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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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Electron-beam welding yields reliable, leakproof joints. Welding bands (also called "doublers") sandwiched between layers welded to increase final weld-section thickness. New technique ensures repeatable leakproof assemblies.
This study evaluates various non-intrusive techniques for the measurement of the flow field on the windward side of the Space Shuttle orbiter or a similar reentry vehicle. Included are linear (Rayleigh, Raman, Mie, Laser Doppler Velocimetry, Resonant Doppler Velocimetry) and nonlinear (Coherent Anti-Stokes Raman, Laser-Induced Fluorescence) light scattering, electron-beam fluorescence, thermal emission, and mass spectroscopy. Flow-field properties were taken from a nonequilibrium flow model by Shinn, Moss, and Simmonds at the NASA Langley Research Center. Conclusions are, when possible, based on quantitative scaling of known laboratory results to the conditions projected. Detailed discussion with researchers in the field contributed further to these conclusions and provided valuable insights regarding the experimental feasibility of each of the techniques.
Palladium was deposited inside a controlled-vacuum specimen chamber of a transmission electron microscope (TEM) onto MgO and alpha-alumina substrate surfaces. Annealing and various effects of gas exposure of the particulate Pd deposits were studied in-situ by high resolution TEM and electron diffraction. Whereas substrate temperatures of 500 C or annealing of room temperature (RT) deposits to 500 C were needed to obtain epitaxy on sapphire, RT deposits on MgO were perfectly epitaxial. For Pd/MgO a lattice expansion of 2 to 4% was noted; the highest values of expansion were found for the smallest particles. The lattice expansion of small Pd particles on alumina substrates was less than 1%. Long-time RT exposure of Pd/MgO in a vacuum yielded some moblity and coalescence events, but notably fewer than for Pd on sapphire. Exposure to air or oxygen greatly enhanced the particle mobility and coalescence and also resulted in the flattening of Pd particles on MgO substrates. Electron-beam irradiation further enhanced this effect. Exposure to air for several tens of hours of Pd/MgO led to strong coalescence.
Three types of cast silicon, Silso, HEM (Heat-Exchanger Method) and UCP (Ubiquitous Crystallization Process) were studied for their use as solar cells. Optical microscopy after etching revealed a high density of uniform dislocations (approaching 1,000,000/sq cm), lines of dislocations indicating stress during crystal growth, and precipitates, some of which generate dislocations. Solar cells were fabricated by three processes. Results of solar cell processing revealed that these materials produce cells of lower efficiency than Czochralski control cells, and that the efficiencies of the three materials were quite close. Diffusion length and spectral response data are shown. Certain structural features are correlated with solar cell efficiency, diffusion length, and spectral response. Electron-beam induced current (EBIC) and light spot scanning are used to back up other measurements.
Electron-beam scanning method suggested for determining back-surface recombination velocity, SB, of back-surface-field (BSF) solar photovoltaic cell. Recombination velocity important because smaller value correlated with smaller saturation current and therefore higher cell efficiency. Method involves analyzing short-circuit current measured while electron beam scanned along edge of cell.
Mathematical model developed for microfissuring of commercial nickel alloy during electron-beam welding. Number of measured microfissures per unit length of weld plotted against excess power calculated by computer model. Excess power that above level likely to produce microfissures. In agreement with model, measured microfissures increase at rate of 4.5 per inch (1.8 per centimeter) per excess kilowatt.
Potential fatigue rejuvenation processes were carried out on fatigue-damaged material both with and without observable surface-connected fatigue cracks. The fatigue life of fatigue-damaged MAR-M246(Hf)(DS), a directionally solidified nickel-base superalloy used in turbine airfoils, was extended by reheat treatment. The fatigue life of fatigue-cracked Inconel 718, a wrought nickel-base superalloy used in a wide variety of advanced rocket engine components, was extended by electron-beam welding to close off the surface-connected crack, followed by hot isostatic pressing and reheat treatment.
The use of surface analysis methods in the detection and evaluation of elemental and impurity species in Si is presented. Examples are provided from polycrystalline Si and high-efficiency MINP cells. Auger electron spectroscopy and secondary ion mass spectrometry are used to complement microelectrical data obtained by electron-beam induced-current measurements. A new method is discussed which utilizes the volume indexing of digital secondary ion mass spectroscopy signals, providing compositional information and impurity maps on internal materials/device interfaces.
It is demonstrated that layered synthetic microstructures (LSMs) can provide mirrors with enhanced normal incidence reflectance in the 300-A spectral region. Experimental results are presented for Pt-Si and Ir-Si structures fabricated by electron-beam deposition at pressures of about 10 to the -6th Torr, and it is shown that the enhancement is realized over a limited bandwidth of 75 A. One potential application of LSMs is their use as coatings on diffraction gratings to enhance normal incidence reflection efficiencies. Preliminary results for the Ir-Si combination on a diffraction grating show that LSMs enhance grating efficiencies in the EUV by a factor of about 3.
It is pointed out that electrostatic ion cyclotron (EIC) waves have been extensively investigated in connection with both space and laboratory plasmas. The present investigation has the objective to study the excitation of low-frequency waves in a multiion plasma by electron beams. The frequencies considered range from below the lowest gyrofrequency of the heaviest ion to about the lower hybrid frequency. It is shown that electron-beam instabilities can produce peaks in the growth rate below the cyclotron frequency of each ion species if nonzero perpendicular wave number effects are included in the ion dynamics. The dispersion relations for neutralized ion Bernstein (NIB) and pure ion Bernstein (PIB) waves are considered along with an instability analysis for a cold plasma and warm electron beam, the electron beam-plasma mode, banded ion cyclotron (EIC) waves with small perpendicular wavelengths, and the growth lengths of the waves.
