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NASA NTRS2002

Techniques Optimized for Reducing Instabilities in Advanced Nickel-Base Superalloys for Turbine Blades

The High-Speed Research (HSR) Airfoil Alloy program developed fourth-generation single-crystal superalloys with up to an 85 F increase in creep rupture capability over current production airfoil alloys. Recent results have been generated at the NASA Glenn Research Center on these fourth-generation alloys, but in coated form, for subsonic turbine blade applications under NASA's Ultra-Efficient Engine Technology (UEET) Program. One goal for UEET is to optimize the airfoil alloy/thermal barrier coating system for 3100 F turbine inlet temperatures. The state-of-the art turbine blade airfoil system consists of a superalloy single crystal that provides the basic mechanical performance of the airfoil. A thermal barrier coating is used to reduce the temperature of the base superalloy, and a bondcoat is deposited between the base material and the thermal barrier coating. The bondcoat improves the oxidation and corrosion resistance of the base superalloy and improves the spallation resistance of the thermal barrier coating. A commercial platinum aluminide bondcoat was applied to the HSR-developed alloys, and a diffusion zone developed as a result of interaction between the bondcoat and the superalloy. Optimized strength is obtained for superalloys when the refractory element content is high and the limits of microstructural stability are approached or exceeded slightly. For fourthgeneration alloys, instability leads to the formation of topologically close packed (TCP) phases, which form internally in the superalloy, and a secondary reaction zone (SRZ), which forms under the diffusion zone. There was a concern that excessive quantities of either TCP or SRZ might decrease the mechanical properties of the superalloy, with SRZ thought to be particularly detrimental and its formation unpredictable. Thus, an SRZreduction effort was initiated in the NASA UEET Program so that methods developed during the HSR project could be optimized further to reduce or eliminate the SRZ. An SRZ is a three-phase constituent composed of TCP and stringers of gamma phase in a matrix of gamma prime. An incoherent grain boundary separates the SRZ from the gammagamma prime microstructure of the superalloy. The SRZ is believed to form as a result of local chemistry changes in the superalloy due to the application of the diffusion aluminide bondcoat. Locally high surface stresses also appear to promote the formation of the SRZ. Thus, techniques that change the local alloy chemistry or reduce surface stresses have been examined for their effectiveness in reducing SRZ. These SRZ-reduction steps are performed on the test specimen or the turbine blade before the bondcoat is applied. Stressrelief heat treatments developed at NASA Glenn have been demonstrated to reduce significantly the amount of SRZ that develops during subsequent high-temperature exposures. Stress-relief heat treatments reduce surface stresses by recrystallizing a thin surface layer of the superalloy. However, in alloys with very high propensities to form SRZ, stress relief heat treatments alone do not eliminate SRZ entirely. Thus, techniques that modify the local chemistry under the bondcoat have been emphasized and optimized successfully at Glenn. One such technique is carburization, which changes the local chemistry by forming submicron carbides near the surface of the superalloy. Detailed characterizations have demonstrated that the depth and uniform distribution of these carbides are enhanced when a stress relief treatment and an appropriate surface preparation are employed in advance of the carburization treatment. Even in alloys that have the propensity to develop a continuous SRZ layer beneath the diffusion zone, the SRZ has been completely eliminated or reduced to low, manageable levels when this combination of techniques is utilized. Now that the techniques to mitigate SRZ have been established at Glenn, TCP phase formation is being emphasized in ongoing work under the UEET Program. The limitsf stability of the fourth-generation alloys with respect to TCP phase formation are currently being defined along with high-temperature creep rupture properties. In addition, a regression model is being developed at Glenn for the prediction of the presence of TCP phase in the microstructure and SRZ under the diffusion zone. The model is based on a design-of-experiments methodology with emphasis on the potential synergistic effects of alloying elements.

MacKay, Rebecca A.↗

NASA NTRS1987

The nonlinear thermodynamics of meteors, noctilucent clouds, enhanced airglow and global atmospheric circulation

Two types of fundamental topological junctions of elements are deduced from a nonlinear thermodynamical model. Using this scheme, the possibility of a causal relation between fireballs and faint meteors as nonlinear sources on the one hand, and noctilucent clouds (NC) and Hoffmeister's enhanced airglow (EA) as complementary formative processes in the middle atmosphere and ionosphere, on the other hand, is examined. The principal role of the global atmospheric circulation in this relation is demonstrated. Such circulation in the mesosphere appears to prevent the neutral dust dissipated by fireballs from becoming an efficient agent in NLC generation. In this case, the behavior of ionized material deposited by both the bright and faint meteors is more probably controlled, as shown from the annual variation of the E sub s layer by the darkness of lunar eclipses and the global circulation of the lower thermosphere. The role of fireballs and neutral dust might be more significant as a source of EA phenomenon.

