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NASA NTRS2015

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing of Ceramic Composites: Additive Manufacturing and Characterization of Ceramic Composites - Part III

This publication is the third part of a three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce ceramic matrix composite materials and aircraft engine components by the binder jet process. Different SiC powders with median sizes ranging from 9.3 to 53.0 microns were investigated solely and in powder blends in order to maximize powder packing. Various infiltration approaches were investigated to include polycarbosilane (SMP-10), phenolic, and liquid silicon. Single infiltrations of SMP-10 and phenolic only slightly filled in the interior. When the SMP-10 was loaded with sub-micron sized SiC powders, the infiltrant gave a much better result of filling in the interior. Silicon carbide fibers were added to the powder bed to make ceramic matrix composite materials. Microscopy showed that the fibers were well distributed with no preferred orientation on the horizontal plane and fibers in the vertical plane were at angles as much as 45deg. Secondary infiltration steps were necessary to further densify the material. Two to three extra infiltration steps of SMP-10 increased the density by 0.20 to 0.55 g/cc. However, the highest densities achieved were 2.10 to 2.15 g/cc. Mechanical tests consisting of 4 point bend tests were conducted. Samples from the two CMC panels had higher strengths and strains to failure than the samples from the two nonfiber reinforced panels. The highest strengths were from Set N with 65 vol% fiber loading which had an average strength of 66 MPa. Analysis of the fracture surfaces did not reveal pullout of the reinforcing fibers. Blunt fiber failure suggested that there was not composite behavior. The binder jet additive manufacturing method was used to also demonstrate the fabrication of turbine engine vane components of two different designs and sizes. The binder jet method has benefits over the conventional manufacturing of CMCs in that prototype and production parts can be fabricated quickly and economically with no tooling and extensive hand layup.

Additive Manufacturing↗
NASA NTRS2019

Water Storage and Transport Processes During Impact Experiments on Nominally Anhydrous Minerals

Water, in the form of structurally bound hydrogen in the crystal lattice of nominally anhydrous minerals (NAMs), strongly influences many important physical processes on terrestrial planets and planetary objects. Water enhances the rates of plastic deformation and controls the degree of partial melting in silicate rocks, which influences the generation of melt and therefore the nature of planetary volcanism. Water has also been experimentally demonstrated to influence the nature of lattice preferred orientation in deformed aggregates, and thus may be important in the interpretation of seismic anisotropy data collected from planetary bodies, such as from the current InSight mission on Mars. Therefore, much attention has been focused on characterizing the distribution and concentration of water in the planets and rocky bodies of our solar system.

Tielke, J.↗
NASA NTRS1995

Thermally Stable, Piezoelectric and Pyroelectric Polymeric Substrates and Method Relating Thereto

Production of an electric voltage in response to mechanical excitation (piezoelectricity) or thermal excitation (pyroelectricity) requires a material to have a preferred dipole orientation in its structure. This preferred orientation or polarization occurs naturally in some crystals such as quartz and can be induced into some ceramic and polymeric materials by application of strong electric or mechanical fields. For some materials, a combination of mechanical and electrical orientation is necessary to completely polarize the material. The only commercially available piezoelectric polymer is poly(vinylidene fluoride) (PVF2). However, this polymer has material and process limitations which prohibit its use in numerous device applications where thermal stability is a requirement. By the present invention, thermally stable, piezoelectric and pyroelectric polymeric substrates were prepared from polymers having a softening temperature greater than 1000C. A metal electrode material is deposited onto the polymer substrate and several electrical leads are attached to it. The polymer substrate is heated in a low dielectric medium to enhance molecular mobility of the polymer chains. A voltage is then applied to the polymer substrate inducing polarization. The voltage is then maintained while the polymer substrate is cooled 'freezing in' the molecular orientation. The novelty of the invention resides in the process of preparing the piezoelectric and pyroelectric polymeric substrate. The nonobviousness of the invention is found in heating the polymeric substrate in a low dielectric medium while applying a voltage.

