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At least 19 records

Mod II engine performance

The testing of a prototype of an automotive Stirling engine, the Mod II, is discussed. The Mod II is a one-piece cast block with a V-4 single-crankshaft configuration and an annular regenerator/cooler design. The initial testing of Mod II concentrated on the basic engine, with auxiliaries driven by power sources external to the engine. The performance of the engine was tested at 720 C set temperature and 820 C tube temperature. At 720 C, it is observed that the power deficiency is speed dependent and linear, with a weak pressure dependency, and at 820 C, the power deficiency is speed and pressure dependent. The effects of buoyancy and nozzle spray pattern on the heater temperature spread are investigated. The characterization of the oil pump and the operating cycle and temperature spread tests are proposed for further evaluation of the engine.

Richey, Albert E.↗

Experimental Study on Mitigation of Lifetime-Limiting Dielectric Cracking in Extreme Temperature 4H-SiC JFET Integrated Circuits

While NASA Glenn Research Center's "Generation 10" 4H-SiC Junction Field Effect Transistor (JFET) integrated circuits (ICs) have uniquely demonstrated 500 °C electrical operation for durations of over a year, this experimental work has also revealed that physical cracking of chip dielectric passivation layers ultimately limits extreme-environment operating lifetime [1-3]. The prevention of such dielectric passivation cracks should therefore improve IC high temperature durability and yield, leading to more beneficial technology adoption into aerospace, automotive, and energy systems. This report describes Generation 10.2, 11.1, and 11.2 die tested under unbiased and unpackaged accelerated age testing at 500 °C, 600 °C, 720 °C, and 800 °C in air-atmosphere ovens for 100- and 200-hour duration. Additional samples were separately subjected to 10 thermal cycles between the same high temperatures (with 10-hour high-temperature soak each cycle) and 50 °C. It is shown that having two stoichiometric Si3N4 layers in the interconnect dielectric stack substantially decreases the amount of dielectric cracking observed following these oven tests.

Spry, D. J.↗

Isotherm Sensor Calibration Program for Mars Science Laboratory Heat Shield Flight Data Analysis

Seven instrumented sensor plugs were installed on the Mars Science Laboratory heat shield in December 2008 as part of the Mars Science Laboratory Entry, Descent, and Landing Instrumentation (MEDLI) project. These sensor plugs contain four in-depth thermocouples and one Hollow aErothermal Ablation and Temperature (HEAT) sensor. The HEAT sensor follows the time progression of a 700 C isotherm through the thickness of a thermal protection system (TPS) material. The data can be used to infer char depth and, when analyzed in conjunction with the thermocouple data, the thermal gradient through the TPS material can also be determined. However, the uncertainty on the isotherm value is not well defined. To address this uncertainty, a team at NASA Ames Research Center is carrying out a HEAT sensor calibration test program. The scope of this test program is described, and initial results from experiments conducted in the laboratory to study the isotherm temperature of the HEAT sensor are presented. Data from the laboratory tests indicate an isotherm temperature of 720 C 60 C. An overview of near term arc jet testing is also given, including preliminary data from 30.48cm 30.48cm PICA panels instrumented with two MEDLI sensor plugs and tested in the NASA Ames Panel Test Facility. Forward work includes analysis of the arc jet test data, including an evaluation of the isotherm value based on the instant in time when it reaches a thermocouple depth.

Santos, Jose A.↗

Lattice defects in semiconducting Hg/1-x/Cd/x/Te alloys. III - Defect structure of undoped Hg0.6Cd0.4Te

Hall effect measurements were carried out on undoped Hg0.6Cd0.4Te crystals quenched to room temperature subsequent to equilibration at temperatures varying from 450 to 720 C under various partial pressures of Hg. The variation of the hole concentration as a function of the partial pressure of Hg indicates that the native acceptor defects are doubly ionized. Native donor defects are found to be negligible in concentration and the p-type to n-type conversion is shown to be due to residual donors and not due to native donor defects. Thermodynamic constant for the incorporation of the doubly ionized native acceptor defect has been established.

Vydyanath, H. R.↗

Effect of water on hydrogen permeability

Doping of hydrogen with CO or CO2 was developed to reduce hydrogen permeation in Stirling engines by forming low permeability oxide coatings in the heater tubes. An end product of this process is water - which can condense in the cold parts of the engine system. If the water vapor is reduced to a low enough level, the hydrogen can reduce the oxide coating resulting in increased permeability. The equilibrium level of water (oxygen bearing gas) required to avoid reduction of the oxide coating was investigated. Results at 720 C and 13.8 MPa have shown that: (1) pure hydrogen will reduce the coating; (2) 500 ppm CO (500 ppm water equivalent) does not prevent the reduction; and (3) 500 ppm CO2 (1000 ppm water) appears to be close to the equilibrium level. Further tests are planned to define the equilibrium level more precisely and to extend the data to 820 C and 3.4, 6.9, and 13.8 MPa.

