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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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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Finite Element Models for Electron Beam Freeform Fabrication Process

Electron beam freeform fabrication (EBF3) is a member of an emerging class of direct manufacturing processes known as solid freeform fabrication (SFF); another member of the class is the laser deposition process. Successful application of the EBF3 process requires precise control of a number of process parameters such as the EB power, speed, and metal feed rate in order to ensure thermal management; good fusion between the substrate and the first layer and between successive layers; minimize part distortion and residual stresses; and control the microstructure of the finished product. This is the only effort thus far that has addressed computer simulation of the EBF3 process. The models developed in this effort can assist in reducing the number of trials in the laboratory or on the shop floor while making high-quality parts. With some modifications, their use can be further extended to the simulation of laser, TIG (tungsten inert gas), and other deposition processes. A solid mechanics-based finite element code, ABAQUS, was chosen as the primary engine in developing these models whereas a computational fluid dynamics (CFD) code, Fluent, was used in a support role. Several innovative concepts were developed, some of which are highlighted below. These concepts were implemented in a number of new computer models either in the form of stand-alone programs or as user subroutines for ABAQUS and Fluent codes. A database of thermo-physical, mechanical, fluid, and metallurgical properties of stainless steel 304 was developed. Computing models for Gaussian and raster modes of the electron beam heat input were developed. Also, new schemes were devised to account for the heat sink effect during the deposition process. These innovations, and others, lead to improved models for thermal management and prediction of transient/residual stresses and distortions. Two approaches for the prediction of microstructure were pursued. The first was an empirical approach involving the computation of thermal gradient, solidification rate, and velocity (G,R,V) coupled with the use of a solidification map that should be known a priori. The second approach relies completely on computer simulation. For this purpose a criterion for the prediction of morphology was proposed, which was combined with three alternative models for the prediction of microstructure; one based on solidification kinetics, the second on phase diagram, and the third on differential scanning calorimetry data. The last was found to be the simplest and the most versatile; it can be used with multicomponent alloys and rapid solidification without any additional difficulty. For the purpose of (limited) experimental validation, finite element models developed in this effort were applied to three different shapes made of stainless steel 304 material, designed expressly for this effort with an increasing level of complexity. These finite element models require large computation time, especially when applied to deposits with multiple adjacent beads and layers. This problem can be overcome, to some extent, by the use of fast, multi-core computers. Also, due to their numerical nature coupled with the fact that solid mechanics- based models are being used to represent the material behavior in liquid and vapor phases as well, the models have some inherent approximations that become more pronounced when dealing with multi-bead and multi-layer deposits.

Chandra, Umesh↗
NASA NTRS1933

The Mechanism of Atomization Accompanying Solid Injection

A brief historical and descriptive account of solid injection is followed by a detailed review of the available theoretical and experimental data that seem to throw light on the mechanism of this form of atomization. It is concluded that this evidence indicates that (1) the atomization accompanying solid injection occurs at the surface of the liquid after it issues as a solid stream from the orifice; and (2) that such atomization has a mechanism physically identical with the atomization which takes place in an air stream, both being due merely to the formation, at the gas-liquid interface, of fine ligaments under the influence of the relative motion of gas and liquid, and to their collapse, under the influence of surface tension, to form the drops in the spray.

Castleman, R A , Jr↗
NASA NTRS2014

CO Self-Shielding as a Mechanism to Make O-16 Enriched Solids in the Solar Nebula

Photochemical self-shielding of CO has been proposed as a mechanism to produce solids observed in the modern, O-16 depleted solar system. This is distinct from the relatively O-16 enriched composition of the solar nebula, as demonstrated by the oxygen isotopic composition of the contemporary sun. While supporting the idea that self-shielding can produce local enhancements in O-16 depleted solids, we argue that complementary enhancements of O-16 enriched solids can also be produced via CO-16 based, Fischer-Tropsch type (FTT) catalytic processes that could produce much of the carbonaceous feedstock incorporated into accreting planetesimals. Local enhancements could explain observed O-16 enrichment in calcium-aluminum-rich inclusions (CAIs), such as those from the meteorite, Isheyevo (CH/CHb), as well as in chondrules from the meteorite, Acfer 214 (CH3). CO selfshielding results in an overall increase in the O-17 and O-18 content of nebular solids only to the extent that there is a net loss of CO-16 from the solar nebula. In contrast, if CO-16 reacts in the nebula to produce organics and water then the net effect of the self-shielding process will be negligible for the average oxygen isotopic content of nebular solids and other mechanisms must be sought to produce the observed dichotomy between oxygen in the Sun and that in meteorites and the terrestrial planets. This illustrates that the formation and metamorphism of rocks and organics need to be considered in tandem rather than as isolated reaction networks.

