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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Wrapped Wire Detects Rupture Of Pressure Vessel

Simple, inexpensive technique helps protect against damage caused by continuing operation of equipment after rupture or burnout of pressure vessel. Wire wrapped over area on outside of vessel where breakthrough most likely. If wall breaks or burns, so does wire. Current passing through wire ceases, triggering cutoff mechanism stopping flow in vessel to prevent further damage. Applied in other situations in which pipes or vessels fail due to overpressure, overheating, or corrosion.

Hunt, James B.↗
NASA NTRS1939

The Effect of Continuous Weathering on Light Metal Alloys Used in Aircraft

An investigation of the corrosion of light metal alloys used in aircraft was begun at the National Bureau of Standards in 1925 and has for its purpose causes of corrosion in aluminum-rich and magnesium-rich alloys together with the development of methods for its prevention. The results, obtained in an extensive series of laboratory and weather-exposure tests, reveal the relative durability of a number of commercially available materials and the extent to which the application of various surface coatings of oxide alone and with paint coatings afforded additional protection. The paper may be considered as a supplement to NACA report 490.

Mutchler, Willard↗
NASA NTRS2015

Body of Knowledge (BOK) for Copper Wire Bonds

Copper wire bonds have replaced gold wire bonds in the majority of commercial semiconductor devices for the latest technology nodes. Although economics has been the driving mechanism to lower semiconductor packaging costs for a savings of about 20% by replacing gold wire bonds with copper, copper also has materials property advantages over gold. When compared to gold, copper has approximately: 25% lower electrical resistivity, 30% higher thermal conductivity, 75% higher tensile strength and 45% higher modulus of elasticity. Copper wire bonds on aluminum bond pads are also more mechanically robust over time and elevated temperature due to the slower intermetallic formation rate - approximately 1/100th that of the gold to aluminum intermetallic formation rate. However, there are significant tradeoffs with copper wire bonding - copper has twice the hardness of gold which results in a narrower bonding manufacturing process window and requires that the semiconductor companies design more mechanically rigid bonding pads to prevent cratering to both the bond pad and underlying chip structure. Furthermore, copper is significantly more prone to corrosion issues. The semiconductor packaging industry has responded to this corrosion concern by creating a palladium coated copper bonding wire, which is more corrosion resistant than pure copper bonding wire. Also, the selection of the device molding compound is critical because use of environmentally friendly green compounds can result in internal CTE (Coefficient of Thermal Expansion) mismatches with the copper wire bonds that can eventually lead to device failures during thermal cycling. Despite the difficult problems associated with the changeover to copper bonding wire, there are billions of copper wire bonded devices delivered annually to customers. It is noteworthy that Texas Instruments announced in October of 2014 that they are shipping microcircuits containing copper wire bonds for safety critical automotive applications. An evaluation of copper wire bond technology for applicability to spaceflight hardware may be warranted along with concurrently compiling a comprehensive understanding of the failure mechanisms involved with copper wire bonded semiconductor devices.

Body of Knowledge (BOK)↗
NASA NTRS2003

Thermographic Inspections Save Skins and Prevent Blackouts

Scanning thermography involves heating a component s surface and subsequently measuring the surface temperature, using an infrared camera to identify structural defects such as corrosion and disbonding. It is a completely noninvasive and noncontacting process. Scans can detect defects in conventional metals and plastics, as well as in bonded aluminum composites, plastic- and resinbased composites, and laminated structures. The apparatus used for scanning is highly portable and can cover the surface of a test material up to six times faster than conventional thermography. NASA scientists affirm that the technology is an invaluable asset to the airlines, detecting potential defects that can cause structural failure.In 1996, ThermTech Services, Inc., of Stuart, Florida, approached NASA in an effort to evaluate the technology for application in the power and process industries, where corrosion is of serious concern. ThermTech Services proceeded to develop the application for inspecting boiler waterwall tubing at fossil-fueled electric-generating stations. In 1999, ThermTech purchased the rights to NASA s patented technology and developed the specialized equipment required to apply the inspecting method to power plant components. The ThermTech robotic system using NASA technology has proved to be extremely successful and cost effective in performing detailed inspections of large structures such as boiler waterwalls and aboveground chemical storage tanks. It is capable of inspecting a waterwall, tank-wall, or other large surfaces at a rate of approximately 10 square feet per minute or faster.

Source record↗
NASA NTRS1980

Hot corrosion of Co-Cr, Co-Cr-Al, and Ni-Cr alloys in the temperature range of 700-750 deg C

The effect of SO3 pressure in the gas phase on the Na2SO4 induced hot corrosion of Co-Cr, Ni-Cr, and Co-Cr-Al alloys was studied in the temperature range 700 to 750 C. The degradation of the Co-Cr and Ni-Cr alloys was found to be associated with the formation of liquid mixed sulfates (CoSO4-Na2SO4 or NiSO4-Na2SO4) which provided a selective dissolution of the Co or Ni and a subsequent sulfidation oxidation mode of attack which prevented the maintenance of a protective Cr2O3 film. A clear mechanism was not developed for the degradation of Co-Cr-Al alloys. A pitting corrosion morphology was induced by a number of different mechanisms.