Simpson, Joycelyn O.↗
NASA NTRS1994

Preferred Negative Geotactic Orientation in Mobile Cells: Tetrahymena Results

For the protozoan species Tetrahymena a series of airplane experiments are reported, which varied gravity as an active laboratory parameter and tested for corresponding changes in geotaxic orientation of single cells. The airplane achieved altemating periods of low (0.01 g) and high (1.8 g, g = 980 cm/s) gravity by flying repeated Keplerian parabolas. The experimental design was undertaken to clearly distinguish gravity from competing aerodynamic and chemical gradients. In this way, each culture served as its own control, with gravity level alone determining the orientational changes. On average, 6.3% of the Tetrahymena oriented vertically in low gravity, while 27% oriented vertically in high-gravity phases. Simplified physical models are explored for describing these cell trajectores as a function of gravity, aerodynamic drag, and lift. The notable effect of gravity on turning behavior is emphasized as the biophysical cause of the observed negative geotaxis in Tetrahymena. A fundamental investigation of the biological gravity receptor (it it exists) and improved modeling for vertical migration in important types of ocean plankton motivate the present research.

Noever, David A.↗
NASA NTRS2000

Asymptotic Solutions for Optical Properties of Large Particles with Strong Absorption

For scattering calculations involving nonspherical particles such as ice crystals, we show that the transverse wave condition is not applicable to the refracted electromagnetic wave in the context of geometric optics when absorption is involved. Either the TM wave condition (i.e., where the magnetic field of the refracted wave is transverse with respect to the wave direction) or the TE wave condition (i.e., where the electric field is transverse with respect to the propagating direction of the wave) may be assumed for the refracted wave in an absorbing medium to locally satisfy the electromagnetic boundary condition in the ray tracing calculation. The wave mode assumed for the refracted wave affects both the reflection and refraction coefficients. As a result, a nonunique solution for these coefficients is derived from the electromagnetic boundary condition. In this study we have identified the appropriate solution for the Fresnel reflection/refraction coefficients in light scattering calculation based on the ray tracing technique. We present the 3 x 2 refraction or transmission matrix that completely accounts for the inhomogeneity of the refracted wave in an absorbing medium. Using the Fresnel coefficients for an absorbing medium, we derive an asymptotic solution in an analytical format for the scattering properties of a general polyhedral particle. Numerical results are presented for hexagonal plates and columns with both preferred and random orientations. The asymptotic theory can produce reasonable accuracy in the phase function calculations in the infrared window region (wavelengths near 10 micron) if the particle size (in diameter) is on the order of 40 micron or larger. However, since strong absorption is assumed in the computation of the single-scattering albedo in the asymptotic theory, the single scattering albedo does not change with variation of the particle size. As a result, the asymptotic theory can lead to substantial errors in the computation of single-scattering albedo for small and moderate particle sizes. However, from comparison of the asymptotic results with the FDTD solution, it is expected that a convergence between the FDTD results and the asymptotic theory results can be reached when the particle size approaches 200 micron. We show that the phase function at side-scattering and backscattering angles is insensitive to particle shape if the random orientation condition is assumed. However, if preferred orientations are assumed for particles, the phase function has a strong dependence on scattering azimuthal angle. The single-scattering albedo also shows very strong dependence on the inclination angle of incident radiation with respect to the rotating axis for the preferred particle orientations.

Yang, Ping↗
NASA NTRS1980

Orientations of central peaks in lunar craters - Implications for regional structural trends

Impact craters are dominant features on the lunar surface and all fresh craters with diameters greater than 35 km possess central peaks. Approximately half of these central peaks (54%) have either linear or arcuate geometry and display some preferential orientation. These orientations were measured for 200 lunar craters of Pre-Nectarian to Copernican age. A pervasive regional north-south trend is identified for central peak orientation, with secondary trends at + or - 20-30 deg from this axis. No evidence for regional east-west trends is found. These orientations are shown to persist in craters formed through the last 4 billion years of lunar history. A lack of coincidence between impact direction, as determined from ejecta asymmetries and peak orientation, argues for structural control by the target as a source of the linear peak morphology. This is supported by the regional and temporal persistence of preferred peak orientations. It is proposed that linear central peak orientations in lunar craters reflect a pervasive regional structural system which developed early in lunar history and has persisted through geologic time.

