Structural prospects for hypersonic air vehicles.
Structural design problems of hypersonic air vehicles with air breathing propulsion, discussing relation to future hypersonic commercial air transport
STRUCTURAL DESIGN↗
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Development of advanced material composites for use as internal insulation for LH2 tanks (gas layer concept)
A program is described that was conducted to develop an internal insulation system for potential application to the liquid hydrogen tanks of a reusable booster, where the tanks would be subjected to repeated high temperatures. The design of the internal insulation is based on a unique gas layer concept, in which capillary or surface tension effects are used to maintain a stable gas layer, within a cellular core structure, between the tank wall and the contained liquid hydrogen. Specific objectives were to select materials for insulation systems that would be compatible with wall temperatures of 350 F and 650 F during reentry into the earth's atmosphere, and to fabricate and test insulation systems under conditions simulating the operating environment. A materials test program was conducted to evaluate the properties of candidate materials at elevated temperatures and at the temperature of liquid hydrogen, and to determine the compatibility of the materials with a hydrogen atmosphere at the appropriate elevated temperature. The materials that were finally selected included Kapton polyimide films, silicone adhesives, fiber glass batting, and in the case of the 350 F system, Teflon film.
Gille, J. P.↗
Test and analysis of Celion 3000/PMR-15, graphite/polyimide bonded composite joints: Data report
Standard single lap, double lap and symmetric step lap bonded joints of Celion 3000/PMR-15 graphite/polyimide composite were evaluated. Composite to composite and composite to titanium joints were tested at 116 K (-250 F), 294 K (70 F) and 561 K (550 F). Joint parameters evaluated are lap length, adherend thickness, adherend axial stiffness, lamina stacking sequence and adherend tapering. Advanced joint concepts were examined to establish the change in performance of preformed adherends, scalloped adherends and hybrid systems. The material properties of the high temperature adhesive, designated A7F, used for bonding were established. The bonded joint tests resulted in interlaminar shear or peel failures of the composite and there were very few adhesive failures. Average test results agree with expected performance trends for the various test parameters. Results of finite element analyses and of test/analysis correlations are also presented.
Cushman, J. B.↗
Test and analysis of Celion 3000/PMR-15, graphite/polyimide bonded composite joints: Summary
Standard single lap, double lap and symmetric step lap bonded joints of Celion 3000/PMR-15 graphite/polyimide composite were evaluated. Composite to composite and composite to titanium joints were tested at 116K (-250 F), 294K (70 F) and 561K (550 F). Joint parameters evaluated were lap length, adherend thickness, adherend axial stiffness, lamina stacking sequence and adherend tapering. Tests of advanced joint concepts were also conducted to establish the change in performance of preformed adherends, scalloped adherends and hybrid systems. Special tests were conducted to establish material properties of the high temperature adhesive, designated A7F, used for bonding. Most of the bonded joint tests resulted in interlaminar shear or peel failures of the composite. There were very few adhesive failures. Average test results agree with expected performance trends for the various test parameters. Results of finite element analyses and of test/analysis correlations are also presented.
Cushman, J. B.↗
Characterization of macrosegregation in ESR IN-718
Aspects of macrosegregation theory, such as dendrite arm spacing, pool profile and mushy zone depth are beneficial to developing consumable melting process for Ion Nickel IN-718, Electro-Slag Refining, especially ESR. Aspects of microsegregation theory, such as correlation of dendrite arm spacing with heat transfer mechanisms and local solidification time, are used to minimize remnant dendritism in both ESR and Vacuum Arc Remelting VAR IN-718. Specifically, ESR IN-718 must be optimized by developing practices which maximize ingot cooling rate and minimize the steepness of the solidus and liquidus isotherms. The knowledge concerning macrosegregation in consumable melted IN-718 is in the form of correlations. Since the isotherm steepness is undoubtedly involved, investigations which include a microgravity environment might separate microsegregation effects from macrosegregation effects. Accounting for the effects of gravity and density differences between the metal pool and the interdendritic fluid, in combination with the pool and mushy zone profiles, can lead to improved melting solidification practices for IN-718, and allow prediction of macrosegregation tendency to be incorporated into high temperature alloy design.
