini/Apollo Programs with the evaluation of long-term protective coatings for the atmospheric protection of carbon steel. An outdoor exposure facility on the beach near the launch pad was established for this purpose at that time. The site has provided over 35 years of technical information on the evaluation of the long-term corrosion performance of many materials and coatings as well as on maintenance procedures. Results from these evaluations have helped NASA find new materials and processes that increase the safety and reliability of our flight hardware, launch structures, and ground support equipment. The launch environment at the Kennedy Space Center (KSC) is extremely corrosive due to the combination of ocean salt spray, heat, humidity, and sunlight. With the introduction of the Space Shuttle in 1981, the already highly corrosive conditions at the launch pad were rendered even more severe by the acidic exhaust from the solid rocket boosters. Over the years, many materials have been evaluated for their corrosion performance under conditions similar to those found at the launch pads. These studies have typically included atmospheric exposure and evaluation with conventional electrochemical methods such as open circuit potential (OCP) measurements, polarization techniques, and electrochemical impedance spectroscopy (EIS). The atmosphere at the Space Shuttle launch site is aggressive to most metals and causes severe pitting in many of the common stainless steel alloys such as type 304L stainless steel (304L SS). A study was undertaken to find a more corrosion resistant material to replace the existing 304L SS tubing. This paper presents the results from atmospheric exposure as well as electrochemical measurements on the corrosion resistance of AL-6XN (UNS N08367) and 254-SMO (UNS S32154). Type 304L SS (UNS S30403) was used as a control. Conditions at the Space Shuttle launch pad were simulated by using a hydrochloric acid (HC1) and alumina (Al203) slurry rinse for the atmospheric exposure and an electrolyte consisting of 3.55% sodium chloride (NaC1) with increased concentrations of hydrochloric acid (HC1) for the electrochemical measurements. The results from both types of measurements revealed the superior corrosion performance of the higher-alloyed materials. Unlike 304L SS, 254-SMO and AL-6XN exhibited a significantly improved resistance to corrosion as the concentration of hydrochloric acid in he 3.55% NaCl electrolyte solution was increased.
Calle, L. M.↗
Evaluation of present-day thermal barrier coatings for industrial/utility applications
Atmospheric burner rig tests have been conducted to evaluate the corrosion resistance of present-day thermal barrier coatings. The coatings are primarily plasma-sprayed and zirconia-based. Both duplex and graded coating systems were tested at a gas temperature of 2100 F and metal temperatures that range from 1475 F to 1650 F. The fuels ranged from clean GT No. 2 to that doped with impurity levels which simulate water-washed residual fuels. Results to date suggest that liquid sulfate condensates play an important role in the coating degradation mechanisms, whereas the role of vanadium and its salts is less clear.
Bratton, R. J.↗
Weathering of Thermal Control Coatings
Spacecraft radiators reject heat to their surroundings. Radiators can be deployable or mounted on the body of the spacecraft. NASA's Crew Exploration Vehicle is to use body mounted radiators. Coatings play an important role in heat rejection. The coatings provide the radiator surface with the desired optical properties of low solar absorptance and high infrared emittance. These specialized surfaces are applied to the radiator panel in a number of ways, including conventional spraying, plasma spraying, or as an applique. Not specifically designed for a weathering environment, little is known about the durability of conventional paints, coatings, and appliques upon exposure to weathering and subsequent exposure to solar wind and ultraviolet radiation exposure. In addition to maintaining their desired optical properties, the coatings must also continue to adhere to the underlying radiator panel. This is a challenge, as new composite radiator panels are being considered as replacements for the aluminum panels used previously. Various thermal control paints, coatings, and appliques were applied to aluminum and isocyanate ester composite coupons and were exposed for 30 days at the Atmospheric Exposure Site of the Kennedy Space Center s Beach Corrosion Facility for the purpose of identifying their durability to weathering. Selected coupons were subsequently exposed to simulated solar wind and vacuum ultraviolet radiation to identify the effect of a simulated space environment on the as-weathered surfaces. Optical properties and adhesion testing were used to document the durability of the paints and coatings. The purpose of this paper is to present the results of the weathering testing and to summarize the durability of several thermal control paints, coatings, and appliques to weathering and postweathering environments.