Hale, W.↗
NASA NTRS2001

Controlling Growth Orientation of Phthalocyanine Films by Electrical Fields

Organic Phthalocyanine films have many applications ranging from data storage to various non-linear optical devices whose quality is affected by the growth orientation of Phthalocyanine films. Due to the structural and electrical properties of Phthalocyanine molecules, the film growth orientation depends strongly on the substrate surface states. In this presentation, an electrical field up to 4000 V/cm is introduced during film growth. The Phthalocyanine films are synthesized on quartz substrates using thermal evaporation. An intermediate layer is deposited on some substrates for introducing the electrical field. Scanning electron microscopy, x-ray diffraction, and Fourier transform infrared spectroscopy are used for measuring surface morphology, film structure, and optical properties, respectively. The comparison of Phthalocyanine films grown with and without the electrical field reveals different morphology, film density, and growth orientation, which eventually change optical properties of these films. These results suggest that the growth method in the electrical field can be used to synthesized Phthalocyanine films with a preferred crystal orientation as well as propose an interaction mechanism between the substrate surface and the depositing molecules. The details of growth conditions and of the growth model of how the Phthalocyanine molecules grow in the electrical field will be discussed.

Zhu, S.↗
NASA NTRS2005

Structures Self-Assembled Through Directional Solidification

Nanotechnology has created a demand for new fabrication methods with an emphasis on simple, low-cost techniques. Directional solidification of eutectics (DSE) is an unconventional approach in comparison to low-temperature biomimetic approaches. A technical challenge for DSE is producing microstructural architectures on the nanometer scale. In both processes, the driving force is the minimization of Gibb's free energy. Selfassembly by biomimetic approaches depends on weak interaction forces between organic molecules to define the architectural structure. The architectural structure for solidification depends on strong chemical bonding between atoms. Constituents partition into atomic-level arrangements at the liquid-solid interface to form polyphase structures, and this atomic-level arrangement at the liquid-solid interface is controlled by atomic diffusion and total undercooling due to composition (diffusion), kinetics, and curvature of the boundary phases. Judicious selection of the materials system and control of the total undercooling are the keys to producing structures on the nanometer scale. The silicon-titanium silicide (Si-TiSi2) eutectic forms a rod structure under isothermal cooling conditions. At the NASA Glenn Research Center, directional solidification was employed along with a thermal gradient to promote uniform rods oriented with the thermal gradient. The preceding photomicrograph shows the typical transverse microstructure of a solidified Si-TiSi2 eutectic composition. The dark and light gray regions are Si and TiSi2, respectively. Preferred rod orientation along the thermal gradient was poor. The ordered TiSi2 rods have a narrow distribution in diameter of 2 to 3 m, as shown. The rod diameter showed a weak dependence on process conditions. Anisotropic etch behavior between different phases provides the opportunity to fabricate structures with high aspect ratios. The photomicrographs show the resulting microstructure after a wet chemical etch and a dry plasma etch. The wet chemical etches the silicon away, exposing the TiSi2 rods, whereas plasma etching preferentially etches the Si-TiSi2 interface to form a crater. The porous architectures are applicable to fabricating microdevices or creating templates for part fabrication. The porous rod structure can serve as a platform for fabricating microplasma devices for propulsion or microheat exchangers and for fabricating microfilters for miniatured chemical reactors. Although more work is required, self-assembly from DSE can have a role in microdevice fabrication.

Dynys, Frederick W.↗
NASA NTRS1999

HRDI Observations of Inertia-Gravity Waves in the Mesosphere and Lower Thermosphere