Domingue, J. A.↗
Bonded and Bolted Graphite/Polyimide Composite Joints
Four types of high-temperature joints designed for control surfaces. Design, analysis, and testing performed to develop four types of graphite/polyimide bonded and bolted composite joints for lightly loaded control surfaces on advanced transportation systems that operate at temperatures up to 550 degrees F (288 degrees C).
Skoumal, D. E.↗
Laser-powered MHD generators for space application
Magnetohydrodynamic (MHD) energy conversion systems of the pulsed laser-supported detonation (LSD) wave, plasma MHD, and liquid-metal MHD (LMMHD) types are assessed for their potential as space-based laser-to-electrical power converters. These systems offer several advantages as energy converters relative to the present chemical, nuclear, and solar devices, including high conversion efficiency, simple design, high-temperature operation, high power density, and high reliability. Of these systems, the Brayton cycle liquid-metal MHD system appears to be the most attractive. The LMMHD technology base is well established for terrestrial applications, particularly with regard to the generator, mixer, and other system components. However, further research is required to extend this technology base to space applications and to establish the technology required to couple the laser energy into the system most efficiently. Continued research on each of the three system types is recommended.
Jalufka, N. W.↗
Brush Seal Performance and Durability Issues Based on T-700 Engine Test Results
The integrity and performance of brush seals have been established. Severe bench and engine tests have shown high initial wear or run-in rates, material smearing at the interface, and bristle and rub-runner wear, but the brush seals did not fail. Short-duration (46 hr) experimental T-700 engine testing of the compressor discharge seal established over 1-percent engine performance gain (brush versus labyrinth). Long-term gains were established only as leakage comparisons, with the brush at least 20 percent better at controlling leakage. Long-term materials issues, such as wear and ultimately seal life, remain to be resolved. Future needs are cited for materials and analysis tools that account for heat generation, thermomechanical behavior, and tribological pairing to enable original equipment manufacturers to design high-temperature, high-surface-speed seals with confidence.
Hendricks, R. C.↗
Flammability and Photo-Stability of Selected Polymer Systems
A systematic approach to the improvement of the flammability of epoxy resins, bisphenol-A polycarbonate poly(butylene terephthalate), and Nylon 6.6 by introducing halogens and loop functionality into the flame retardants is described. The phthalides (the loop functionality containing molecules) include 3,3-bis(4-bromophenyl)-phthalide, 3,3-bis(4-chlorophenyl)phthalide, and phenolphthalein. The phthalide containing epoxy resins are synthesized and characterized in comparison with the bisphenol-A epoxy resins in terms of flammability in the copolymer systems. The resins include diglycidyl ethers of phenolphthalein, bisphenol-A. tetrabromobisphenol-A, and tetraoromophenolphthalein. The vaporization of the phthalide additive in the polymers is observed in Thermal Gravimetric Analysis. The flame retardancy is primarily due to the presence of halogens. In the poly(butylene terephthalate) system, the cleavage of the C(sub aromatic) -B bond of the flame retardant additive enhances the crosslinking react ions between the aromatic rings resulting in an increase of char formation. In the epoxy resin systems, loop functionality contributes to char formation to a larger extent. The interaction between the epoxy resin and poly-(butylene terephthalate) follows the mechanism of insertion of the oxirane ring into the ester bond. This mechanism is studied by FT-IR. The investigation of the thermal properties of the char-forming phenol-formaldehyde resins is conducted to provide information for the systematic design of high temperature flame-resistant phenolics. NMR and FT-IR are used to characterize the oligomeric resins and the cured resins. The curing agents used in the study include formaldehyde, s-trioxane and terephthaloyl chloride. The brominated phenolic resins are found to have higher oxygen indices with lower char yields.
Lo, Jeelin↗
Advanced High Temperature Structural Seals
This program addresses the development of high temperature structural seals for control surfaces for a new generation of small reusable launch vehicles. Successful development will contribute significantly to the mission goal of reducing launch cost for small, 200 to 300 lb payloads. Development of high temperature seals is mission enabling. For instance, ineffective control surface seals can result in high temperature (3100 F) flows in the elevon area exceeding structural material limits. Longer sealing life will allow use for many missions before replacement, contributing to the reduction of hardware, operation and launch costs. During the first phase of this program the existing launch vehicle control surface sealing concepts were reviewed, the aerothermal environment for a high temperature seal design was analyzed and a mock up of an arc-jet test fixture for evaluating seal concepts was fabricated.