Rajchl, J.↗

NASA NTRS2014

Elastomeric Structural Attachment Concepts for Aircraft Flap Noise Reduction - Challenges and Approaches to Hyperelastic Structural Modeling and Analysis

Airframe noise is a significant part of the overall noise of transport aircraft during the approach and landing phases of flight. Airframe noise reduction is currently emphasized under the Environmentally Responsible Aviation (ERA) and Fixed Wing (FW) Project goals of NASA. A promising concept for trailing-edge-flap noise reduction is a flexible structural element or link that connects the side edges of the deployable flap to the adjacent main-wing structure. The proposed solution is distinguished by minimization of the span-wise extent of the structural link, thereby minimizing the aerodynamic load on the link structure at the expense of increased deformation requirement. Development of such a flexible structural link necessitated application of hyperelastic materials, atypical structural configurations and novel interface hardware. The resulting highly-deformable structural concept was termed the FLEXible Side Edge Link (FLEXSEL) concept. Prediction of atypical elastomeric deformation responses from detailed structural analysis was essential for evaluating feasible concepts that met the design constraints. The focus of this paper is to describe the many challenges encountered with hyperelastic finite element modeling and the nonlinear structural analysis of evolving FLEXSEL concepts. Detailed herein is the nonlinear analysis of FLEXSEL concepts that emerged during the project which include solid-section, foamcore, hollow, extended-span and pre-stressed concepts. Coupon-level analysis performed on elastomeric interface joints, which form a part of the FLEXSEL topology development, are also presented.

Sreekantamurthy, Thammaiah↗

NASA NTRS1983

Topological reaction rate measurements related to scoffing

A ball-on-plate (both consisting of hardened M-50 steel) sliding elastohydrodynamic contact was run with trimethylolpropane triheptanoate (TMPTH) with and without tricresyl phosphate (TCP). The contact area of the plate was optically profiled with a phase-locked interference microscope (PLIM) both before and after exposure to alcoholic hydrochloric acid. As scuffing was approached, the profile within the contact region changed more rapidly after the acid treatment; after scuffing, it assumed a constant high value. A metallurgical phase found in the scuff mark was apparently responsible for the high reactivity. The microscopic profile changes (sensitivity, + or - 3 nm (+ or - A) in depth) involved primarily the small asperities (radius, 3 microns); the larger ones were unaffected. Soaking the steel in TCP smoothed the fine structure of the surface profile but increased its reactivity toward alcoholic hydrochloric acid before sliding was started. Thus it would appear that PLIM examination could be used for screening potentially scuff-resistant materials.

Lauer, J. L.↗

NASA NTRS1984

Topological reaction rate measurements related to scuffing

Lauer, J. L.↗

NASA NTRS2006

In-Space Radiator Shape Optimization using Genetic Algorithms

Future space exploration missions will require the development of more advanced in-space radiators. These radiators should be highly efficient and lightweight, deployable heat rejection systems. Typical radiators for in-space heat mitigation commonly comprise a substantial portion of the total vehicle mass. A small mass savings of even 5-10% can greatly improve vehicle performance. The objective of this paper is to present the development of detailed tools for the analysis and design of in-space radiators using evolutionary computation techniques. The optimality criterion is defined as a two-dimensional radiator with a shape demonstrating the smallest mass for the greatest overall heat transfer, thus the end result is a set of highly functional radiator designs. This cross-disciplinary work combines topology optimization and thermal analysis design by means of a genetic algorithm The proposed design tool consists of the following steps; design parameterization based on the exterior boundary of the radiator, objective function definition (mass minimization and heat loss maximization), objective function evaluation via finite element analysis (thermal radiation analysis) and optimization based on evolutionary algorithms. The radiator design problem is defined as follows: the input force is a driving temperature and the output reaction is heat loss. Appropriate modeling of the space environment is added to capture its effect on the radiator. The design parameters chosen for this radiator shape optimization problem fall into two classes, variable height along the width of the radiator and a spline curve defining the -material boundary of the radiator. The implementation of multiple design parameter schemes allows the user to have more confidence in the radiator optimization tool upon demonstration of convergence between the two design parameter schemes. This tool easily allows the user to manipulate the driving temperature regions thus permitting detailed design of in-space radiators for unique situations. Preliminary results indicate an optimized shape following that of the temperature distribution regions in the "cooler" portions of the radiator. The results closely follow the expected radiator shape.