Vertical profiles of High-resolution Doppler imager (HRDI) mesospheric winds have small-scale structure (vertical wavelengths between 10 and 20 km) that is virtually always present. Fourier analysis of HRDI zonal and meridional wind profiles have been carried out, and the spectral characteristics are sorted by latitude, month and local time. Power spectral density (PSD) exhibits a universal exp(-km) structure in the 10-20km wavelength regime, with K lying between 2 and 3. The observed PSD for wavelengths between 10 and 20 km is a factor of 3 higher than a null spectrum constructed from HRDI reported error bars multiplied by randomly varying numbers between -1 and +1. Stokes parameters were consolidated by month into Northern and Southern hemisphere middle and high latitudes belts (40-72 degrees), tidal belts (32-16 degrees) and a tropical belt (8S-8N). Vertical waves between 10 and 15 km in wavelength are about 10-15% polarized everywhere. The inferred propagation direction in the middle and high latitude Southern hemisphere is predominantly meridional during solstice, and significantly more zonal during equinoxes. In the tropical belt, the wave orientations are nearly North-South during solstices, with a slightly higher east-west component during equinox. In the tidal belts where the background wind includes a strong meridional tidal wind, the preferred wave orientation has a significant zonal component during equinox. These findings are consistent with the interpretation of wave filtering by the background wind.

Lieberman, Ruth S.↗
NASA NTRS2009

Radar Differential Phase Signatures of Ice Orientation for the Prediction of Lightning Initiation and Cessation

The majority of lightning-related casualties typically occur during thunderstorm initiation (e.g., first flash) or dissipation (e.g., last flash). The physics of electrification and lightning production during thunderstorm initiation is fairly well understood. As such, the literature includes a number of studies presenting various radar techniques (using reflectivity and, if available, other dual-polarimetric parameters) for the anticipation of initial electrification and first lightning flash. These radar techniques have shown considerable skill at forecasting first flash. On the other hand, electrical processes and lightning production during thunderstorm dissipation are not nearly as well understood and few, if any, successful techniques have been developed to anticipate the last flash and subsequent cessation of lightning. One promising approach involves the use of dual-polarimetric radar variables to infer the presence of oriented ice crystals in lightning producing storms. In the absence of strong vertical electric fields, ice crystals fall with their largest (semi-major) axis in the horizontal associated with gravitational and aerodynamic forces. In thunderstorms, strong vertical electric fields (100-200 kV m(sup -1)) have been shown to orient small (less than 2 mm) ice crystals such that their semi-major axis is vertical (or nearly vertical). After a lightning flash, the electric field is typically relaxed and prior radar research suggests that ice crystals rapidly resume their preferred horizontal orientation. In active thunderstorms, the vertical electric field quickly recovers and the ice crystals repeat this cycle of orientation for each nearby flash. This change in ice crystal orientation from primarily horizontal to vertical during the development of strong vertical electric fields prior to a lightning flash forms the physical basis for anticipating lightning initiation and, potentially, cessation. Research has shown that radar reflectivity (Z) and other co-polar back-scattering radar measurements like differential reflectivity (Z(sub dr)) typically measured by operational dual-polarimetric radars are not sensitive to these changes in ice crystal orientation. However, prior research has demonstrated that oriented ice crystals cause significant propagation effects that can be routinely measured by most dual-polarimetric radars from X-band (3 cm) to S-band (10 cm) wavelengths using the differential propagation phase shift (often just called differential phase, phi(sub dp)) or its range derivative, the specific differential phase (K(sub dp)). Advantages of the differential phase include independence from absolute or relative power calibration, attenuation, differential attenuation and relative insensitivity to ground clutter and partial beam occultation effects (as long as the signal remains above noise). In research mode, these sorts of techniques have been used to anticipate initial cloud electrification, lightning initiation, and cessation. In this study, we develop a simplified model of ice crystal size, shape, orientation, dielectric, and associated radar scattering and propagation effects in order to simulate various idealized scenarios of ice crystals responding to a hypothetical electric field and their dual-polarimetric radar signatures leading up to lightning initiation and particularly cessation. The sensitivity of the K(sub dp) ice orientation signature to various ice properties and radar wavelength will be explored. Since K(sub dp) is proportional to frequency in the Rayleigh- Gans scattering regime, the ice orientation signatures should be more obvious at higher (lower) frequencies (wavelengths). As a result, simulations at radar wavelengths from 10 cm down to 1 cm (Ka-band) will be conducted. Resonance effects will be considered using the T-matrix method. Since most K(sub dp) Vbased observations have been shown at S-band, we will present ice orientation signatures from C-band (UAH/NASA ARMOR) and X-bd (UAH MAX) dual-polarimetric radars located in Northern Alabama. Issues related to optimal radar scanning for the detection of oriented ice will be discussed. Preliminary suggestions on how these differential phase signatures of oriented ice could contribute to lightning initiation and cessation algorithms will be presented.

