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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1959

Halogen-Containing Gases as Boundary Lubricants for Corrosion-Resistant Alloys at 1200 F

The extreme temperatures anticipated for lubricated parts in advanced flight powerplants dictate the consideration of unconventional methods of lubrication such as solid lubricants and the reactive gases described in the present research. These halogen-containing "reactive" gases such as dichlorodifluoromethane, CF2Cl2, are among the most stable of organic molecules. The high "flash" temperatures generated at the contacting asperities as a result of frictional heat are sufficient to cause local decomposition of the halogen-containing gases. The active atoms thus released (e.g., chlorine) then react with the metal to be lubricated to form halides capable of effective lubrication. The presence of small amounts of a sulfur-containing gas (e.g., 1 percent sulfur hexafluoride, SF6) was found to catalyze the formation of metal halides. Friction and wear studies were made with a hemisphere (3/16-in. rad.) rider sliding in a circumferential path on the flat surface of a rotating disk (2 1/2-in. diam.). The specimens of corrosion-resistant 2 alloys were run in an atmosphere of the various gases with a load of 1200 grams, a sliding velocity of 120 feet per minute, and temperature from 75 to 1200 F. An effective lubricant for ferritic materials (M-1 tool steel) was CF2Cl2, but significant corrosion occurred above 600 F. Corrosion evaluation in CF2Cl2 suggested a number of nickel- and cobalt-base alloys for additional lubrication study. Several combinations of gases and these metals were found to lubricate to 1200 F without excessive corrosion. The gases were CF2Cl2 Plus 1 percent SF6, monobromotrifluoromethane CF3Br plus 1 percent SF6, dibromodifluoromethane CF2Br2, iodotrifluoromethane, CF3I, and I2. Careful selection of metals and gas are necessary for successful lubrication over specific temperature ranges. Optimum combinations give friction coefficients as low as 0.05 without

Buckley, Donald H.↗
NASA NTRS1976

Brayton-cycle heat exchanger technology program

The following five tasks designed to advance this development of heat exchanger systems for close loop Brayton cycle power systems are presented: (1) heat transfer and pressure drop data for a finned tubular heat transfer matrix. The tubes are arranged in a triangular array with copper stainless steel laminate strips helically wound on the tubes to form a disk fin geometry; (2) the development of a modularized waste heat exchanger. Means to provide verified double containment are described; (3) the design, fabrication, and test of compact plate fin heat exchangers representative of full scale Brayton cycle recuperators; (4) the analysis and design of bellows suitable for operation at 1600 F and 200 psia for 1,000 cycles and 50,000 hours creep life; and (5) screening tests used to select a low cost braze alloy with the desirable attributes of a gold base alloy. A total of 22 different alloys were investigated; the final selection was Nicrobraz 30.

Killackey, J. J.↗
NASA NTRS2011

Resilient and Corrosion-Proof Rolling Element Bearings Made from Superelastic Ni-Ti Alloys for Aerospace Mechanism Applications

Mechanical components (bearings, gears, mechanisms) typically utilize hard materials to minimize wear and attain long life. In such components, heavily loaded contact points (e.g., meshing gear teeth, bearing ball-raceway contacts) experience high contact stresses. The combination of high hardness, heavy loads and high elastic modulus often leads to damaging contact stress. In addition, mechanical component materials, such as tool steel or silicon nitride exhibit limited recoverable strain (typically less than 1 percent). These material attributes can lead to Brinell damage (e.g., denting) particularly during transient overload events such as shock impacts that occur during the launching of space vehicles or the landing of aircraft. In this paper, a superelastic alloy, 60NiTi, is considered for rolling element bearing applications. A series of Rockwell and Brinell hardness, compressive strength, fatigue and tribology tests are conducted and reported. The combination of high hardness, moderate elastic modulus, large recoverable strain, low density, and intrinsic corrosion immunity provide a path to bearings largely impervious to shock load damage. It is anticipated that bearings and components made from alloys with such attributes can alleviate many problems encountered in advanced aerospace applications.