Jaworske, Donald A.↗
Optical Properties of Thermal Control Coatings After Weathering, Simulated Ascent Heating, and Simulated Space Radiation Exposure
Spacecraft radiators reject heat to their surroundings and coatings play an important role in this heat rejection. The coatings provide the combined optical properties of low solar absorptance and high infrared emittance. The coatings are applied to the radiator panel in a number of ways, including conventional spraying, plasma spraying, or as an applique. Not designed for a terrestrial weathering environment, the durability of spacecraft paints, coatings, and appliques upon exposure to weathering and subsequent exposure to ascent heating, solar wind, and ultraviolet radiation was studied. In addition to traditional aluminum panels, new isocyanate ester composite panels were exposed for a total of 90 days at the Atmospheric Exposure Site of Kennedy Space Center's (KSC) Beach Corrosion Facility for the purpose of identifying their durability to weathering. Selected panel coupons were subsequently exposed to simulated ascent heating, solar wind, and vacuum ultraviolet (UV) radiation to identify the effect of a simulated space environment on as-weathered surfaces. Optical properties and adhesion testing were used to document the durability of the paints, coatings, and appliques.
Jaworske, Donald A.↗
Advanced Coating Removal Techniques
An important step in the repair and protection against corrosion damage is the safe removal of the oxidation and protective coatings without further damaging the integrity of the substrate. Two such methods that are proving to be safe and effective in this task are liquid nitrogen and laser removal operations. Laser technology used for the removal of protective coatings is currently being researched and implemented in various areas of the aerospace industry. Delivering thousands of focused energy pulses, the laser ablates the coating surface by heating and dissolving the material applied to the substrate. The metal substrate will reflect the laser and redirect the energy to any remaining protective coating, thus preventing any collateral damage the substrate may suffer throughout the process. Liquid nitrogen jets are comparable to blasting with an ultra high-pressure water jet but without the residual liquid that requires collection and removal .As the liquid nitrogen reaches the surface it is transformed into gaseous nitrogen and reenters the atmosphere without any contamination to surrounding hardware. These innovative technologies simplify corrosion repair by eliminating hazardous chemicals and repetitive manual labor from the coating removal process. One very significant advantage is the reduction of particulate contamination exposure to personnel. With the removal of coatings adjacent to sensitive flight hardware, a benefit of each technique for the space program is that no contamination such as beads, water, or sanding residue is left behind when the job is finished. One primary concern is the safe removal of coatings from thin aluminum honeycomb face sheet. NASA recently conducted thermal testing on liquid nitrogen systems and found that no damage occurred on 1/6", aluminum substrates. Wright Patterson Air Force Base in conjunction with Boeing and NASA is currently testing the laser remOval technique for process qualification. Other applications of liquid nitrogen operations include cutting of both soft and hard materials. While the laser will not cut materials, it can be used to roughen surfaces and to remove other materials from the substrate including oil, grease, and mold. The space program can benefit from several of these applications with the need for precise removal of coatings and other organic compounds in areas adjacent to sensitive space flight hardware. Significant advantages are evident when comparing liquid nitrogen and laser removal operations over current techniques of media blasting and sanding.
Seibert, Jon↗
Corrosion of metal particle and metal evaporated tapes
Very high coercivity metal particle (MP) and metal evaporated (ME) tapes are being used in 8mm video and digital audio tape applications, and more recently in digital data recording applications. In view of the inherent susceptibility of such media to environmental corrosion, a number of recent studies have addressed their long term stability and archivability. These studies have used an accelerated corrosion test based either on elevated temperature-humidity or polluting gas atmospheres known as Battelle tests. A comparison of the Battelle test results performed at different laboratories reveals a large variation from one location to another, presumably due to incorrect replication of the Battelle condition. Furthermore, when the Battelle tests are performed on enclosed cartridges, it is quite possible that diffusion limits the penetration of the extremely low concentration polluting gaseous species to the inner layers of the tapes during the short time of the accelerated test, whereas in real life these diffusion limitations may not apply. To avoid this uncertainty, the corrosion behavior of commercial 8mm MP and ME tapes when cassettes without their external plastic cases were exposed to 50 deg C and 80 percent RH for 7.5 weeks is investigated.