Hull, Patrick V.↗

NASA NTRS1998

Martian Polar Region Impact Craters: Topographical Perspectives from the Mars Orbiter Laser Altimeter

The Mars Orbiter Laser Altimeter (MOLA) has acquired over 100 topographic cross-sections of impact landforms in the polar regions of Mars as part of Mars Global Surveyor (MGS) Science Phasing Orbit observations during the period from April to July, 1998. These MOLA topographic profiles offer the first three-dimensional perspectives of high latitude craters on Mars yet available, and provide evidence of landform geometries not previously recognized. Indeed, the relatively poor quality of Viking Orbiter images of many high northern latitude regions has allowed the MOLA data to provide insights into the cavities and ejecta topologies of non-degraded impact landforms that have clearly experienced interactions with condensates, either as part of their formation, or as a post-modification stage effect. Here we report a preliminary summary of the results associated with topographic measurements for a statistically significant population of impact features all of which lie north of 60N latitude. MOLA sampled four impact features with frost-related interior deposits, including the 81 km (diameter) Korolev feature. In several cases, there is evidence from near-centerline MOLA cross-sections of crater interior features (i.e., central peak or ice-dust deposits) that are anomalously large relative to the crater cavity. Central structures that make up more than 50% of the volume of a crater cavity are observed, suggesting that either substantial accumulation of mantling materials has occurred, or that crater excavation triggered production of volume-enhancing materials (ice?). Pedestal craters sampled by MOLA also attest to enhanced production of ejecta materials in high latitude terrains. For example, many of the pedestal craters suggest a volume of ejecta (Ve) to volume of cavity (Vc) ratio far in excess of 1.0 (i.e., over 3.0), even in cases where the floor of the cavity appears unfilled. Finally, the well-defined transitions between simple and complex craters observed in MOLA data for non-polar latitude impact features is not preserved at high northern latitudes (for non-degraded craters). This further suggests the role of target materials (i.e., frozen volatiles?) in the cratering process on Mars in such regions.

Garvin, J. B.↗

NASA NTRS2018

NASA Additive Manufacturing Initiatives for Deep Space Human Exploration

Additive Manufacturing (AM) is being infused into aerospace industries at an accelerated pace. Reasons for this rapid adoption include: (1) Innovation Capability e.g. design features such as topology optimization, integrated fluid passages, and mesh structures; (2) Rapid Development and Optimization - ability to quickly iterate the design, development, and test cycle; (3) Affordability - reductions in part counts, cost, and schedule. NASA's Marshall Space Flight Center (MSFC) has taken a leadership role in application of AM technologies for deep space human exploration, leading the Agency's In Space Manufacturing (ISM) initiative and the application of AM for a broad variety of space propulsion systems. MSFC has championed the development of ISM capabilities since our first reduced-gravity aircraft experiment flew in 1999. Partnering with Made In Space, MSFC placed the first 3D Printer on ISS in 2014 and the second generation printer, the Additive Manufacturing Facility, in 2016. The next ISS technology demonstration will be the Refabricator, a recycler/basic printer scheduled to launch in late Fall 2018. Ground-based development is progressing in common use materials, metals 3D printing, printed electronics, and the new cornerstone of ISM, the FabLab. The latest developments in each area will be described. An overview of NASA's In Space Robotic Manufacturing and Assembly (IRMA) ground-based risk reduction projects will also be presented. MSFC has aggressively incorporated AM capabilities for design and development of space propulsion components. The capabilities have been rapidly matured and extensively exercised to produce and hot-fire test the Additive Manufacturing Demonstrator Engine, an in-space class prototype engine. This experience base has been extended to support Aerojet Rocketdyne in the application of AM to the RS-25, the Space Launch System Core Stage engine, and to small propulsion systems and thrusters for small satellites and cubesats. The latest developments will be described. In responding to a request from NASA's Commercial Crew Program for a consistent methodology for evaluation of AM processes and parts, MSFC began development of a draft standard for AM space flight hardware in late 2014. The draft was broadly disseminated for comments in mid-2015, and subsequently revised into two documents, a standard and a specification for AM space flight hardware, which were formally released by MSFC in October 2017. An overview of the key elements of these documents will be presented.