Newquist, Charles W.↗
1 GHz, 200 C, SiC MESFET Clapp Oscillator
A SiC Clapp oscillator frabricated on an alumina substrate with chip capacitors and spiral inductors is designed for high temperature operation at 1 gigahertz. The oscillator operated from 30 to 200 C with an output power of 21.8 dBm at 1 gigahertz and 200 C. The efficiency at 200 C is 15 percent. The frequency variation over the temperature range is less than 0.5 percent.
Ponchak, George E.↗
New High-Performance SiC Fiber Developed for Ceramic Composites
Sylramic-iBN fiber is a new type of small-diameter (10-mm) SiC fiber that was developed at the NASA Glenn Research Center and was recently given an R&D 100 Award for 2001. It is produced by subjecting commercially available Sylramic (Dow Corning, Midland, MI) SiC fibers, fabrics, or preforms to a specially designed high-temperature treatment in a controlled nitrogen environment for a specific time. It can be used in a variety of applications, but it currently has the greatest advantage as a reinforcement for SiC/SiC ceramic composites that are targeted for long-term structural applications at temperatures higher than the capability of metallic superalloys. The commercial Sylramic SiC fiber, which is the precursor for the Sylramic-iBN fiber, is produced by Dow Corning, Midland, Michigan. It is derived from polymers at low temperatures and then pyrolyzed and sintered at high temperatures using boron-containing sintering aids (ref. 1). The sintering process results in very strong fibers (>3 GPa) that are dense, oxygen-free, and nearly stoichiometric. They also display an optimum grain size that is beneficial for high tensile strength, good creep resistance, and good thermal conductivity (ref. 2). The NASA-developed treatment allows the excess boron in the bulk to diffuse to the fiber surface where it reacts with nitrogen to form an in situ boron nitride (BN) coating on the fiber surface (thus the product name of Sylramic-iBN fiber). The removal of boron from the fiber bulk allows the retention of high tensile strength while significantly improving creep resistance and electrical conductivity, and probably thermal conductivity since the grains are slightly larger and the grain boundaries cleaner (ref. 2). Also, as shown in the graph, these improvements allow the fiber to display the best rupture strength at high temperatures in air for any available SiC fiber. In addition, for CMC applications under oxidizing conditions, the formation of an in situ BN surface layer creates a more environmentally durable fiber surface not only because a more oxidation-resistant BN is formed, but also because this layer provides a physical barrier between contacting fibers with oxidation-prone SiC surface layers (refs. 3 and 4). This year, Glenn demonstrated that the in situ BN treatment can be applied simply to Sylramic fibers located within continuous multifiber tows, within woven fabric pieces, or even assembled into complex product shapes (preforms). SiC/SiC ceramic composite panels have been fabricated from Sylramic-iBN fabric and then tested at Glenn within the Ultra-Efficient Engine Technology Program. The test conditions were selected to simulate those experienced by hot-section components in advanced gas turbine engines. The results from testing at Glenn demonstrate all the benefits expected for the Sylramic-iBN fibers. That is, the composites displayed the best thermostructural performance in comparison to composites reinforced by Sylramic fibers and by all other currently available high-performance SiC fiber types (refs. 3 and 5). For these reasons, the Ultra-Efficient Engine Technology Program has selected the Sylramic-iBN fiber for ongoing efforts aimed at SiC/SiC engine component development.
DiCarlo, James A.↗
Turbine Seal Research at NASA GRC
Low-leakage, long-life turbomachinery seals are important to both Space and Aeronautics Missions. (1) Increased payload capability (2) Decreased specific fuel consumption and emissions (3) Decreased direct operating costs. NASA GRC has a history of significant accomplishments and collaboration with industry and academia in seals research. NASA's unique, state-of-the-art High Temperature, High Speed Turbine Seal Test Facility is an asset to the U.S. Engine / Seal Community. Current focus is on developing experimentally validated compliant, non-contacting, high temperature seal designs, analysis, and design methodologies to enable commercialization.
