Metallic heat shield materials for space shuttle
Metallic heat shielding materials for space shuttle thermal protection system
Hall, R. W.↗
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Stress Corrosion Cracking of Metals in Propellants
Stress corrosion cracking (SCC) of a fracture critical metallic material can cause a premature failure if the material is susceptible in the unique service environment. Material fluid compatibility is an area of interest for the current NASA programs leading the human exploration path to Mars. White Sands Test Facility, the agency's lead on hypergolic propellant testing, identifies a lack in stress corrosion cracking susceptibility data for metallic materials in hypergolic propellants. The development of a stress corrosion cracking screening method is necessary to bridge the knowledge gap and enable the community to more confidently select materials for the use in systems containing corrosive fluids.
Alcantara, Ilse↗
Improved oil-off survivability of tapered roller bearings
The aim of this program is to improve the oil-off survivability of a tapered roller bearing when applied to a helicopter transmission, since the tapered bearing has shown a performance advantage in this application. However, the critical roller end-rib conjunction is vulnerable to damage in an oil-off condition. Three powdered metal materials were selected to use as the rib material for oil-off evaluation. These were: M2 steel to a 65% density, CBS 1000M 65% density, and CBS 1000M 75% density. The bearing styles tested were ribbed cone (inner race) and ribbed cup (outer race). Carburized solid CBS 600 was also used as a ribbed material for comparison of oil-off results. The tests were conducted at six speeds from 4000 rpm (0.26 million DN) through 37000 rpm (2.4 million DN).The ribbed cup style bearing achieved longer lives than the ribbed cone style. A standard bearing lasted only 10 minutes at 4000 rpm; however, the 30-min oil-off goal was achieved through 11000 rpm using the survivable ribbed cup bearing. The oil-off lives at 37000 rpm were less than 10 seconds. The grinding of the powder metal materials and surface preparation to achieve an open porosity is extremely critical to the oil-off performance of the powder metal component.
Kreider, Gary E.↗
Risk Assessment for Titanium Pressure Vessels Operating Inside the ARES I's Liquid Hydrogen Tank Environment
Titanium alloy (Ti-6-4) is currently being proposed for the manufacturing of pressure vessels (PV) for storage of compressed helium gas, which are mounted inside the ARES I's liquid hydrogen (LH2) tank. At cryogenic temperature, titanium alloys usually have the highest strength-to-weight ratio property and have been considered as the metallic materials of choice for lightweight PV operating in LH2 environment. Titanium PV s are also considered as heritage hardware because they have been used by NASA for the Saturn IV-B rocket s LH2 tank in the mid 1960 s. However, hydrogen embrittlement is possible if Ti-6-4 alloy is exposed to gaseous hydrogen at certain pressure and temperature during the LH2 tank filling and draining operations on the launch pad, and during the J2X engine burn period for the ARES I s upper stage. Additionally, the fracture toughness and ductility properties of Ti-6-4 are significantly decreased at cryogenic temperature. These factors do not necessary preclude the use of titanium PV in hydrogen or at cryogenic applications; however, their synergistic effects and the material damage tolerance must be accounted for in the mission life assessment for PV s, which are considered as fracture critical hardware. In this paper, an overview of the risk assessment for Ti-6-4 alloy, strategy to control hydrogen embrittlement and brief metallic material trade study for PV operating in LH2 tank will be presented.
Lee, Jonathan A.↗
Promoted Combustion Test Data Re-Examined
Promoted combustion testing of metallic materials has been performed by NASA since the mid-1980s to determine the burn resistance of materials in oxygen-enriched environments. As the technolo gy has advanced, the method of interpreting, presenting, and applying the promoted combustion data has advanced as well. Recently NASA changed the bum criterion from 15 cm (6 in.) to 3 cm (1.2 in.). This new burn criterion was adopted for ASTM G 124, Standard Test Method for Determining the Combustion Behavior- of Metallic Materials in Oxygen-Enriched Atmospheres. Its effect on the test data and the latest method to display the test data will be discussed. Two specific examples that illustrate how this new criterion affects the burn/no-bum thresholds of metal alloys will also be presented.
