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NASA NTRS2013

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗

NASA NTRS2014

Development of Compact, Modular Lunar Heat Flow Probes

Geothermal heat flow measurements are a high priority for the future lunar geophysical network missions recommended by the latest Decadal Survey and previously the International Lunar Network. Because the lander for such a mission will be relatively small, the heat flow instrumentation must be a low-mass and low-power system. The instrument needs to measure both thermal gradient and thermal conductivity of the regolith penetrated. It also needs to be capable of excavating a deep enough hole (approx. 3 m) to avoid the effect of potential long-term changes of the surface thermal environment. The recently developed pneumatic excavation system can largely meet the low-power, low-mass, and the depth requirements. The system utilizes a stem which winds out of a pneumatically driven reel and pushes its conical tip into the regolith. Simultaneously, gas jets, emitted from the cone tip, loosen and blow away the soil. The thermal sensors consist of resistance temperature detectors (RTDs) embedded on the stem and an insitu thermal conductivity probe attached to the cone tip. The thermal conductivity probe consists of a short 'needle' (2.4-mm diam. and 15- to 20-mm length) that contains a platinum RTD wrapped in a coil of heater wire. During a deployment, when the penetrating cone reaches a desired depth, it stops blowing gas, and the stem pushes the needle into the yet-to-be excavated, undisturbed bottom soil. Then, it begins heating and monitors the temperature. Thermal conductivity of the soil can determined from the rate of temperature increase with time. When the measurement is complete, the system resumes excavation until it reaches the next targeted depth.

Lunar↗

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 NTRS1989

The influence of advanced processing on PWA 1480

High thermal gradient casting of PWA 1480 was evaluated as an avenue for reducing the size of casting porosity. Hot isostatic pressing (HIP) was also employed for the elimination of casting pores. An alternate to the standard PWA 1480 coating plus diffusion bonding aging heat treatment cycle was also evaluated for potential improvements in the properties of interest to the Space Shuttle Main Engine (SSME) application. Microstructural changes associated with the high thermal gradient casting process were quantified by measurement of the size and density of the casting porosity, the amount of retained casting eutectic, and dendrite arm spacings. The results of the advanced processing have shown an improvement in material microstructure due to high thermal gradient casting. Improved homogeneity of PWA 1480 is advantageous in providing an improved solution heat treatment window and, potentially, easier HIP. High thermal gradient casting improves fatigue life by reducing casting pore size. The alternate heat treatment improves the balance of strength and ductility which appears to improve low cycle fatigue life, but with a reduction in short time stress rupture life. Based upon these tests, hot isostatic pressing appears to afford further improvements in cyclic life, though additional evaluation is suggested. Development of the alternate heat treatment is not recommended due to the reduced stress rupture capability and the need to develop a new properties data base. High thermal gradient casting and HIP are recommended for application to single crystal castings.

Fritzemeier, L. G.↗

NASA NTRS2006

Thermal Management Techniques for Oil-Free Turbomachinery Systems

Tests were performed to evaluate three different methods of utilizing air to provide thermal management control for compliant journal foil air bearings. The effectiveness of the methods was based on bearing bulk temperature and axial thermal gradient reductions during air delivery. The first method utilized direct impingement of air on the inner surface of a hollow test journal during operation. The second, less indirect method achieved heat removal by blowing air inside the test journal to simulate air flowing axially through a hollow, rotating shaft. The third method emulated the most common approach to removing heat by forcing air axially through the bearing s support structure. Internal bearing temperatures were measured with three, type K thermocouples embedded in the bearing that measured general internal temperatures and axial thermal gradients. Testing was performed in a 1 atm, 260 C ambient environment with the bearing operating at 60 krpm and supporting a load of 222 N. Air volumetric flows of 0.06, 0.11, and 0.17 cubic meters per minute at approximately 150 to 200 C were used. The tests indicate that all three methods provide thermal management but at different levels of effectiveness. Axial cooling of the bearing support structure had a greater effect on bulk temperature for each air flow and demonstrated that the thermal gradients could be influenced by the directionality of the air flow. Direct air impingement on the journal's inside surface provided uniform reductions in both bulk temperature and thermal gradients. Similar to the direct method, indirect journal cooling had a uniform cooling effect on both bulk temperatures and thermal gradients but was the least effective of the three methods.