Carey, L.D.↗
NASA NTRS1982

The effect of grooves in amorphous substrates on the orientation of metal deposits. I - Carbon substrates

The graphoepitaxial alignment of vapor-deposited discrete metal crystallites is investigated in the nucleation and growth stages and during annealing by in situ UHV/TEM techniques. Various stages of nucleation, growth and coalescence of vapor deposits of Au, Ag, Pb, Sn, and Bi on amorphous, topographically structured C substrates are analyzed by advanced dark-field techniques to detect preferred local orientations. It is found that the topography-induced orientation of metal crystallites depends strongly on their mobility and their respective tendency to develop pronounced crystallographic shapes. Lowering of the average surface free energies and increasing the crystallographic surface energy anisotropies cause generally improved graphoepitaxial alignments.

Anton, R.↗
NASA NTRS1995

Growth and Analysis of Highly Oriented (11n) BCSCO Films for Device Research

Films of BCSCO superconductor of the type Bi2CaSr2Cu2O(x), have been grown by liquid phase epitaxy method (LPE), using a partially closed growth chamber. The films were grown on (001) and (110) NdGaO3 substrates by slow cooling process in an optimized temperature range below the peritectic melting point (880 C) of Bi2CaSr2Cu2O8. Optimization of parameters, such as seed rotation, soak of initial growth temperature and growth period results in the formation of 2122 phase BCSCO films. The films grown at rotation rates of less than 30 and more than 70 rpm are observed to be associated with the second phase of Sr-Ca-Cu-O system. Higher growth temperatures (greater than 860 C) also encourage to the formation of this phase. XRD measurements show that the films grown on (110) NdGaO3 have a preferred (11n)-orientation. It is pertinent to mention here that in our earlier results published elsewhere we obtained c-axis oriented Bi2CaSr2Cu2O8 phase films on (001) NdGaO3 substrate. Critical current density is found to be higher for the films grown on (110) than (001) NdGaO3 substrate orientation. The best values, zero resistance (T(sab co)) and critical current density obtained are 87 K and 10(exp 5) A/sq cm respectively.

Raina, K. K.↗
NASA NTRS2016

Transmission Electron Microscopy of Magnetite Plaquettes in Orgueil

Magnetite sometimes takes the form of a plaquette - barrel-shaped stack of magnetite disks - in carbonaceous chondrites (CC) that show evidence of aqueous alteration. The asymmetric nature of the plaquettes caused Pizzarello and Groy to propose magnetite plaquettes as a naturally asymmetric mineral that can indroduce symmetry-breaking in organic molecules. Our previous synchrotron X-ray computed microtomography (SXRCT) and electron backscatter diffraction (EBSD) analyses of the magnetite plaquettes in fifteen CCs indicate that magnetite plaquettes are composed of nearly parallel discs, and the crystallographic orientations of the discs change around a rotational axis normal to the discs surfaces. In order to further investigate the nanostructures of magnetite plaquettes, we made two focused ion beam (FIB) sections of nine magnetite plaquettes from a thin section of CI Orgueil for transmission electron microscope (TEM) analysis. The X-ray spectrum imaging shows that the magnetite discs are purely iron oxide Fe3O4 (42.9 at% Fe and 57.1 at% O), which suggest that the plaquettes are of aqueous origin as it is difficult to form pure magnetite as a nebular condensate. The selected area electron diffraction (SAED) patterns acquired across the plaquettes show that the magnetite discs are single crystals. SEM and EBSD analyses suggest that the planar surfaces of the magnetite discs belong to the {100} planes of the cubic inverse spinel structure, which are supported by our TEM observations. Kerridge et al. suggested that the epitaxial relationship between magnetite plaquette and carbonate determines the magnetite face. However, according to our TEM observation, the association of magnetite with porous networks of phyllosilicate indicates that the epitaxial relationship with carbonate is not essential to the formation of magnetite plaquettes. It was difficult to determine the preferred rotational orientation of the plaquettes due to the symmetry of the cubic structure, however, we are able to observe small but consistent rotational orientation across several discs within a plaquette.