Chiang, K. T.↗
NASA NTRS1971

Ceramic backup ring prevents undesirable weld-metal buildup

Removable ceramic backup material butted against weld zone back prevents weld metal buildup at that site. Method is successful with manual tungsten-inert gas /TIG/ welding of 316 corrosion resistant steel /CRES/ pieces with 0.76 cm throat diameter and 1.57 cm pipe internal diameter.

Leonard, G. E.↗
NASA NTRS1990

Flight set 360L001 (STS-26) igniter, post flight

Space Transportation System (STS-26) was launched from KSC pad 39B. Two of the Redesigned Solid Rocket Motors (RSRM) were part of the launch system and are designated RSRM-1A and RSRM-1B. Each of these motors were initiated by an 1U75164 igniter. The post flight condition of the igniters and associated components is documented. The overall performance of the igniter components was excellent. No damage or heat affected areas were noted. The sealing elements of the igniter functioned as expected with no evidence of erosion or blowby. The thermal protection system protected all areas adequately. No excessive erosion was noted. Corrosion was found in the special bolt holes in the igniter chamber. The corrosion will not affect refurbishment of the chamber. Beginning with flight 5 grease has been added to the chamber holes to prevent this erosion.

Hale, Elgie J.↗
NASA NTRS2005

Reaction Control System Thruster Cracking Consultation: NASA Engineering and Safety Center (NESC) Materials Super Problem Resolution Team (SPRT) Findings

The shuttle orbiter s reaction control system (RCS) primary thruster serial number 120 was found to contain cracks in the counter bores and relief radius after a chamber repair and rejuvenation was performed in April 2004. Relief radius cracking had been observed in the 1970s and 1980s in seven thrusters prior to flight; however, counter bore cracking had never been seen previously in RCS thrusters. Members of the Materials Super Problem Resolution Team (SPRT) of the NASA Engineering and Safety Center (NESC) conducted a detailed review of the relevant literature and of the documentation from the previous RCS thruster failure analyses. It was concluded that the previous failure analyses lacked sufficient documentation to support the conclusions that stress corrosion cracking or hot-salt cracking was the root cause of the thruster cracking and lacked reliable inspection controls to prevent cracked thrusters from entering the fleet. The NESC team identified and performed new materials characterization and mechanical tests. It was determined that the thruster intergranular cracking was due to hydrogen embrittlement and that the cracking was produced during manufacturing as a result of processing the thrusters with fluoride-containing acids. Testing and characterization demonstrated that appreciable environmental crack propagation does not occur after manufacturing.

MacKay, Rebecca A.↗
NASA NTRS1962

Titanium-Oxygen Reactivity Study

A program has been conducted at Astronautics to investigate the likelihood of occurrence of the catastrophic oxidation of titanium alloy sheet under conditions which simulate certain cases of accidental failure of the metal while it is in contact with liquid or gaseous oxygen. Three methods of fracturing the metal were used; they consisted of mechanical puncture, tensile fracture of welded joints, and perforation by very high velocity particles. The results of the tests which have been conducted provide further evidence of the reactivity of titanium with liquid and gaseous oxygen. The evidence indicates that the rapid fracturing of titanium sheet while it is in contact with oxygen initiates the catastrophic oxidation reaction. Initiation occurred when the speed of the fracture was some few feet per second, as in both the drop-weight puncture tests and the static tensile fracture tests of welded joints, as well as when the speed was several thousand feet per second, as in the simulated micrometeoroid penetration tests. The slow propagation of a crack, however, did not initiate the reaction. It may logically be concluded that the localized frictional heat of rapid fracture and/or spontaneous oxidation (exothermic) of minute particles emanating from the fracture cause initiation of the reaction. Under conditions of slow fracture, however, the small heat generated may be adequately dissipated and the reaction is not initiated. A portion of the study conducted consisted of investigating various means by which the reaction might be retarded or prevented. Providing a "barrier" at the titanium-oxygen interface consisting of either aluminum metal or a coating of a petroleum base corrosion inhibitor appeared to be only partially effective in retarding the reaction. The accidental puncturing or similar rupturing of thin-walled pressurized oxygen tanks on missiles and space vehicle will usually constitute loss of function, and may sometimes cause their catastrophic destruction by explosive decompression regardless of the type of material used for their construction. In the case of tanks constructed of titanium alloys the added risk is incurred of catastrophic burning of the tanks. In view of this it is recommended that thin-walled tanks constructed of titanium alloys should not be used to contain liquid or gaseous oxygen.