Radil, Kevin↗

NASA NTRS2003

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZTO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long- term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

Zhu, Dongming↗

NASA NTRS2003

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZrO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long-term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

Zhu, Dong-Ming↗

NASA NTRS1990

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier

In this paper, surface cracking and interface reactions of a ZrO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions that were largely enhanced by the coating surface cracking in the water vapor environment were investigated in detail, and the reaction phases were identified for the coating system after the long-term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions. The coating design issues will also be discussed based on the observed failure mechanisms under the high-heat-flux test conditions.

Zhu, Dongming↗

NASA NTRS1994

Thermal-infrared remote sensing and Kirchhoff's Law. 1: Laboratory measurements

By the end of this century the Earth Observing System (EOS) will provide worldwide, thermal infrared, multispectral images of the Earth, presenting geologists with a new kind of remote sensing data for interpretation. Thus it has become essential to understand the spectral emittance behavior of terrestrial surface materials. Perhaps the most fundamental question to be answereed is the extent to which such materials follow Kirchhoff's law (epsilon = 1 -R) under laboratory and field conditions, especially when a sample displays a thermal gradient. We present the first rigorous quantitative comparison of directional and hemispherical reflectance and directional emittance of rock and soil samples in the laboratory, with thermal gradients induced by heating them from below and allowing them to radiate to a colder background. The results show that only an extemeley low density sample composed of fine particles sifted into a 'fairy castle' structure displays a thermal gradient steep enough within the infrared skin depth to cause significant (6%) departure from Kirchhoff's law. There is no detectable effect on the more normal terrestrial samples, such as soils and rocks measured in the laboratory, even when semitransparent coatings are involved. Thus both emittance and reflectance measurements can be used to calculate sample emissivity for most terrestrial surface materieals. However, the effect on Kirchhoffian behavior of different field environments, which may induce a steeper thermal gradient in particulate samples, has yet to be determined, and some low-density surface materials like newly fallen snow, frost, and efflorescent salts on playas have yet to be measured in emittance.

Salisbury, John W.↗

DOE OSTI2021

Sensitivity of cellular automata grain structure predictions for high solidification rates

Understanding as-solidified grain structure development during constrained (G 0) alloy solidification conditions is a necessary component of understanding the larger process-microstructure relationships during additive manufacturing (AM) processing. This study applies a cellular automata (CA) model, for static solidification velocities and thermal gradients on the order of those expected in AM melt pools, to investigate grain shape development across ranges of input parameters governing temperature field evolution, nucleation, and growth. Variation in nucleated grain shape from columnar to equiaxed as a function of thermal gradient and nucleation density is modeled with CA and verified against the established transition model of Hunt and Gaumann. Furthermore, while thermal conditions and nucleation density are shown to have the largest roles on microstructure development, the sensitivity of grain structure was very unevenly distributed across parameter space. In particular, it was found that microstructure is very sensitive to mean nucleation undercooling and the interfacial response function in process space regimes near grain structure transitions, but entirely controlled by a combination of thermal gradient, solidification velocity, and nucleation density away from such transitions. The understanding of grain shape sensitivity obtained through CA modeling, particularly at large thermal gradient and nucleation density, will be necessary for accurate microstructure prediction during the extreme processing conditions and large input parameter uncertainty common to AM.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Improved Cloud Condensation Nucleus Spectrometer