Chan, Q. H. S.↗
NASA NTRS1972

A mathematical model concerning reflectance from a row crop

The recent work of Allen, Gayle, and Richardson (1970) and Suits (1972) has been extended to compute directional reflectance from a crop row. A model is constructed which takes into account edge effects and aids in discriminating crops with leaf orientation in preferred directions. This report only contains the development of the mathematical equations. Numerical results will be published in a forthcoming report.

Jaggi, R. K.↗
NASA NTRS1974

The influence of acceleration forces on nucleation, solidification, and deformation processes in tin single crystals

An apparatus was designed and assembled to directionally solidify single crystals under the influence of acceleration forces of various magnitudes. The investigation conducted showed that acceleration gradients produce a preferred growth orientation effect not previously observed for tin. Convection currents at approximately 5-g encourage multiple nucleation and subsequent random orientation of growth direction. Deformation effects such as recrystallization and twinning are observed at acceleration levels greater than 2-g.

Johnston, M. H.↗
NASA NTRS1980

The direct observation of unidirectional solidification as a function of gravity level

A saturated solution of NH4 Cl-H2O was solidified unidirectionally on earth at 1 g and in a suborbital rocket at 0.001 g. In the 1 g experiment, extensive fluid flow was apparent, creating plumes which carry numerous crystallites vertically above the interface in a manner associated with freckling in castings. During growth the interface grew into the liquid at the same rate as the individual dendrites. When solidified in low g, the interface grew at a slower rate than the individual dendrites. No plumes of liquid carrying crystals were seen, but several crystals did appear and grow ahead of the interface. Growth rates, dendrite morphologies and preferred crystallographic orientations are compared for the two experiment conditions. Results indicate that solidification in low gravity produces more uniform dendrite arm spacings, and tends to be controlled by diffusion and crystallographic orientation.

Johnston, M. H.↗
NASA NTRS1989

Transient oxidation of single-crystal beta-NiAl

The transient oxidation of beta-NiAl in air at 800 C and 1100 C has been studied using electron microscopy. The oxide scale consists predominantly of metastable Al2O3 phases. Theta-Al2O3 is the major oxide phase within 10.0 hr of oxidation at 800 C and 0.1 hr at 1100 C. The scales form epitaxially on (001) sub beta and (012) sub beta specimens throughout the transient stage, whereas the degree of preferred oxide orientation decreases with oxidation time on (011) sub beta and (111) sub beta specimens. The orientation relationships reflect the small mismatch between parallel close-packed directions in the metal and in the cation sublattice of the oxides. The correlation of distinctive oxide surface morphologies with internal structural defects indicates the strong tendency of the Al2O3 scale to grow via short-circuit diffusion paths.

Doychak, J.↗
NASA NTRS1990

Aircraft microwave observations and simulations of deep convection from 18 to 183 GHz. I - Observations

Aircraft passive microwave observations of deep atmospheric convection at frequencies between 18 and 183 GHz are presented in conjunction with visible and infrared satellite and aircraft observations and ground-based radar observations. Deep convective cores are indicated in the microwave data by negative brightness temperature, T/(B) deviations from the land background (270 K) to extreme T(B) values below 100 K at 37, 92, and 183 GHz and below 200 K at 18 GHz. These T(B) minima, due to scattering by ice held aloft by the intense updrafts, are well correlated with areas of high radar reflectivity. For this land background case, T(B) is inversely correlated with rain rate at all frequencies due to T(B)-ice-rain correlations. Mean Delta-T between vertically polarized and horizontally polarized radiance in precipitation areas is approximately 6 K at both 18 GHz and 37 GHz, indicating nonspherical precipitation-size ice particles with a preferred horizontal orientation. Convective cores not observed in the visible and infrared data are clearly defined in the microwave observations, and borders of convective rain areas are well defined using the high-frequency (90 GHz and greater) microwave observations.

Adler, Robert F.↗