DellaCorte, Christopher↗
NASA NTRS1972

An investigation of plastic fracture in aluminum alloys

The brittle fracture of many high strength alloys such as steel, titanium, and aluminum was shown to occur by a process called plastic fracture. According to this process microscopic voids form at impurity particles, then grow and coalesce to cause the final rupture. To further understand the role of impurities, four aluminum alloys were investigated: 2024-T851, 2124-T851, 7075-T7351 and 7079-T651. Fractography, quantitative metallography, and microprobe studies assessed the roles of various impurity particles relative to these alloys.

Low, J. R., Jr.↗
NASA NTRS1993

Radioactivities induced in some LDEF samples

Radioactivities induced in several Long Duration Exposure Facilities (LDEF) samples were measured by low-level counting at Los Alamos and elsewhere. These radionuclides have activities similar to those observed in meteorites and lunar samples. Some trends were observed in these measurements in terms of profiles in trunnion layers and as a function of radionuclide half-life. Several existing computer codes were used to model the production by the protons trapped in the Earth's radiation belts and by the galactic cosmic rays of some of these radionuclides, Mn-54 and Co-57 in steel, Sc-46 in titanium, and Na-22 in alloys of titanium and aluminum. Production rates were also calculated for radionuclides possibly implanted in LDEF, Be-7, Be-10, and C-14. Enhanced concentrations of induced isotopes in the surfaces of trunnion sections relative to their concentrations in the center are caused by the lower-energy protons in the trapped radiation. Secondary neutrons made by high-energy trapped protons and by galactic cosmic rays produce much of the observed radioactivities, especially deep in an object. Comparisons of the observed to calculated activities of several radionuclides with different half-lives indicate that the flux of trapped protons at LDEF decreased significantly at the end of the mission.

Reedy, Robert C.↗
NASA NTRS2003

Selection And Evaluation Of An Alloy For Nozzle Application

The present work includes results on material characterization conducted under COBRA Hydrogen Cooled Nozzle Program and was funded by NASA MSFC. The nozzle requires a material that has high strength at ambient and high (up to l200 F) temperatures in air and hydrogen. Presently, a precipitation hardened steel; A-286 is used in nozzles for Space Shuttle Engines. The A-286 alloy has limited hydrogen compatibility and weldability. The present work focused on selection and characterization of JBK-75 alloy that has significantly higher capability in hydrogen and weldability in addition to other attributes. The alloy was evaluated at different temperatures and environments. Tungsten Inert Gas (TIG) and Electron Beam welding techniques were used to evaluate the weldability of material. Brazing was also conducted on the alloy and evaluated. The characterization of base JBK-75 alloy, welded and brazed alloy included tensile properties, low cycle fatigue and crack growth resistance at different temperatures in air and hydrogen environments. The results indicated that JBK-75 has excellent tensile and fatigue properties in air and hydrogen. The welded and brazed alloy also showed very good properties.

Pandey, A. B.↗
NASA NTRS1983

An experimental investigation of the internal methane pressure in hydrogen attack

An experimental investigation of the internal methane pressure that is the driving force for bubble growth in hydrogen attack (HA) was done on pure iron (204 ppm C) and on two low carbon steels of slightly different compositions. The methane content N (c.c gas/g. material) in attacked specimens was measured by a vacuum extraction technique. The total void volume V (c.c) was determined from density measurements before and after HA exposure. The two values, N and V, were then used in an equation of state to calculate an average methane pressure P for the attack stages beyond a density loss (d.l.) greater than 0.05 pct. It was determined that N and P depend on hydrogen exposure conditions and the presence of traces of strong carbide forming alloying elements (in steel). They are independent of specimen size and grain size over a limited range. P varies as the bubble volume increases, showing a generally decreasing trend which brings it to values lower than calculated equilibrium pressures, although well within the same order of magnitude. Possible reasons for this behavior are discussed.