Proctor, Margaret P.↗
A Cryogenic Magnetostrictive Actuator using a Persistent High Temperature Superconducting Magnet, Part 1: Concept and Design: Concept and Design - Part 1
Cryogenic magnetostrictive materials, such as rare earth zinc crystals, offer high strains and high forces with minimally applied magnetic fields, making the material ideally suited for deformable optics applications. For cryogenic temperature applications, such as Next Generation Space Telescope (NGST), the use of superconducting magnets offer the possibility of a persistent mode of operation, i.e., the magnetostrictive material will maintain a strain field without power. High temperature superconductors (HTS) are attractive options if the temperature of operation is higher than 10 degrees Kelvin (K) and below 77 K. However, HTS wires have constraints that limit the minimum radius of winding, and even if good wires can be produced, the technology for joining superconducting wires does not exist. In this paper, the design and capabilities of a rare earth zinc magnetostrictive actuator using bulk HTS is described. Bulk superconductors can be fabricated in the sizes required with excellent superconducting properties. Equivalent permanent magnets, made with this inexpensive material, are persistent, do not require a persistent switch as in HTS wires, and can be made very small. These devices are charged using a technique which is similar to the one used for charging permanent magnets, e.g., by driving them into saturation. A small normal conducting coil can be used for charging or discharging. Very fast charging and discharging of HTS tubes, as short as 100 microseconds, has been demonstrated. Because of the magnetic field capability of the superconductor material, a very small amount of superconducting magnet material is needed to actuate the rare earth zinc. In this paper, several designs of actuators using YBCO and BSCCO 2212 superconducting materials are presented. Designs that include magnetic shielding to prevent interaction between adjacent actuators will also be described. Preliminary experimental results and comparison with theory for BSSCO 2212 with a magnetostrictive element will be discussed.
Horner, Garnett C.↗
Joining and Attachment Technologies for Ceramic Matrix Composites: Current Status and Future Prospects
Fiber reinforced ceramic composites are either currently being used, or are under active consideration for use in a wide variety of high temperature applications. The engineering designs require fabrication and manufacturing of complex shaped parts. In many instances, it is more economical to build up complex shapes by joining simple geometrical shapes. Thus, joining and attachment have been recognized as enabling technologies for successful utilization of ceramic components in various aerospace and ground based applications. In this presentation, various challenges and opportunities in design, fabrication, and testing of high temperature joints in composites will be presented. Various joint design philosophies and design issues in joining of composites will be discussed along with an affordable, robust ceramic joining technology (ARCJoinT). A wide variety of ceramic composites (C/C, C/SiC, and SiC), in different shapes and sizes, have been joined using this technology. Microstructure and mechanical properties of joints will be reported. Current status of various ceramic joining technologies and future prospects for their applications will also be discussed.
Singh, M.↗
The preliminary design of bearings for the control system of a high-temperature lithium-cooled nuclear reactor
The design of bearings for the control system of a fast reactor concept is presented. The bearings are required to operate at temperatures up to 2200 F in one of two fluids, lithium or argon. Basic bearing types are the same regardless of the fluid. Crowned cylindrical journals were selected for radially loaded bearings and modified spherical bearings were selected for bearings under combined thrust and radial loads. Graphite and aluminum oxide are the materials selected for the argon atmosphere bearings while cermet compositions (carbides or nitrides bonded with refractory metals) were selected for the lithium lubricated bearings. Mounting of components is by shrink fit or by axial clamping utilizing differential thermal expansion.
Yacobucci, H. G.↗
Buckling analysis and test correlation of high temperature structural panels
This paper focuses on the design, analysis, and test of a high temperature structural panel, constructed of Ti-6-4, subjected to a variety of thermal and mechanical load conditions. A follow-on panel, constructed of TMC, is also discussed in less detail. The design constraints and test set-up are discussed, as well as the test methods that were used: the grid shadow moire method and a single gage force stiffness method. The agreement between the test data and analysis for this test program provides confidence in the methods that are currently being used to design structures for hypersonic vehicles. The agreement also suggests that postbuckled strength may potentially be used to reduce the vehicle weight.
Teare, Wendy P.↗