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Microscopic pores in thin-walled aluminum castings are sealed by impregnation pretreatment. Technique was developed for investment castings used in hermetically sealed chassic for electronic circuitry. Excessively high leakage rates were previously measured in some chassis.
A method for making aluminum-mica particle composites is presented in which mica particles are stirred in molten aluminum alloys followed by casting in permanent molds. Magnesium is added either as an alloying element or in the form of pieces to the surface of the alloy melts to disperse up to 3 wt% mica powders in the melts and to obtain high recoveries of mica in the castings. The mechanical properties of the aluminum alloy-mica composite decrease with increasing mica content; however, even at 2.2% it has a tensile strength of 14.22 kg/sq mm with 1.1% elongation, a compression strength of 42.61 kg/sq mm, and an impact strength of 0.30 kgm/sq cm. Cryogenic and self-lubricating bearing are mentioned applications.
A highly thromboresistant blood contacting interface for use in implanatable blood pump is investigated. Biomaterials mechanics, dynamics, durability, surface morphology, and chemistry are among the critical consideration pertinent to the choice of an appropriate blood pump bladder material. The use of transfer cast biopolymers from ion beam textured surfaces is investigated to detect subtle variations in blood pump surface morphology using Biomer as the biomaterial of choice. The efficacy of ion beam sputtering as an acceptable method of fabricating textured blood interfaces is evaluated. Aortic grafts and left ventricular assist devices were implanted in claves; the blood interfaces were fabricated by transfer casting methods from ion beam textured polytetrafluorethylene mandrels. The mandrels were textured by superimposing a 15 micron screen mesh; ion sputtering conditions were 300 volts beam energy, 40 to 50 mA beam, and a mandrel to source distance of 25 microns.
A technique for fabricating textured surfaces on polymers without altering their surface chemistries is described. A surface of a fluorocarbon polymer is exposed to a beam of ions to texture it. The polymer which is to be surface-roughened is then cast over the textured surface of the fluorocarbon polymer. After curing, the cast polymer is peeled off the textured fluorocarbon polymer, and the peeled off surface has negative replica of the textured surface. The microscopic surface texture provides large surface areas for adhesive bonding. In cardiovascular prosthesis applications the surfaces are relied on for the development of a thin adherent well nourished thrombus.
In-vitro, steady flow in a casting of the profunda femoris branch of the femoral artery of man was studied by measuring pressure differences in the main lumen and also in the branch over a large Reynolds number range from 200 to 1600. Effects of viscous and inviscid flows in this femoral artery branch were demonstrated quantitatively. The critical ratio of the flow rate in the branch to the upstream main lumen in this casting was found to be 0.4, above which the inviscid flow analysis indicated a pressure rise and below which it yielded a pressure drop in the main lumen across the branch junction. Pressure rises were experimentally found to occur both in the main lumen and in the branch for certain ranges of the aforementioned ratio.
Powdered Silicon was slip-cast with a CaSO4 x 0.5H2O mold and nitrided in a N atm. containing 0 or 5 vol. % H at 1000 to 1420 deg. To remove the castings, the modeling faces were coated successively with an aq. salt soap and powdered cellulose containing Na alginate, and thus prevented the sticking problem.
Continuous casting becomes practicable because of reduced eutectic temperature. Experimental ferrous alloy has melting point about 350 degrees C lower than conventional steels, making possible to cast structural members and eliminating need for hot rolling. Product has normal metal structure and good physical properties. Process used to make rails, beams, slabs, channels, and pipes.
The development of a quantitative nondestructive method which involves ultrasonic attenuation measurements in frequency domain to determine volume fraction of porosity in aluminum cast is discussed. The aluminum alloy A357 casting samples were produced at the Ohio State University Foundry with controlled porosity contents ranging from 0% to 6%. A computer controlled system was used to direct ultrasonic beam to a test sample to different places to conduct ultrasonic attenuation measurements. The plot of attenuation coefficients as a function of frequency was then evaluated based on existing theories to determine volume fraction of porosity and pore size.
The effect of varying pH, sonication times, and solid loading of silicon powder suspensions on the properties of powder/water suspensions and on the resulting pore characteristics of slip-cast bodies was studied. Aqueous suspensions of ground an aged silicon powder (of 0.3 micron median Stokes diameter and containing 1.3 vol pct Fe2O3 powder) were prepared, with solids loading in the range of 30-56 vol pct, and were adjusted to varying pH values by addition of either HCl or NH4OH or NaOH. Suspension aliquots were sonicated for 0, 15, 30, or 60 min. Suspensions were characterized by zeta potentials, ionic strength, and viscosity. Pore characteristics of cast bodies were determined by mercury porosimetry. It was found that intermediate pH values (pH 7-9), long sonication (60 min), and high solid loadings (56 vol pct) produced samples with highest green densities and smallest median pore radius.
Novel mathematical techniques are here used to treat general boundary conditions in convectively cooled continuous ingot casting problems, applying a constant convective heat transfer coefficient at the ingot sides (so that the temperature distribution along the sides is unknown). The problem is first inverted to treat the physical coordinates as dependent variables of temperature and heat flow, mapping the ingot into a region that is nearly rectangular. A boundary perturbation method is then used to obtain an analytical solution in this near-rectangular region. Solidification interface shapes depend on two dimensionless parameters: one is a function of the casting velocity, while the other is dependent on the convective heat transfer coefficient at the cooled wall.