Natan, M.↗
NASA NTRS2001

Lightweight Chambers for Thrust Assemblies

The Marshall Space Flight Center (MSFC) of the National Aeronautics and Space Administration (NASA) has successfully applied new materials and fabrication techniques to create actively cooled thrust chambers that operate 200-400 degrees hotter and weigh 50% lighter than conventional designs. In some vehicles, thrust assemblies account for as much as 20% of the engine weight. So, reducing the weight of these components and increasing their operating range will benefit many engines and vehicle designs, including Reusable Launch Vehicle (RLV) concepts. Obviously, copper and steel alloys have been used successfully for many years in the chamber components of thrust assemblies. Yet, by replacing the steel alloys with Polymer Matrix Composite (PMC) and/or Metal Matrix Composite (MMC) materials, design weights can be drastically reduced. In addition, replacing the traditional copper alloys with a Ceramic Matrix Composite (CMC) or an advanced copper alloy (Cu-8Cr-4Nb, also known as GRCop-84) significantly increases allowable operating temperatures. Several small MMC and PMC demonstration chambers have recently been fabricated with promising results. Each of these designs included GRCop-84 for the cooled chamber liner. These units successfully verified that designs over 50% lighter are feasible. New fabrication processes, including advanced casting technology and a low cost vacuum plasma spray (VPS) process, were also demonstrated with these units. Hot-fire testing at MSFC is currently being conducted on the chambers to verify increased operating temperatures available with the GRCop-84 liner. Unique CMC chamber liners were also successfully fabricated and prepared for hot-fire testing. Yet, early results indicate these CMC liners need significantly more development in order to use them in required chamber designs. Based on the successful efforts with the MMC and PMC concepts, two full size "lightweight" chambers are currently being designed and fabricated for hot-fire testing at MSFC in 2001. These "full size" chambers will be similar in size to those used on the X33 engine (RS2200). One will be fabricated with a MMC structural jacket, while the other uses a PMC jacket. Each will be designed for thrust levels of 15,000 pounds in an oxygen/hydrogen environment with liquid hydrogen coolant. Both chambers will use GRCop-84 for its channel wall liner. Each unit is expected to be at least 60% lighter than a conventional design with traditional materials. Hot-fire testing on the full size units in late 2001 will directly compare performance results between a conventional chamber design and these "lightweight" alternatives. The technology developed and demonstrated by this effort will not only benefit next generation RLV programs, but it can be applied to other existing and future engine programs, as well. Efforts were sponsored by the Advanced Space Transportation Program for RLV Focused Technologies. The task team was led by MSFC with additional members from NASA-Glenn Research Center and the Rocketdyne Division of The Boeing Company. Specific materials development and fabrication processes were provided by Aerojet, Lockheed Martin Astronautics, Composite Optics, Inc., Hyper-Therm, Ceramic Composites, Inc., MSE Technology Applications, and Plasma Processes, Inc.

Elam, Sandra K.↗
NASA NTRS1998

An Evaluation of the Plasticity-Induced Crack-Closure Concept and Measurement Methods

An assessment of the plasticity-induced crack-closure concept is made, in light of some of the questions that have been raised on the validity of the concept, and the assumptions that have been made concerning crack-dp damage below the crack-opening stress. The impact of using other crack-tip parameters, such as the cyclic crack-tip displacement, to model crack-growth rate behavior was studied. Crack-growth simulations, using a crack-closure model, showed a close relation between traditional Delta K eff, and the cyclic crack-tip displacement (Delta eff) for an aluminum alloy and a steel. Evaluations of the cyclic hysteresis energy demonstrated that the cyclic plastic damage below the crack-opening stress was negligible in the Paris crack-growth regime. Some of the standard and newly proposed remote measurement methods to determine the 'effective' crack-tip driving parameter were evaluated on middle-crack tension specimens. A potential source of the Kmax effect on crack-growth rates was studied on an aluminum alloy. Results showed that the ratio of Kmax to Kc had a strong effect on crack-growth rates at high stress ratios and at low stress ratios for very high stress levels. The crack-closure concept and the traditional crack-growth rate equations were able to correlate and predict crack-growth rates under these extreme conditions.