Lewis, Michelle↗
Back stress in dislocation creep. Part 1: Basic concepts and measuring techniques
A theory is proposed whereby the plastic deformation of metal materials is determined by the difference between the applied stress and the back stress which characterizes the resistance of the material to plastic deformation. The back stress is usually equivalent to the internal stress or the friction stress and depends on the magnitude of the applied stress and temperature. The concept of back stress is applied to the case of the dislocation creep of precipitation-hardened or dispersion-strengthened metal materials. An additivity rule is formulated which can be useful in interpreting the creep behavior of such materials.
Cadek, J.↗
Design of a unidirectional composite momentum wheel rim
A preliminary study comparing twelve unidirectional-fiber composite systems to five metal materials conventionally used in momentum wheels is presented. Six different fibers are considered in the study: E-Glass, S-Glass, Boron, AS, T300, and Kevlar. Because of the possibility of high momentum requirements, and thus high stresses, only two matrix materials are considered: a high-modulus (HM) and a intermediate-modulus-high-strength (IMHS) matrix. Each of the six fibers are coupled with each of the two matrix materials. In an effort to optimize the composite system, each composite is considered while varying the fiber volume ratio from 0.0 to 0.7 in increments of 0.1. For fiber volume ratios above 0.2, all twelve unidirectional-fiber composite systems meet the study's requirements with higher factors of safety and less mass than the five conventional isotropic (metal) materials. For example, at a fiber volume ratio of 0.6, the Kevlar/IMHS composite system has a safety factor 4.5 times greater than that of a steel (maraging) system and an approximately 10 percent reduction in weight.
Shogrin, Bradley↗
Low Pt content direct methanol fuel cell anode catalyst: nanophase PtRuNiZr
A method for the preparation of a metallic material having catalytic activity that includes synthesizing a material composition comprising a metal content with a lower Pt content than a binary alloy containing Pt but that displays at least a comparable catalytic activity on a per mole Pt basis as the binary alloy containing Pt; and evaluating a representative sample of the material composition to ensure that the material composition displays a property of at least a comparable catalytic activity on a per mole Pt basis as a representative binary alloy containing Pt. Furthermore, metallic compositions are disclosed that possess substantial resistance to corrosive acids.
Narayanan, Sekharipuram R.↗
Simulated orbital impact of multi-wall composite structures
This paper presents the results of an experimental investigation in which several different composite materials were tested for their ability to prevent the perforation of multiwall systems under hypervelocity projectile impact. The damage in the composite specimens is compared to the damage in aluminum specimens of similar geometry and weight caused by hypervelocity projectiles with similar impact energies. The analysis shows that using composite materials in combination with metallic materials in multiwall structures can increase the protection afforded a spacecraft against perforation by orbital debris over that provided by traditional, purely metallic multiwall structures.
Walker, Eve J.↗
Method of making self lubricating fluoride- metal composite materials Patent
Production of barium fluoride-calcium fluoride composite lubricant for bearings or seals
Sliney, H. E.↗
Crack barriers improve the mechanical and thermal properties of non-metallic sinter materials
Means of improving the tensile strength of ceramic composites by introducing ductile intermediate layers capable of absorbing the elastic energy at the rupture front are studied. Tests with an Al203 laminate with niobium inclusions showed that crack propagation could be successfully precluded by dissipation of the energy by deformation and/or delamination at the inclusion/matrix interface.
Gruenthaler, K. H.↗
Adhesion and friction of transition metals in contact with non-metallic hard materials
(Previously announced in STAR as N81-28233)
Miyoshi, K.↗
Non-linear properties of metallic cellular materials with a negative Poisson's ratio
Negative Poisson's ratio copper foam was prepared and characterized experimentally. The transformation into re-entrant foam was accomplished by applying sequential permanent compressions above the yield point to achieve a triaxial compression. The Poisson's ratio of the re-entrant foam depended on strain and attained a relative minimum at strains near zero. Poisson's ratio as small as -0.8 was achieved. The strain dependence of properties occurred over a narrower range of strain than in the polymer foams studied earlier. Annealing of the foam resulted in a slightly greater magnitude of negative Poisson's ratio and greater toughness at the expense of a decrease in the Young's modulus.
Choi, J. B.↗
Combustion synthesis of ceramic-metal composite materials in microgravity
Combustion synthesis, self-propagating high temperature synthesis (SHS) or reactive synthesis provides an attractive alternative to conventional methods of producing advanced materials since this technology is based on the ability of highly exothermic reactions to be self sustaining and, therefore, energetically efficient. The exothermic SHS reaction is initiated at the ignition temperature, T(sub ig), and generates heat which is manifested in a maximum or combustion temperature, T(sub c), which can exceed 3000 K . Such high combustion temperatures are capable of melting and/or volatilizing reactant and product species and, therefore, present an opportunity for producing structure and property modification and control through liquid-solid, vapor-liquid-solid, and vapor-solid transformations.