Solar Nebula↗
NASA NTRS1993

CFD flowfield simulation of Delta Launch Vehicles in a power-on configuration

This paper summarizes recent work at McDonnell Douglas Aerospace (MDA) to develop and validate computational fluid dynamic (CFD) simulations of under expanded rocket plume external flowfields for multibody expendable launch vehicles (ELVs). Multi engine reacting gas flowfield predictions of ELV base pressures are needed to define vehicle base drag and base heating rates for sizing external nozzle and base region insulation thicknesses. Previous ELV design programs used expensive multibody power-on wind tunnel tests that employed chamber/nozzle injected high pressure cold or hot-air. Base heating and pressure measurements were belatedly made during the first flights of past ELV's to correct estimates from semi-empirical engineering models or scale model tests. Presently, CFD methods for use in ELV design are being jointly developed at the Space Transportation Division (MDA-STD) and New Aircraft Missiles Division (MDA-NAMD). An explicit three dimensional, zonal, finite-volume, full Navier-Stokes (FNS) solver with finite rate hydrocarbon/air and aluminum combustion kinetics was developed to accurately compute ELV power-on flowfields. Mississippi State University's GENIE++ general purpose interactive grid generation code was chosen to create zonal, finite volume viscous grids. Axisymmetric, time dependent, turbulent CFD simulations of a Delta DSV-2A vehicle with a MB-3 liquid main engine burning RJ-1/LOX were first completed. Hydrocarbon chemical kinetics and a k-epsilon turbulence model were employed and predictions were validated with flight measurements of base pressure and temperature. Zonal internal/external grids were created for a Delta DSV-2C vehicle with a MB-3 and three Castor-1 solid motors burning and a Delta-2 with an RS-27 main engine (LOX/RP-1) and 9 GEM's attached/6 burning. Cold air, time dependent FNS calculations were performed for DSV-2C during 1992. Single phase simulations that employ finite rate hydrocarbon and aluminum (solid fuel) combustion chemistry are currently in progress. Reliable and efficient Eulerian algorithms are needed to model two phase (solid-gas) momentum and energy transfer mechanisms for solid motor fuel combustion products.

Pavish, D. L.↗
NASA NTRS2000

Mechanical Property Allowables Generated for the Solid Rocket Booster Composite Note Cap

Mechanical property characterization was performed on AS4/3501-6 graphite/epoxy and SC350G syntactic foam for the SRB Composite Nose Cap Shuttle Upgrades Project. Lamina level properties for the graphite/epoxy were determined at room temperature, 240 F, 350 F, 480 F, 600 F, and 350 F after a cycle to 600 F. Graphite/epoxy samples were moisture conditioned prior to testing. The syntactic foam material was tested at room temperature, 350 F, and 480 F. A high-temperature test facility was developed at MSFC. Testing was performed with quartz lamp heaters and high resistance heater strips. The thermal history profile of the nose cap was simulated in order to test materials at various times during launch. A correlation study was performed with Southern Research Institute to confirm the test methodology and validity of test results. A-basis allowables were generated from the results of testing on three lots of material.

Hodge, A. J.↗
NASA NTRS1980

Effect of load, area of contact, and contact stress on the wear mechanisms of a bonded solid lubricant film

A pin on disk type of friction and wear apparatus was used to study the effect of load, contact stress and rider area of contact on the friction and wear properties of polyimide bonded graphite fluoride films. Different rider area contacts were obtained by initially generating flats (with areas of 0.0035, 0.0071, 0.0145, and 0.0240 cm) on 0.476-cm radius hemispherically tipped riders. Different projected contact stresses were obtained by applying loads of 2.5- to 58.8-N to the flats. Two film wear mechanisms were observed. The first was found to be a linear function of contact stress and was independent of rider area of contact. The second was found to increase exponentially as the stress increased. The second also appeared to be a function of rider contact area. Wear equations for each mechanism were empirically derived from the experimental data. In general, friction coefficients increased with increasing rider contact area and with sliding duration. This was related to the build up of thick rider transfer films.