Newman, James C., Jr.↗
NASA NTRS2017

Cryo-Gearbox Using Bulk Metallic Glasses

Harmonic drives are a highly efficient and compact gearing technology that are widely used in robotics and aerospace applications (e.g. Mars Science Lab) due to their excellent torque-to-mass ratio, low backlash, and high positional accuracy. One major problem using any gearing on other planetary bodies is the need for heaters to keep the gearbox from freezing. Currently the Mars Science Lab uses 40% of its daily power output to operate heaters to keep the grease in the gearboxes from freezing. Also wear can limit the lifetime and performance of these systems. One possible solution to this problem could be to use a relatively new material known as Bulk Metallic Glasses (BMGs, also known as Amorphous Metals). BMGs are non-crystalline metallic alloys that exhibit superior mechanical properties. Compared to modern aerospace steels BMGs have a higher strength, higher elastic limit, and lower density. BMGs used in harmonic drives (especially the flex spline) could lead to longer system lifetimes, lower mass, and increased performance. Jet Propulsion Laboratory (JPL) is researching a new method of manufacturing the flex spline by injection molding and is hoping to have reduced costs as well as the benefits listed above. In conjunction with Kennedy Space Center (KSC), JPL is providing gearboxes that KSC will test greaseless in an extreme environment. KSC has completed the assembly and checkout of a test stand that is capable of testing a gearbox in a vacuum of less than 2 milli torr, 100 Kelvin temperature, 250 Nm of load, input and output torque measurements and 120 RPM input speed.

Drew Smith↗
NASA NTRS1996

Mechanical and Thermal Properties of Two Cu-Cr-Nb Alloys and NARloy-Z

A series of creep tests were conducted on Cu-8 Cr-4 Nb (Cu-8 at.% Cr-4 at.% Nb), Cu-4 Cr-2 Nb (Cu-4 at.% Cr-2 at% Nb), and NARloy-Z (Cu-3 wt.% Ag-0.5 wt.% Zr) samples to determine their creep properties. In addition, a limited number of low cycle fatigue and thermal conductivity tests were conducted. The Cu-Cr-Nb alloys showed a clear advantage in creep life and sustainable load over the currently used NARloy-Z. Increases in life at a given stress were between 100% and 250% greater for the Cu-Cr-Nb alloys depending on the stress and temperature. For a given life, the Cu-Cr-Nb alloys could support a stress between 60% and 160% greater than NARloy-Z. Low cycle fatigue lives of the Cu-8 Cr-4 Nb alloy were equivalent to NARloy-Z at room temperature. At elevated temperatures (538 C and 650 C), the fatigue lives were 50% to 200% longer than NARloy-Z samples tested at 538 C. The thermal conductivities of the Cu-Cr-Nb alloys remained high, but were lower than NARloy-Z and pure Cu. The Cu-Cr-Nb thermal conductivities were between 72% and 96% that of pure Cu with the Cu-4 Cr-2 Nb alloy having a significant advantage in thermal conductivity over Cu-8 Cr4 Nb. In comparison, stainless steels with equivalent strengths would have thermal conductivities less than 25% the thermal conductivity of pure Cu. The combined results indicate that the Cu-Cr-Nb alloys offer an attractive alternative to current high temperature Cu-based alloys such as NARloy-Z.

Ellis, David L.↗
NASA NTRS2023

Shock- and Corrosion-Resistant Bearings for Space Mechanisms

Nickel-titanium (NiTi) alloys are an emerging class of materials for rolling element bearing applications that require superior corrosion resistance and/or high load capability. Certain space mechanisms fall into one or both of those categories. Often, due to size and mass considerations, space mechanism systems are limited in torque margin and necessarily require small, precision-instrument bearings with very little frictional drag (i.e., low torque). In addition, space mechanism bearings must survive launch conditions without suffering raceway dents known as brinnelling, which would increase operating torque and reduce overall smoothness. Consequently, a bearing material or design that reduces or eliminates brinnelling under high contact stress conditions would represent a beneficial technology advancement. One specific alloy, nickel-titanium-hafnium (NiTi-Hf), under development for several years at the NASA Glenn Research Center as a bearing material, has the potential to mitigate concerns about brinnelling under extreme load conditions due to its unusually high elastic strain capability. In the present work, a sample of small precision bearings produced with three different ball materials (steel, ceramic, and NiTi-Hf) is subjected to a range of load conditions sufficient to dent the races. The dent depth as a function of load is compared and demonstrates that NiTi-Hf has the potential to increase bearing load capacity from the perspective of brinnelling under severe load conditions; additional testing of full NiTi-Hf bearings demonstrates corrosion resistance superior to that of 440C bearings.