Moore, John↗
Investigation of Anomalous Behavior in Metallic-Based Materials Under Compressive Loading
An anomalous material response has been observed under the action of applied compressive loads in fibrous SiC/Ti (both Ti-6242 and Ti-15-3 alloys) and the monolithic nickel-base alloy IN-718 in the aged condition. The observed behavior is an increase, rather than a decrease, in the instantaneous Young's modulus with increasing load. This increase is small, but can be significant in yield surface determination tests, where an equivalent offset strain on the order of 10 micron(1 x 10(exp -6) m/m) is being used. Stiffening has been quantified by calculating offset strains from the linear elastic loading line. The offset strains associated with stiffening during compressive loading are positive and of the same order as the target offset strains in yield surface determination tests. At this time we do not have a reasonable explanation for this response nor can we identify a deformation mechanism that might cause it. On the other hand, we are not convinced that it is an artifact of the experimental procedure because a number of issues have been identified and seemingly ruled out. In fact, stiffening appears to be temperature dependent, since it decreases as the temperature increases.
Gil, Christopher M.↗
Metal Matrix Composite Materials for Aerospace Applications
Metal matrix composites (MMC) are attractive materials for aerospace applications because of their high specific strength, high specific stiffness, and lower thermal expansion coefficient. They are affordable since complex parts can be produced by low cost casting process. As a result there are many commercial and Department of Defense applications of MMCs today. This seminar will give an overview of MMCs and their state-of-the-art technology assessment. Topics to be covered are types of MMCs, fabrication methods, product forms, applications, and material selection issues for design and manufacture. Some examples of current and future aerospace applications will also be presented and discussed.
Bhat, Biliyar N.↗
2nd Generation RLV Airframe Structures and Materials
The goals and objectives of the project summarized in this viewgraph presentation are the following: (1) Develop and demonstrate verified airframe and cryotank structural design and analysis technologies, including damage tolerance, safety, reliability, and residual strength technologies, robust nonlinear shell and cryotank analysis technologies, high-fidelity analysis and design technologies for local structural detail features and joints, and high-fidelity analysis technologies for sandwich structures; (2) Demonstrate low cost, robust materials and processing, including polymeric matrix composite (PMC) and metallic materials and processing, and refractory composite and metallic hot structures materials and processing; (3) Develop and demonstrate robust airframe structures and validated integrated airframe structural concepts, including low cost fabrication and joining, operations efficient designs and inspection techniques (non-destructive evaluation), scale-up and integrated thermal structure tests, and airframe structures IVHM; (4) Demonstrate low cost, robust repair techniques; and (5) Develop verified integrated airframe structural concepts, including integrated structural concepts.
Johnson, Theodore F.↗
The Application of Metal Matrix Composite Materials in Propulsion System Valves
Metal Matrix Composite (MMC) materials have been developed and used in many applications to reduce the weight of components where weight and deflection are the driving design requirement. MMC materials are being developed for use in some propulsion system components, such as turbo-pumps and thrust chambers. However, to date, no propulsion system valves have been developed that take advantage of the materials unique properties. The stiffness of MMC's could help keep valves light or improve life where deflection is the design constraint (such as seal and bearing locations). The low CTE of the materials might allow the designer to reduce tolerances and clearances producing better performance and lighter weight valves. Using unique manufacturing processes allow parts to be plated/coated for longer life and allow joining either by welding or threading/bolting. Additionally, casting of multi part pre-forms to form a single part can lead to designs that would be hard or impossible to manufacture with other methods. Therefore, NASA's Marshall Space Flight Center (MSFC) has developed and tested a prototype propulsion system valve that utilizes these materials to demonstrate these advantages. Through design and testing, this effort will determine the best use of these materials in valves designed to achieve the goal of a highly reliable and lightweight propulsion system. This paper is a continuation of the paper, The Application of Metal Matrix Composite Materials In Propulsion System Valves, presented at the JANNAF Conference held in April, 2002. Fabrication techniques employed, valve development, and valve test results will be discussed in this paper.
Laszar, John↗