Clinton, Raymond↗

NASA NTRS2006

CAPRI: A Geometric Foundation for Computational Analysis and Design

CAPRI is a software building tool-kit that refers to two ideas; (1) A simplified, object-oriented, hierarchical view of a solid part integrating both geometry and topology definitions, and (2) programming access to this part or assembly and any attached data. A complete definition of the geometry and application programming interface can be found in the document CAPRI: Computational Analysis PRogramming Interface appended to this report. In summary the interface is subdivided into the following functional components: 1. Utility routines -- These routines include the initialization of CAPRI, loading CAD parts and querying the operational status as well as closing the system down. 2. Geometry data-base queries -- This group of functions allow all top level applications to figure out and get detailed information on any geometric component in the Volume definition. 3. Point queries -- These calls allow grid generators, or solvers doing node adaptation, to snap points directly onto geometric entities. 4. Calculated or geometrically derived queries -- These entry points calculate data from the geometry to aid in grid generation. 5. Boundary data routines -- This part of CAPRI allows general data to be attached to Boundaries so that the boundary conditions can be specified and stored within CAPRI s data-base. 6. Tag based routines -- This part of the API allows the specification of properties associated with either the Volume (material properties) or Boundary (surface properties) entities. 7. Geometry based interpolation routines -- This part of the API facilitates Multi-disciplinary coupling and allows zooming through Boundary Attachments. 8. Geometric creation and manipulation -- These calls facilitate constructing simple solid entities and perform the Boolean solid operations. Geometry constructed in this manner has the advantage that if the data is kept consistent with the CAD package, therefore a new design can be incorporated directly and is manufacturable. 9. Master Model access This addition to the API allows for the querying of the parameters and dimensions of the model. The feature tree is also exposed so it is easy to see where the parameters are applied. Calls exist to allow for the modification of the parameters and the suppression/unsuppression of nodes in the tree. Part regeneration is performed by a single API call and a new part becomes available within CAPRI (if the regeneration was successful). This is described in a separate document. Components 1-7 are considered the CAPRI base level reader.

Haimes, Robert↗

NASA NTRS2009

Performance of a Cylindrical Hall-Effect Thruster Using Permanent Magnets

While annular Hall thrusters can operate at high efficiency at kW power levels, it is difficult to construct one that operates over a broad envelope from 1 kW down to 100 W while maintaining an efficiency of 45-55%. Scaling to low power while holding the main dimensionless parameters constant requires a decrease in the thruster channel size and an increase in the magnetic field strength. Increasing the magnetic field becomes technically challenging since the field can saturate the miniaturized inner components of the magnetic circuit and scaling down the magnetic circuit leaves very little room for magnetic pole pieces and heat shields. In addition, the central magnetic pole piece defining the interior wall of the annular channel can experience excessive heat loads in a miniaturized Hall thruster, with the temperature eventually exceeding the Curie temperature of the material and in extreme circumstances leading to accelerated erosion of the channel wall. An alternative approach is to employ a cylindrical Hall thruster (CHT) geometry. Laboratory model CHTs have operated at power levels ranging from 50 W up to 1 kW. These thrusters exhibit performance characteristics that are comparable to conventional, annular Hall thrusters of similar size. Compared to the annular Hall thruster, the CHTs insulator surface area to discharge chamber volume ratio is lower. Consequently, there is the potential for reduced wall losses in the channel of a CHT, and any reduction in wall losses should translate into lower channel heating rates and reduced erosion, making the CHT geometry promising for low-power applications. This potential for high performance in the low-power regime has served as the impetus for research and development efforts aimed at understanding and improving CHT performance. Recently, a 2.6 cm channel diameter permanent magnet CHT (shown in Fig. 1) was tested. This thruster has the promise of reduced power consumption over previous CHT iterations that employed electromagnets. Data are presented to expose the effect different controllable parameters have on the discharge and to summarize performance measurements (thrust, Isp, efficiency) obtained using a thrust stand. In addition, beam current data are presented to show the effect of the magnetic field topology on the plume profile and current utilization and to gain insight into the thruster s operation. These data extend and improve upon the results previously presented by the authors in Ref. [1].