Fusaro, R. L.↗
NASA NTRS2006

Mechanical Characterization of ZnSe Windows for Use With the Flow Enclosure Accommodating Novel Investigations in Combustion of Solids (FEANICS) Module

Mechanical and physical properties of ZnSe windows to be used with the FEANICS (Flow Enclosure Accommodating Novel Investigations in Combustion of Solids) experiments were measured in order to determine design allowables. The average Young s modulus, Poisson's ratio, equibiaxial fracture strength, flaw size, grain size, Knoop hardness, Vicker s hardness, and branching constant were 74.3 +/- 0.1 GPa, 0.31, 57.8 +/- 6.5 MPa, 21 +/- 4 mm, 43 +/- 9 microns, 0.97 +/- 0.02 GPa, 0.97 +/- 0.02 GPa, and 1.0 +/- 0.1 MPa(square root of)m, respectively. The properties of current ZnSe made by chemical vapor deposition are in good agreement with those measured in the 1970 s. The hardness of CVD ZnSe windows is about one-twentieth of the sapphire window being replaced, and about one-sixth of that of window glass. Thus the ZnSe window must be handled with great care. The large grain size relative to the inherent crack size implies the need to use single crystal crack growth properties in the design process. In order to determine the local failure stresses in one of the test specimens, a solution for the stresses between the support ring and the edge of a circular plate load between concentric rings was derived

Salem, Jonathan A.↗
NASA NTRS1976

A description of the mechanical behavior of composite solid propellants based on molecular theory

Both the investigation and the representation of the stress-strain response (including rupture) of gum and filled elastomers can be based on a simple functional statement. Internally consistent experiments are used to sort out the effects of time, temperature, strain and crosslink density on gum rubbers. All effects are readily correlated and shown to be essentially independent of the elastomer when considered in terms of non-dimensionalized stress, strain and time. A semiquantitative molecular theory is developed to explain this result. The introduction of fillers modifies the response, but, guided by the framework thus provided, their effects can be readily accounted for.

Landel, R. F.↗
NASA NTRS1978

Mechanism of combustion of solid carbon

Measurements of temperature distribution in the reaction zone above the surface of carbon were studied. Using a method of spectral line reversal it was found that the minimum temperature in that zone is several hundred degrees higher than that of the carbon surface.

Degraaf, J. G. A.↗
NASA NTRS1986

How to evaluate solid lubricant films using a pin-on-disk tribometer

Over the years, the author has evaluated and compared hundreds of solid lubricant films using a pin-on-disk tribometer. The intent of this paper is to describe to the reader experimental techniques and some of parameters that have been observed to be important for the evaluation and development of new solid lubricant films. Pin-on-disk tribometers will be described and discussed as will experimental methods for evaluating solid lubricant materials. Methods of preparing surfaces for the coating of the thin films and different methods for applying the films will be reviewed. Factors that affect solid lubricant performance will also be discussed. Two different macroscopic mechanisms of solid lubricant film wear exist. These will be characterized schematically, and methods of measuring wear will be examined.

Fusaro, R. L.↗
NASA NTRS1987

How to evaluate solid lubricant films using a Pin-on-disk tribometer

Over the years, the author has evaluated and compared hundreds of solid lubricant films using a Pin-on-disk tribometer. The intent of this paper is to describe to the reader experimental techniques and some of the parameters that have been observed to be important for the evaluation and development of new solid lubricant films. Pin-on-disk tribometers will be described and discussed as will experimental methods for evaluating solid lubricant materials. Methods of preparing surfaces for the coating of the thin films and different methods for applying the films will be reviewed. Factors that affect solid lubricant performance will also be discussed. Two different macroscopic mechanisms of solid lubricant film wear exist. These will be characterized schematically, and methods of measuring wear will be examined.

Fusaro, Robert L.↗