Robotic welding controlled by reliable, relatively-noise-free optoelectronic unit. Bounding off meniscus of pool of molten metal, laser beam impinges on position-sensitive photodetector. Beam diameter adjusted for width of weld. Optical filters screen out light from arc. Made from small, low-cost components and utilizing optical fibers to conduct signals, system immune to electromagnetic interference common in industrial environments. Aimed for automatic welders, robot welders in particular and also adaptable to other types of welding, including tungsten/inert-gas, laser, and electron-beam techniques.
Considerable progress has been made in the development of perforated suction surface material for laminar flow control applications. Electron-beam perforated titaniuum skin was used as the suction surface. Critical issues related to suction panel manufacturing were identified and largely resolved. The final product included fabrication of a 7-foot chord by 7-foot span perforated laminar flow control wind tunnel model. Techniques used can be adapted to modern aircraft production lines. The report includes details on panel instrumentation and other features required for testing in a transonic pressure tunnel.
The shock melt glasses of the Bloomington LL-group chondrite were examined using electron-beam microscopy and compared with data from studies of other shock melt glasses. Petrologic and mineralogic characterizations were also performed of the samples. The metal contents of the meteorite were almost wholly Ni-rich martensite. The glasses resembled shock melt glasses in L-group chondrites, and were indicative of isochemical melting during one melt phase, i.e., a very simple history.
The effect of pretreatments on the morphology and properties of aluminum oxide thermally grown from NiCoCrAlY was investigated. The goal was to optimize process steps to produce a highly adherent, continuous, and insulating aluminum oxide. Two pretreatments were carried out, one in vacuum (about 0.0001 Torr) at 1350 K for 5 h, and the other consisting of deposition of a 1-micron thick Al2O3 film by activated reactive evaporation. Samples were subsequently oxidized thermally at 1000 C for 50 h at 0.5 Torr oxygen pressure. The two pretreatments were carried out on electron-beam evaporation NiCoCrAlY, about 120 microns thick, deposited on a superalloy turbine blade substrate. The results showed that the thermally grown oxide was significantly different in microstructure, surface topography and in its adherence to the NiCoCrAlY for the two pretreatments. Optimum results were obtained by combining the two pretreatments to produce an adherent, continuous, and insulating oxide film on the NiCoCrAlY-coated superalloy substrate.
Using an electron-beam - molecular-beam apparatus and employing the relative flow technique, ratios of the differential elastic scattering cross sections (DCSs of H2 to He were measured at incident electron energies of 15-100 eV and over the angular range of 10-125 degrees. From these ratios, the absolute elastic DCSs for H2 were determined by normalization to accurate, available elastic DCSs of He. Since pure rotational structure was not resolved in this work, the DCSs reported are the sum of elastic and rotational excitations of H2 at room temperature. The reliability of the relative flow normalization to He was checked at each energy and angle by performing similar elastic DCS measurements on Ne (for which the cross sections are known). The resulting absolute Ne DCSs were found to be in good agreement (within 10 percent with the Ne elastic DCSs measured previously (Register and Trajmar, 1984). From the DCSs, integral and momentumtransfer cross sections were calculated. The present results are compared with other recent measurements.
Life predictions are made for two types of strain-tolerant and oxidation-resistant Thermal Barrier Coating (TBC) systems produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation-resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron-beam/physical vapor deposition process by Temescal. Thermomechanical and thermochemical testing of the program TBCs is in progress. A number of the former tests has been completed. Fracture mechanics data for the Chromalloy plasma-sprayed TBC system indicate that the cohesive toughness of the zirconia layer is increased by thermal cycling and reduced by high temperature exposure at 1150 C. Eddy current technology feasibility has been established with respect to nondestructively measuring zirconia layer thickness of a TBC system. High pressure turbine blades have been coated with program TBC systems for a piggyback test in a TFE731-5 turbofan factory engine test. Data from this test will be used to validate the TBC life models.
Tripling the nation’s nuclear energy capacity is a critical component for significantly increasing energy production and reducing energy costs for American families and businesses. Achieving this vision requires fuel cycle technologies that maximize resource utilization while minimizing radioactive waste generation. Advanced sulfur chloride–based chlorination technologies are being developed to enable efficient recycling of fuel cladding materials, which account for a significant fraction of used nuclear fuel. However, the impacts of ionizing radiation on the longevity and performance of these sulfur chloride compounds are not well established. Here, we will explore the effects of gamma and electron-beam irradiation on the chemical composition of select sulfur chloride reagents, specifically sulfur monochloride (S2Cl2) and thionyl chloride (SOCl2), and the impacts of pre-irradiation on the chlorination yield/chemical dissolution of surrogate aluminum alloy 6061 (AA6061-T6) materials.
3D printing down to the nanoscale remains a significant challenge. In this paper, the study explores the use of scanning probes that emit low-energy electrons (<100 eV) coupled with the localized injection and electron-induced decomposition of precursor molecules, for the precise localized deposition of 3D nanostructures. The experiments are performed inside the chamber of a scanning electron microscope (SEM), enabling the use of the in-built gas injector system (GIS) with gaseous naphthalene precursor for carbon deposition, as well as immediate inspection of the deposits by SEM. Substrate materials are planar fused silica with thin conductive coatings and non-planar copper wedges. After investigation of the deposition process parameters, various 2D and 3D carbon deposits are grown. Vertical nanowires several microns in length with a diameter <100 nm are achieved and 3D deposits with a high degree of nanoscale branching are also obtained, presumably due to a charging effect. High aspect ratio carbon nanostructures such as those demonstrated here can be employed as miniaturized electrodes or field emitters. The tip-based approach presented thus paves the way toward 3D nanoscale printing of various materials and functional nanostructures.