An improved thermal-gradient cloud condensation nucleus spectrometer (CCNS) has been designed to provide several enhancements over prior thermal- gradient counters, including fast response and high-sensitivity detection covering a wide range of supersaturations. CCNSs are used in laboratory research on the relationships among aerosols, supersaturation of air, and the formation of clouds. The operational characteristics of prior counters are such that it takes long times to determine aerosol critical supersaturations. Hence, there is a need for a CCNS capable of rapid scanning through a wide range of supersaturations. The present improved CCNS satisfies this need. The improved thermal-gradient CCNS (see Figure 1) incorporates the following notable features: a) The main chamber is bounded on the top and bottom by parallel thick copper plates, which are joined by a thermally conductive vertical wall on one side and a thermally nonconductive wall on the opposite side. b) To establish a temperature gradient needed to establish a supersaturation gradient, water at two different regulated temperatures is pumped through tubes along the edges of the copper plates at the thermally-nonconductive-wall side. Figure 2 presents an example of temperature and supersaturation gradients for one combination of regulated temperatures at the thermally-nonconductive-wall edges of the copper plates. c) To enable measurement of the temperature gradient, ten thermocouples are cemented to the external surfaces of the copper plates (five on the top plate and five on the bottom plate), spaced at equal intervals along the width axis of the main chamber near the outlet end. d) Pieces of filter paper or cotton felt are cemented onto the interior surfaces of the copper plates and, prior to each experimental run, are saturated with water to establish a supersaturation field inside the main chamber. e) A flow of monodisperse aerosol and a dilution flow of humid air are introduced into the main chamber at the inlet end. The inlet assembly is designed to offer improved (relative to prior such assemblies) laminar-flow performance within the main chamber. Dry aerosols are subjected to activation and growth in the supersaturation field. f) After aerosol activation, at the outlet end of the main chamber, a polished stainless-steel probe is used to sample droplets into a laser particle counter. The probe features an improved design for efficient sampling. The counter has six channels with size bins in the range of 0.5- to 5.0-micron diameter. g) To enable efficient sampling, the probe is scanned along the width axis of the main chamber (thereby effecting scanning along the temperature gradient and thereby, further, effecting scanning along the supersaturation gradient) by means of a computer-controlled translation stage.

Leu, Ming-Taun↗

NASA NTRS1985

A two-dimensional primitive equation model of frontogenesis forced by confluence and horizontal shear

A two-dimensional primitive equation model of frontogenesis is presented. The model treats confluence and horizontal shear in combination. The structure and evolution of model frontal zones forced by confluence are described for a control case featuring a zero alongfront thermal gradient and positive and negative thermal gradients, facing downstream. A comparison is made with Miller's (1948) equation for the zero gradient situation to illustrate the significance of horizontal and vertical motions for the structure of the upper level frontal zone. Finally, the effects of ageostrophic circulations on the evolutionary and structural differences of frontal formations are studied.

Keyser, D.↗

NASA NTRS1990

Heterogeneities in the thickness of the elastic lithosphere of Mars - Constraints on heat flow and internal dynamics

Estimates of the effective thickness of the Martian elastic lithosphere are reviewed, and these thickness values are converted to estimates of lithospheric thermal gradients and surface heat flow by means of temperature-dependent strength envelopes. The results of estimates of thermal gradients for various locations, together with the information on the geological epochs appropriate to each estimate of thermal gradient, were related to the global heat flux, the interior thermal evolution, the Martial lithospheric reheating mechanisms, and the evolution of major volcanic provinces on Mars.

Solomon, Sean C.↗

NASA NTRS2001

Development of a Semi-Span Test Capability at the National Transonic Facility

A need for low-speed, high Reynolds number test capabilities has been identified for the design and development of advanced subsonic transport high-lift systems. In support of this need, multiple investigations have been conducted in the National Transonic Facility (NTF) at the NASA Langley Research Center to develop a semi-span testing capability that will provide the low-speed, flight Reynolds number data currently unattainable using conventional sting-mounted, full-span models. Although a semi-span testing capability will effectively double the Reynolds number capability over full-span models, it does come at the expense of contending with the issue of the interaction of the flow over the model with the windtunnel wall boundary layer. To address this issue the size and shape of the semi-span model mounting geometry have been investigated, and the results are presented herein. The cryogenic operating environment of the NTF produced another semi-span test technique issue in that varying thermal gradients have developed on the large semi-span balance. The suspected cause of these thermal gradients and methods to eliminate them are presented. Data are also presented that demonstrate the successful elimination of these varying thermal gradients during cryogenic operations.

Gatlin, G. M.↗

NASA NTRS1977

Processing eutectics in space

The examination of the Ni-Mo-Al system is discussed. Experiments were performed to examine the role of thermal gradient magnitude at the solidifying interface on the geometrical regularity of the microstructure. The difficulty in measuring the thermal gradient in the melt using superheat temperatures as high as 1800 C resulted in the examination of three liquid temperature gradient ranges. Examination of the microstructure from directionally solidified ingots using transverse sections indicated that the highest gradient runs produced microstructure of no greater regularity than runs made at lower gradients. For the Ni-Al-Mo monovariant eutectic system, the magnitude of the thermal gradient at the solidifying interface is not a controlling parameter with respect to the geometrical regularity of the microstructure, provided it is sufficient to satisfy the gradient/rate ratio needed to produce a planar interface growth.