Speliotis, Dennis E.↗
Fabrication of cermet bearings for the control system of a high temperature lithium cooled nuclear reactor
The techniques used to fabricate cermet bearings for the fueled control drums of a liquid metal cooled reference-design reactor concept are presented. The bearings were designed for operation in lithium for as long as 5 years at temperatures to 1205 C. Two sets of bearings were fabricated from a hafnium carbide - 8-wt. % molybdenum - 2-wt. % niobium carbide cermet, and two sets were fabricated from a hafnium nitride - 10-wt. % tungsten cermet. Procedures were developed for synthesizing the material in high purity inert-atmosphere glove boxes to minimize oxygen content in order to enhance corrosion resistance. Techniques were developed for pressing cylindrical billets to conserve materials and to reduce machining requirements. Finishing was accomplished by a combination of diamond grinding, electrodischarge machining, and diamond lapping. Samples were characterized in respect to composition, impurity level, lattice parameter, microstructure and density.
Yacobucci, H. G.↗
Adsorption of O2, SO2, and SO3, on nickel oxide - Mechanism for sulfate formation
Calculations based on the atom superposition and electron delocalization molecular orbital technique suggest that O2 will adsorb preferentially end-on at an angle 45 deg from normal on a nickel cation site on the (100) surface of NiO. SO2 adsorption is also stronger on the nickel site; SO2 bonds through the sulfur atom in a plane perpendicular to the surface. Adsorption energies for SO3 on the nickel and oxygen sites are comparable in the preferred orientation in which the SO3 plane is parallel to the surface. The calculations suggest that the strength of adsorption varies as O2 greater than SO2 greater than SO3. On activation, SO3 adsorbed to an O(2-) site forms a trigonal pyramidal SO4 species which yields, with a low barrier, a tetrahedral sulfate anion. Subsequently the anion reorients on the surface. Alternative mechanisms which require the formation of Ni(3+) or O(-) are discussed. NiSO4 thus formed may play a passivating role for the corrosion of Ni at low temperatures in the SO2 + O2 + SO3 atmospheres and an active role at high temperatures, as discussed in the experimental literature.
Mehandru, S. P.↗
Sintered silicon nitrode recuperator fabrication
The preliminary design and a demonstration of the feasibility of fabricating submodules of an automotive Stirling engine recuperator for waste heat recovery at 370 C are described. Sinterable silicon nitride (Sialon) tubing and plates were fabricated by extrusion and hydrostatic pressing, respectively, suitable for demonstrating a potential method of constructing ceramic recuperator-type heat exchangers. These components were fired in nitrogen atmosphere to 1800 C without significant scale formation so that they can be used in the as-fired condition. A refractory glass composition (Al2O3 x 4.5 CaO.MgO x 11SiO2) was used to join and seal component parts by a brazing technique which formed strong recuperator submodules capable of withstanding repeated thermal cycling to 1370 C. The corrosion resistance of these materials to Na2SO4 + NaCl carbon mixtures was also assessed in atmospheres of air, hydrogen and CO2-N2-H2O mixtures at both 870 C and 1370 C for times to 1000 hours. No significant reaction was observed under any of these test conditions.
Gatti, A.↗
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's Corrosion Technology Laboratory at the Kennedy Space Center: Anticipating, Managing, and Preventing Corrosion
Corrosion is the degradation of a material that results from its interaction with the environment. The marine environment at NASAs Kennedy Space Center (KSC) has been documented by ASM International (formerly American Society for Metals) as the most corrosive in the United States. With the introduction of the Space Shuttle in 1981, the already highly corrosive conditions at the launch pads were rendered even more severe by the 70 tons of highly corrosive hydrochloric acid that were generated by the solid rocket boosters. Numerous failures at the launch pads are caused by corrosion.The structural integrity of ground infrastructure and flight hardware is critical to the success, safety, cost, and sustainability of space missions. As a result of fifty years of experience with launch and ground operations in a natural marine environment that is highly corrosive, NASAs Corrosion Technology Laboratory at KSC is a major source of corrosion control expertise in the launch and other environments. Throughout its history, the Laboratory has evolved from what started as an atmospheric exposure facility near NASAs launch pads into a world-wide recognized capability that provides technical innovations and engineering services in all areas of corrosion for NASA and external customers.This presentation will provide a historical overview of the role of NASAs Corrosion Technology in anticipating, managing, and preventing corrosion. One important challenge in managing and preventing corrosion involves the detrimental impact on humans and the environment of what have been very effective corrosion control strategies. This challenge has motivated the development of new corrosion control technologies that are more effective and environmentally friendly. Strategies for improved corrosion protection and durability can have a huge impact on the economic sustainability of human spaceflight operations.
Corrosion↗