Polzin, Kurt A.↗

NASA NTRS1993

Comparative study of x ray and microwave emissions during solar flares

The work supported by the grant consisted of two projects. The first project involved making detailed case studies of two flares using SMM data in conjunction with ground based observations. The first flare occurred at 1454 UT on June 20, 1989 and involved the eruption of a prominence near the limb. In the study we used data from many wavelength regimes including the radio, H-alpha, hard X-rays, and soft X-rays. We used a full gyrosynchrotron code to model the apparent presence of a 1.4 GHz source early in the flare that was in the form of a large coronal loop. The model results lead us to conclude that the initial acceleration occurs in small, dense loops which also produced the flare's hard X-ray emission. We also found evidence that a source at 1.4 GHz later in the event was due to second harmonic plasma emission. This source was adjacent to a leg of the prominence and comes from a dense column of material in the magnetic structure supporting the prominence. Finally, we investigated a source of microwaves and soft X-rays, occurring approximately 10 min after the hard X-ray peak, and calculate a lower limit for the density of the source. The second flare that was studied occurred at 2156 UT on June 20, 1989 and was observed with the VLA and the Owens Valley Radio Observatory (OVRO) Frequency Agile Array. We have developed a gyrosynchrotron model of the sources at flare peak using a new gyrosynchrotron approximation which is valid at very low harmonics of the gyrofrequency. We found that the accelerated particle densities of the sources decreased much more with radius from the source center than had been supposed in previous work, while the magnetic field varied less. We also used the available data to analyze a highly polarized source which appeared late in the flare. The second project involved compiling a statistical base for the relative timing of the hard X-ray peak, the turbulent and blue-shift velocities inferred from soft X-ray line emissions observed by SMM and the microwave peak as determined from ground-based observations. This timing was then used to aid the testing of newly developed global models for flares that incorporate the global magnetic topology as well as the electron dynamics that are responsible for the hard X-rays and microwaves.

Winglee, Robert M.↗

NASA NTRS2000

A Parallel Genetic Algorithm for Automated Electronic Circuit Design

Parallelized versions of genetic algorithms (GAs) are popular primarily for three reasons: the GA is an inherently parallel algorithm, typical GA applications are very compute intensive, and powerful computing platforms, especially Beowulf-style computing clusters, are becoming more affordable and easier to implement. In addition, the low communication bandwidth required allows the use of inexpensive networking hardware such as standard office ethernet. In this paper we describe a parallel GA and its use in automated high-level circuit design. Genetic algorithms are a type of trial-and-error search technique that are guided by principles of Darwinian evolution. Just as the genetic material of two living organisms can intermix to produce offspring that are better adapted to their environment, GAs expose genetic material, frequently strings of 1s and Os, to the forces of artificial evolution: selection, mutation, recombination, etc. GAs start with a pool of randomly-generated candidate solutions which are then tested and scored with respect to their utility. Solutions are then bred by probabilistically selecting high quality parents and recombining their genetic representations to produce offspring solutions. Offspring are typically subjected to a small amount of random mutation. After a pool of offspring is produced, this process iterates until a satisfactory solution is found or an iteration limit is reached. Genetic algorithms have been applied to a wide variety of problems in many fields, including chemistry, biology, and many engineering disciplines. There are many styles of parallelism used in implementing parallel GAs. One such method is called the master-slave or processor farm approach. In this technique, slave nodes are used solely to compute fitness evaluations (the most time consuming part). The master processor collects fitness scores from the nodes and performs the genetic operators (selection, reproduction, variation, etc.). Because of dependency issues in the GA, it is possible to have idle processors. However, as long as the load at each processing node is similar, the processors are kept busy nearly all of the time. In applying GAs to circuit design, a suitable genetic representation 'is that of a circuit-construction program. We discuss one such circuit-construction programming language and show how evolution can generate useful analog circuit designs. This language has the desirable property that virtually all sets of combinations of primitives result in valid circuit graphs. Our system allows circuit size (number of devices), circuit topology, and device values to be evolved. Using a parallel genetic algorithm and circuit simulation software, we present experimental results as applied to three analog filter and two amplifier design tasks. For example, a figure shows an 85 dB amplifier design evolved by our system, and another figure shows the performance of that circuit (gain and frequency response). In all tasks, our system is able to generate circuits that achieve the target specifications.

Long, Jason D.↗