Bearings↗
NASA NTRS2002

Surface Enhancement Improves Crack Resistance

The low plasticity burnishing (LPB) process produces a deep layer of surface compression in a quick and affordable manner to produce metal surfaces free of scratches, nicks, and gouges. The process, designed for easy inclusion in the manufacturing environment, can be performed with conventional Computer Numerical Control machine tools. This allows parts to be processed during manufacturing, rather than as a post process in a separate facility. A smooth, free-rolling spherical ball suspended in a fluid allows for single-point contact. The ball comes into mechanical contact only with the surface to be burnished, and can be moved in any direction. LPB can be applied to all types of carbon and alloy steel, stainless steel, cast iron, aluminum, titanium, and nickel- based super alloys. In addition to improving a surface's resistance to fatigue and damage, treatment stops the growth of shallow cracks. The LPB process is used on the leading edges of turbine blades to improve resistance to foreign object damage and crack growth. This means significant savings for aircraft owners, since maintenance requirements to inspect for fatigue damage, replace parts, and remove corrosion damage increase the cost of operation.

Source record↗
NASA NTRS2018

Ni-Ti Next Generation Bearings for Space Applications

NASA applications challenge traditional bearing materials. The rigors of launch often include heavy shock loads and exposure to corrosive environments (e.g., salt spray). Unfortunately, ball and roller bearings made from hardened steels are vulnerable to Brinell denting and rust which can limit performance and life. Ceramic materials can eliminate corrosion concerns but their high stiffness and extreme hardness actually makes denting problems worse. In this presentation, an emerging superelastic alloy, NiTi, is introduced for rolling element bearing applications. Through a decade of RD, NiTi alloy bearings have been put through a comprehensive series of life and performance tests. Hardness, corrosion, strength, stiffness, and rolling contact fatigue tests have been conducted and reported. Ball bearings ranging in size from 12 to 50mm bore have been successfully engineered and operated over a wide range of speeds and test conditions including being submerged in water. The combination of high hardness, moderate elastic modulus, low density, and intrinsic corrosion immunity provide new possibilities for mechanisms that operate under extreme conditions. Recent preliminary tests indicate that bearings can be made from NiTi alloys that are easily lubricated by conventional oils and greases and exhibit acceptable rolling contact fatigue resistance. This presentation introduces the NiTi materials systems and shows how NASA is using it to alleviate several specific problems encountered in advanced space applications.

bearings↗
NASA NTRS1974

An investigation of the plastic fracture of AISI 4340 and 18 nickel - 200 grade maraging steels

The mechanisms of plastic fracture (dimpled rupture) in high-purity and commercial 18 Ni, 200 grade maraging steels and quenched and tempered AISI 4340 steels have been studied. Plastic fracture takes place in the maraging alloys through void initiation by fracture of titanium carbo-nitride inclusions and the growth of these voids until impingement results in coalescence and final fracture. The fracture of AISI 4340 steel at a yield strength of 200 ksi occurs by nucleation and subsequent growth of voids formed by fracture of the interface between manganese sulfide inclusions and the matrix. The growth of these inclusion-nucleated voids is interrupted long before coalescence by impingement, by the formation of void sheets which connect neighboring sulfide-nucleated voids.

Cox, T. B.↗
NASA NTRS2014

Crack Growth Behavior in the Threshold Region for High Cycle Fatigue Loading

The research results described in this paper presents a new understanding of the behavior of fatigue crack growth in the threshold region. It is believed by some crack growth experts that the ASTM load shedding test method does not produce true or valid threshold properties. The concern involves the observed fanning of threshold region da/dN data plots for some materials in which the low R-ratio data fans out or away from the high R-ratio data. This data fanning or elevation of threshold values is obviously caused by an increase in crack closure in the low R-ratio tested specimens. This increase in crack closure is assumed by some investigators to be caused by a plastic wake on the crack surfaces that was created during the load shedding test phase. This study shows that the increase in crack closure is the result of an extensive occurrence of crack bifurcation behavior in some materials, particularly in aluminum alloys, when the crack tip cyclic yield zone size becomes less than the grain size of the alloy. This behavior is related to the high stacking fault energy (SFE) property of aluminum alloys which results in easier slip characteristics. Therefore, the particular fanning behavior in aluminum alloys is a function of intrinsic dislocation property of the materials and that the fanned data represents valid material properties. However, for corrosion sensitive steel alloys used in this study the fanning was caused by a build-up of iron oxide at the crack tip from fretting corrosion.