Chafey, J. E.↗
NASA NTRS1989

Test Data of Flow Field of Shuttle SRM Nozzle Joint with Bond Defects, Using Unheated Air

The nozzle-to-case joint on the Shuttle SRM (as redesigned after the Challenger accident) features an adhesive sealant filling and bonding the joint, with a wiper O-ring to prevent the adhesive from reaching and disabling the closure O-ring. Flawless implementation of that joint design would ensure that hot, corrosive propellant combustion gases never reach the closure O-ring. However, understanding the flow field related to bonding defects is prudent. A comprehensive test program was conducted to quantify such flow fields and associated heating environments. A two-dimensional, full-scale model represented 65 inches of the nozzle joint, using unheated air as the test medium, in a blowdown mode. Geometry variations modeled RSRM assembly tolerances, and two types of bonding defects: pullaways and blowholes. A range of the magnitude of each type defect was tested. Also a range of operational parameters was tested, representative of the RSRM flow environment, including duplication of RSRM Mach and Reynolds numbers. Extensive instrumentation was provided to quantify pressures, heat rates, and velocities. The resulting data established that larger geometric defects cause larger pressure and larger heating, at the closure O-ring region. Velocity trends were not so straight-forward. Variations in assembly tolerances did not generally affect flow fields or heating. Operational parameters affected flow fields and heating as might be expected, increasing density or velocity increased heating. Complete details of this test effort are presented.

Hair, Leroy M.↗
NASA NTRS1992

UPT scenarios: Implications for system reliability

The objective of this project was to examine the corrosion resistance of 316L stainless steel in several urine pre-treat solutions. Four solutions were examined: untreated urine (control); urine pretreated with oxone (potassium peroxymonosulfate sulfate); urine pretreated with sodium hypochlorite (NaOCl); and urine pretreated with ozone (O3). In accordance with current procedures, all solutions but the control were acidified to a pH of 2.5 using sulfuric acid--this suppresses the generation of ammonia in the solutions and is intended to limit microbial growth. Welded and unwelded coupons were exposed to each solution. In addition, Titanium coupons (welded and unwelded) were exposed to biologically active environmental control and life support system (ECLSS) water. Microbial attachment and biofilm growth were monitored. Ozone was examined as a biocide/oxidizer/corrosion preventative (simultaneous addition) and as a remediation method (added one week after exposure). In an unrelated effort, HP 9-4-30 coupons were exposed to biologically active solutions. Corrosion rates for welded and unwelded samples were determined--results were correlated to the ongoing HP 9-4-30 weldment stress corrosion study.

Walsh, Daniel W.↗
NASA NTRS1982

Oceanic corrosion test of bare and zinc-protected aluminum alloys for seawater heat exchangers

Bare 3004 tubes, 7072 Alclad 3004 tubes, and bare and zinc diffusion treated 3003 extrusions from a brazed aluminum, plate-fin heat exchanger were exposed to 1.8 m/sec flowing seawater aboard an open ocean test facility moored 3.4 km off the southeast coast of Puerto Rico. After six months exposure, the average corrosion rates for most varieties of aluminum materials converged to a low value of 0.015 mm/yr (0.6 mils/yr). Pitting did not occur in bare 3003 and 3004 samples during the six month test. Pitting did occur to varying degrees in the Alclad and zinc diffusion treated material, but did not penetrate to the base metal. Biofouling countermeasures (intermittent chlorination and brushing) did not affect the corrosion rates to any significant extent. Intermittent chlorination at a level of 0.5 ppm for 28 minutes daily controlled microbiofouling of the samples but did not prevent the development of a macrobiofouling community in areas of the plumbing with low flow.

Sasscer, D. S.↗
NASA NTRS2015

Lightning Protection and Structural Bonding for the B2 Test Stand

With the privatization of the space industry, NASA has entered a new era. To explore deeper parts of the solar system, NASA is developing a new spacecraft, the Space Launch System (SLS), capable of reaching these destinations, such as an asteroid or Mars. However, the test stand that is capable of testing the stage has been unused for many years. In addition to the updating/repair of the stand, more steel is being added to fully support the SLS. With all these modifications, the lightning protection system must be brought up to code to assure the protection of all personnel and assets. Structural bonding is a part of the lightning protection system. The focus of this project was to assure proper structural bonding. To begin, all relevant technical standards and the construction specifications were reviewed. This included both the specifications for the lightning protection and for general construction. The drawings were reviewed as well. From the drawings, bolted structural joints were reviewed to determine whether bonding was necessary. Several bolted joints were determined to need bonding according to the notes in the drawings. This exceeds the industry standards. The bolted joints are an electrically continuous joint. During tests, the stand experiences heavy vibration that may weaken the continuity of the bolted joint. Therefore, the secondary bonding is implemented to ensure that the structural joint has low resistance. If the structural joint has a high resistance because of corrosion, a potential gradient can occur that can cause a side flash. Damage, injury, or death can occur from a side flash so they are to be prevented. A list of the identified structural joints was compiled and sent to the contractor to be bonded. That covers the scope of this project.