The combustion chamber liner of the space shuttle main engine is made of NARloy-Z, a copper-silver-zirconium alloy. This alloy was produced by vacuum melting and vacuum centrifugal casting; a production method that is currently now available. Using conventional melting, casting, and forging methods, NASA has produced an alloy of the same composition called NASA-Z. This report compares the composition, microstructure, tensile properties, low-cycle fatigue life, and hot-firing life of these two materials. The results show that the materials have similar characteristics.
The adaptation of the powdered particle process used for pure metal oxides to the coprocessing of rhenium oxides suitable to produce pure miniature resistojet hardware has been successful. Both slip casting and extrusion processes were used. The metal oxide ZrO2 was stabilized into the cubic phase with Y2O3, for use as a potentially grain stabilizing additive to rhenium. Straight meter long tubing in two sizes are reported. Tubing suitable for resistojet ohmic heater use of fully fired dimensions of nominally 3.8 mm o.d. x 2.2 mm i.d.. and 1.26 mm o.d. x .45 mm i.d. with 0, 0.5, 1.0 and 5.0% zirconia additives were produced for further study. Photomicrographs of these are discussed. The addition of the metal oxide zirconia to rhenium resulted in more dense and less porous parts. The additions of phase stabilized zirconia most likely act as a sintering aid. Tubes of varying diameter were slip cast which were representative of miniature pressure cases.
NASACC-1 is a castable iron-base alloy designed to replace the costly and strategic cobalt-base X-40 alloy used in the automotive Stirling engine cylinder/generator housing. Over 40 alloy compositions were evaluated using investment cast test bars for stress-rupture testing. Also, hydrogen compatibility and oxygen corrosion resistance tests were used to determine the optimal alloy. NASACC-1 alloy was characterized using elevated and room temperature tensile, creep-rupture, low cycle fatigue, heat capacity, specific heat, and thermal expansion testing. Furthermore, phase analysis was performed on samples with several heat treated conditions. The properties are very encouraging. NASACC-1 alloy shows stress-rupture and low cycle fatigue properties equivalent to X-40. The oxidation resistance surpassed the program goal while maintaining acceptable resistance to hydrogen exposure. The welding, brazing, and casting characteristics are excellent. Finally, the cost of NASACC-1 is significantly lower than that of X-40.
A NASA KC-135 research aircraft, flying repeated low-g trajectories that yield 20-30 sec of 0.1-0.001 g microgravity, has been used to study microgravity solidification's elimination of sedimentation and convection (with formation of unique and advantageous microstructures) for the case of eutectic-composition cast irons. The solidification interface of hypereutectic flake and spheroidal graphite cast irons has been slowly advanced through a 4 mm-diameter rod sample. Sample solidification rates have been correlated with accelerometer data, while independently controlling thermal gradients and solidification rates.
Two and three dimensional turbulent calculations around RAE2822, CAST 10 airfoils and a wing side-wall configuration are presented. A finite volume, cell-center method based on flux difference splitting schemes is used to solve the steady state thin-layer Navier-Stokes equations. Comparisons between the performances of different Riemann solvers and reconstruction schemes are also presented. The influence of a side-wall on the symmetry plane of a cylindrical CAST 10 wing is found to be highly sensitive to the turbulence modeling in the vicinity of the wing side-wall juncture.
The transonic airfoil CAST 10-2/DOA 2 was investigated in several major transonic wind tunnels at Reynolds numbers ranging from Re=1.3 x 10(exp 6) to 45 x 10(exp 6) at ambient and cryogenic temperature conditions. The main objective was to study the degree and extent of the effects of Reynolds number on both the airfoil aerodynamic characteristics and the interference effects of various model-wind-tunnel systems. The initial analysis of the CAST 10-2 airfoil results revealed appreciable real Reynolds number effects on this airfoil and showed that wall interference can be significantly affected by changes in Reynolds number thus appearing as true Reynolds number effects.
The aim of this cooperative NASA/DFVLR/ONERA project was to examine the performance of the CAST-10 airfoil in the T2 cryogenic wind tunnel. Tests included general characteristics of the CAST-10 airfoil and fundamental studies on Reynold number effects. Good T2 cryogenic operation was observed. Improvements should be done for moisture elimination and for side wall boundary layer effects.
A program was performed to address the mechanical and environmental needs of Stirling engine heater head and regenerator housing components, while reducing the dependence on strategic materials. An alloy was developed which contained no strategic elemental additions per se. The base is iron with additions of manganese, molybdenum, carbon, silicon, niobium, and ferro-chromium. Such an alloy should be producible on a large scale at very low cost. The resulting alloy, designated as NASAUT 4G-Al, contained 15 Mn, 15 Cr, 2 Mo, 1.5 C, 1.0 Si, 1.0 Nb (in weight percent) with a balance of Fe. This alloy was optimized for chemistry, based upon tensile strength, creep-rupture strength, fracture behavior, and fatigue resistance up to 800 C. Alloys were also tested for environmental compatibility. The microstructure and mechanic properties (including hardness) were assessed in the as-cast condition and following several heat treatments, including one designed to simulate a required braze cycle. The alloy was fabricated and characterized in the form of both equiaxed and columnar-grained castings. The columnar grains were produced by directional solidification, and the properties were characterized in both the longitudinal and transverse orientations. The NASAUT 4G-Al alloy was found to be good in cyclic-oxidation resistance and excellent in both hydrogen and hot-corrosion resistance, especially in comparison to the baseline XF-818 alloy. The mechanical properties of yield strength, stress-rupture life, high-cycle-fatigue resistance, and low-cycle-fatigue resistance were good to excellent in comparison to the current alloy for this application, HS-31 (X-40), with precise results depending in a complex manner on grain orientation and temperature. If required, the ductility could be improved by lowering the carbon content.