Forman, Royce G.↗
NASA NTRS1964

Studies of Lubricating Materials in Vacuum

Lubricating materials for use in a vacuum environment have been the subject of a series of experimental investigations. Evaporation properties were evaluated for solid polymeric compositions. Friction and wear studies explored the behavior during sliding contact for series of polymeric compositions, binary alloys containing soft film-forming phases, complex alloys with film-forming materials, and a burnished MoS2 film. Friction and wear experiments were conducted at 10(exp-9)mm Hg with a 3/16-inch-radius-hemisphere rider specimen sliding on the flat surface of a rotating 2-1/2-inch-diameter disk specimen with materials that had low rates of evaporation. The influence of fillers in polytetrafluoroethylene (PTFE) on decomposition during vacuum friction studies was determined with a mass spectrometer. A real advantage in reducing decomposition and improving friction wear properties is gained by adding fillers (e.g., copper) that improve thermal conductivity through the composite materials. A polyimide and an epoxy-MoS2 composition material were found to have better friction and wear properties than PTFE compositions. A series of alloys (cast binary as well as more complex alloys) that contained microinclusions of potential film-forming material was studied. These materials replaced the normal surface oxides as they were worn away on sliding contact. Iron sulfide, nickel oxide, and tin are typical film-forming materials employed and were demonstrated to be effective in inhibiting surface welding and reducing friction. A burnished MoS2 film applied to type 440-C stainless steel in argon with a rotating soft wire brush had good endurance properties but somewhat higher friction than commercially available bonded films. An oil film applied to the burnished MoS2 markedly reduced its endurance life.

WEAR↗
NASA NTRS2001

The Role of Convection and Growth Competition in Phase Selection in Microgravity: Controlled Convection in the Containerless Processing of Steel Alloys

Containerless processing using electromagnetic levitation (EML) is a powerful technique in the investigation of reactive molten metal systems. On ground, the power required to overcome the weight of the sample is sufficient to cause significant heating and induce substantial melt convection. In microgravity, the heating and positioning fields may be decoupled and the field strength may be varied to achieve the desired level of convection within the limits set by the geometry of the levitation coil and the sample size. From high-speed digital images of the double recalescence behavior of Fe-Cr-Ni alloys in ground-based testing and in reduced-gravity aboard the NASA KC-135 parabolic aircraft, we have shown that phase selection can be predicted based on a growth competition model. An important parameter in this model is the delay time between primary nucleation and subsequent nucleation of the stable solid within the liquid/metastable solid array. This delay time is a strong function of composition and a weak function of the undercooling of the melt below the metastable liquidus. From the results obtained during the first Microgravity Sciences Laboratory (MSL-1) mission, we also know that convection may significantly influence the delay time, especially at low undercoolings. Currently, it is unclear what mechanism controls the formation of a heterogeneous site that allows nucleation of the austenitic phase on the pre-existing ferrite skeleton. By examining the behavior of the delay time under different convective conditions, we hypothesize that we can differentiate between several of these mechanisms to gain an understanding of how to control microstructural. evolution. We will anchor these predictions by examining samples quenched at different times following primary recalescence in microgravity. A second important parameter in the growth competition model is the identification of the growth rate of the stable phase into the semi-solid array that formed during primary recalescence. Current dendritic growth theory is inadequate in predicting solidification behavior under these conditions as metallographic analyses show that stable phase growth proceeds along the interface between the metastable solid and residual liquid. Since growth velocity is independent of the initial undercooling relative to the metastable liquidus, we hypothesize that purely thermal effects can be separated from other important growth model parameters by careful selection of the liquid composition in a ternary system.

Matson, D. M.↗