Kinard, Brandon↗
NASA NTRSDate not supplied

Progress of Aluminum/Air Battery Development for SUSAN Electrofan Project

Safe and high-performance battery technologies are demanded by the Subsonic Single Aft eNgine (SUSAN) Electrofan concept design project under National Aeronautics and Space Administration (NASA) electrified aircraft development program. Aluminum (Al)-air battery with very high theoretical specific energy density, is considered as promising battery chemistry which has the potential to meet the targeted specific energy goal of primary battery energy technology for the SUSAN project. In addition to having the exceptional electrochemical properties, aluminum is light weight, rich abundance, low cost, environmentally friendly, and has a good electrical conductivity and recyclability, which is among the key characteristics of SUSAN project on battery energy needs. A non-flammable aqueous electrolyte is used to prevent the fire and thermal runaway hazard for the safety of this battery chemistry. However, there are challenges for Al-air battery in practical application, mainly due to self-corrosion of Al and slow kinetics of oxygen reduction in air-cathode to impact the high-rate performance. Progress on addressing these challenges was made and some of the results were reported in our previous paper. In this paper, the focus is on the investigation of various factors, including electrolyte concentrations, temperature, and air-cathode loadings on ionic transport properties and discharge performance at different current densities. The results are discussed, and the progress is reported.

James J Wu↗
NASA NTRS1979

Restoration Process

In the accompanying photos, a laboratory technician is restoring the once-obliterated serial number of a revolver. The four-photo sequence shows the gradual progression from total invisibility to clear readability. The technician is using a new process developed in an applications engineering project conducted by NASA's Lewis Research Center in conjunction with Chicago State University. Serial numbers and other markings are frequently eliminated from metal objects to prevent tracing ownership of guns, motor vehicles, bicycles, cameras, appliances and jewelry. To restore obliterated numbers, crime laboratory investigators most often employ a chemical etching technique. It is effective, but it may cause metal corrosion and it requires extensive preparatory grinding and polishing. The NASA-Chicago State process is advantageous because it can be applied without variation to any kind of metal, it needs no preparatory work and number recovery can be accomplished without corrosive chemicals; the liquid used is water.

Source record↗
NASA NTRS2000

New Alloys for Electroformed Replicated X-Ray Optics

The process of electroforming x-ray mirror shells off a superpolished mandrel has been widely used. The recently launched XMM mission is a good example of this, containing 174 such mirror shells of diameters ranging from 0.3-0.7 m and thicknesses of 0.47-1.07 mm. To continue to utilize this technique for the next generation of x-ray observatories, where ever-larger collecting areas will be required within the constraints of tight weight budgets, demands that new alloys be developed that can withstand the large stresses imposed on very thin shells by the replication and handling processes. Towards this end, we began a development program in late 1997 to produce a high-strength alloy suitable for electroforming very thin high-resolution x-ray optics. The requirements for this task are quite severe; not only must the electroformed deposit be very strong, it must also have extremely low residual stresses to prevent serious figure distortions in large thin-walled shells. Further, the electroforming must be performed at near room temperature, as large temperature changes will modify the figure of the mandrel, in an environment that is not corrosive for the mandrel. The figure of merit for the strength of the electroformed deposit is its Precision Elastic Limit (PEL). This is a measure of permanent strain, at the few parts per million level, under applied stress. Pure nickel is very ductile and will permanently deform, at the parts-per-million level under loads of a few x 10(exp 7) Pa. These stresses are easily exceeded when thin-walled shells (150 micron thick) are replicated. Our goal was to develop an alloy an order of magnitude stronger than this. We will present the results of our development program, showing the evolution of our plating baths through to our present 'glassy' nickel alloy that satisfies the goals above. For each we will show the electroforming characteristics of the bath and the PEL measurements for the resulting alloys. We estimate the ultimate limit on shell thickness and mass for x-ray mirrors produced in these baths.

Engelhaupt, D.↗
NASA NTRS1991

Effects Of Moisture On Zinc Orthotitanate Paint

Report presents results of tests of electrical conductivity and resistance to corrosion of zinc orthotitanate (ZOT) paint. Measured effects of temperature, humidity, and vacuum on ceramic paint. Used as temperature-control coating designed to have low and stable ratio of absorptance to emittance for heat radiation. Helps to prevent buildup of static electric charge and helps to protect electronic circuitry from potentially damaging static discharges.

Mon, Gordon R.↗