Douglas, F. C.↗

NASA NTRS2005

Tools for Designing and Analyzing Structures

Structural Design and Analysis Toolset is a collection of approximately 26 Microsoft Excel spreadsheet programs, each of which performs calculations within a different subdiscipline of structural design and analysis. These programs present input and output data in user-friendly, menu-driven formats. Although these programs cannot solve complex cases like those treated by larger finite element codes, these programs do yield quick solutions to numerous common problems more rapidly than the finite element codes, thereby making it possible to quickly perform multiple preliminary analyses - e.g., to establish approximate limits prior to detailed analyses by the larger finite element codes. These programs perform different types of calculations, as follows: 1. determination of geometric properties for a variety of standard structural components; 2. analysis of static, vibrational, and thermal- gradient loads and deflections in certain structures (mostly beams and, in the case of thermal-gradients, mirrors); 3. kinetic energies of fans; 4. detailed analysis of stress and buckling in beams, plates, columns, and a variety of shell structures; and 5. temperature dependent properties of materials, including figures of merit that characterize strength, stiffness, and deformation response to thermal gradients

Luz, Paul L.↗

NASA NTRS2005

Development of Detectability Limits for On-Orbit Inspection of Space Shuttle Wing Leading Edge

At the conclusion of the Columbia Accident Investigation, one of the recommendations of the Columbia Accident Investigation Board (CAIB) was that NASA develop and implement an inspection plan for the Reinforced Carbon-Carbon (RCC) system components of the Space Shuttle. To address these issues, a group of scientists and engineers at NASA Langley Research Center proposed the use of an IR camera to inspect the RCC. Any crack in an RCC panel changes the thermal resistance of the material in the direction perpendicular to the crack. The change in thermal resistance can be made visible by introducing a heat flow across the crack and using an IR camera to image the resulting surface temperature distribution. The temperature difference across the crack depends on the change in the thermal resistance, the length of the crack, the local thermal gradient, and the rate of radiation exchange with the environment. This paper describes how the authors derived the minimum thermal gradient detectability limits for a through crack in an RCC panel. This paper will also show, through the use of a transient, 3-dimensional, finite element model, that these minimum gradients naturally exist on-orbit. The results from the finite element model confirm that there are sufficient thermal gradient to detect a crack on 96% of the RCC leading edge.

Stephan, Ryan A.↗

DOE OSTI2025

CFD modeling and simulation for corrosive wear of refractory in molten slag

The development of high-wear resistant refractories having minimal production costs is facilitated by characterizing the wear mechanisms associated with their corrosive wear. Static cup testing is a commonly used method for comparing the corrosion resistance performance of two or more refractory materials. Although the static cup test conditions are not as severe as dynamic tests, this study shows that the thermal gradient present within the system during heating and cooling stages serves to generate movement of the slag leading to mechanical wear. The thermal gradient within the refractory, and between the slag and the refractory, occurs during the ramp stage of the test and lasts until the soaking stage is reached bringing the system to a thermal equilibrium. Using computational fluid dynamics (CFD) capabilities embedded within ANSYS software, this study modelled and quantified the convection currents within the slag and associated shear stresses generated on the refractory walls due to the thermal gradient. A traditional ladle furnace was employed as a case study to verify the results of the studied CFD model. The corrosion rate of the refractory lining was found to depend on the mass transfer coefficient of the refractory dissolution into the slag, and a velocity term which governs the extent of corrosion at any given location. This velocity term is a function of slag viscosity, as well as the concentration gradient and/or temperature gradient at the triple points. In this study, wall shear stress was used as a reliable proxy for identifying high-velocity regions prone to excessive corrosive wear. Elevated wall shear stress near the slag/air and slag/molten steel interfaces align with observed corrosion grooves, which reflects the intensified corrosive wear at these locations.

Ramteke, Rajat Rajat Durgesh Ramteke [University o↗