Hulligan, D. D.↗

Observation of fullerenes (C60-C70) associated with LDEF crater number 31

The presence of fullerenes in and around the LDEF crater number 31 is reported. This crater has a high C level associated with it, and is interpreted as having been produced by the impact of a C-rich micrometeoroid. Fullerenes are large 3-D C structures, among which the species C sub 60 (MW 720) and C sub 70 (MW 840) are preeminent. Fullerenes have several UV absorption bands, hence fullerenes should be detectable using UV laser ionization time-of-flight mass spectrometry. We use a LIMA-2A instrument with pulsed UV laser (266 nm) to search for high mass C species associated with LDEF crater number 31. The mass range was 0 to 1200 amu. Low ablating laser power levels were used (less than or = 5 x 10 exp 7 W/sq. cm); 200 mass spectra were acquired and summed. We observed high mass signals near m/z 720, exhibiting 24 amu separation, which is characteristic of fullerenes. Alkali ion signals were also observed. Little or no C clusters of intermediate mass were observed. We interpret the signals around m/z 720 as fullerenes, mainly C sub 60+ with lower levels of C sub 70+. We propose that the mechanism that produces these signals is resonant multiphoton ionization (REMPI). This selective mechanism explains why low mass C cluster ions are not observed along with the fullerenes, since they have much higher ionization potentials. This finding is unexpected, since up to now the search for fullerenes in extraterrestrial materials has not been successful. We conclude that the fullerenes became associated with crater number 31 in space. Two alternative (and exciting) scenarios are being considered at this time: either the fullerenes were carried by the C-rich projectile that formed crater number 31, or the fullerenes formed upon impact with the LDEF. We show the results of experiments at the ARC Vertical Gun Facility, which may establish some constraints on the origin of the fullerenes.

Radicatidibrozolo, Filippo↗

Characterization of 720 and 940 MHz Oscillators with Chip Antenna for Wireless Sensors from Room Temperature to 200 and 250 deg C

Oscillators that operate at 720 and 940 MHz and characterized over a temperature range of 25 C to 200 C and 250 C, respectively, are presented. The oscillators are designed on alumina substrates with typical integrated circuit fabrication techniques. Cree SiC MESFETs, thin film metal-insulator-metal capacitors and spiral inductors, and Johanson miniature chip antennas make-up the circuits. The output power and phase noise are presented as a function of temperature and frequency. Index Terms MESFETS, chip antennas, oscillators SiC alumina.

Scardelletti, Maximilian C.↗

Automotive Stirling engine development program - Overview and status report

The current status of the automotive-Stirling-engine development program being undertaken by DOE and NASA Lewis is reviewed. The program goals and the reference-engine design are explained, and the modifications introduced to improve performance and lower manufacturing costs are discussed and illustrated, including part-power optimization; increased operating temperature (from 720 to 820 C); 45.4-kg weight reduction; elimination of Co and reduction of Cr used; and improved seals, ceramic components, and high-temperature alloys. The test program, some difficulties encountered, and results after 2042 h are summarized.

Nightingale, N. P.↗

Effect of a Large Population of Seeded Alumina Inclusions on Crack Initiation and Small Crack Fatigue Crack Growth in Udimet 720 Nickel-Base Disk Superalloy

Crack initiation, crack coalescence and small crack growth behavior were monitored for over 400 seeded inclusions during interrupted low cycle fatigue testing conducted on the P/M Udimet 720 nickel disk alloy at 650°C. Two types of seeded alumina inclusions with average sizes of 54 μm and 122 μm were used in the study performed at varying loading conditions resulting in LCF lives ranging from 2,000 cycles to over 1,000,000 cycles. The fatigue behavior was sub-categorized into four groups. Visual maps detailing inclusion size/cycle history were developed. The effect of surface residual stresses on the fatigue life was also investigated.

Superalloys↗

ISAAC: Inflatable Satellite of an Antenna Array for Communications, volume 6

The results of a study to design an antenna array satellite using rigid inflatable structure (RIS) technology are presented. An inflatable satellite allows for a very large structure to be compacted for transportation in the Space Shuttle to the Space Station where it is assembled. The proposed structure resulting from this study is a communications satellite for two-way communications with many low-power stations on the ground. Total weight is 15,438 kilograms which is within the capabilities of the Space Shuttle. The satellite will have an equivalent aperture greater than 100 meters in diameter and will be operable in K and C band frequencies, with a total power requirement of 10,720 watts.

Lodgard, Deborah↗

Alkali metal compatibility testing of candidate heater head materials for a Stirling engine heat transport system

The authors describe work performed as part of the 25-kWe advanced Stirling conversion system project. Liquid alkali metal compatibility is being assessed in an ongoing test program to evaluate candidate heater head materials and fabrication processes at the temperatures and operating conditions required for Stirling engines. Specific materials under evaluation are alloy 713LC, alloy 713LC coated with nickel aluminide, and Udimet 720, each in combination with Waspaloy. The tests were run at a constant 700 C. A eutectic alloy of sodium and potassium (NaK) was the working fluid. Titanium sheet in the system was shown to be an effective oxygen getter. Metallographic and microchemical examination of material surfaces, joints, and their interfaces revealed little or no corrosion after 1000 h. Tests are in progress, with up to 10,000 h exposure.

Noble, Jack E.↗

Effects of High-Temperature Exposures on the Fatigue Life of Superalloy Udimet(Registered Trademark) 720

The purpose of this study was to examine the effects of extended exposures on the near-surface fatigue resistance of a disk superalloy. Powder metallurgy processed, supersolvus heat-treated Udimet 720 (U720) fatigue specimens were exposed in air at temperatures from 650 to 705 C for 100 hr to over 1000 hr. They were then tested using conventional fatigue tests at 650 C to determine the effects of exposure on fatigue resistance. The exposures reduced life by up to 70% and increased the scatter in life, compared to unexposed levels. Fractographic evaluations indicated the failure mode was shifted by the exposures from internal to surface crack initiations. The increased scatter in life was related to the competition between internal crack initiations at inclusions or large grains producing longer lives, and surface crack initiations at an environmentally affected surface layer producing shorter lives.

Gabb, Timothy P.↗

Effects of High Temperature Exposures on Fatigue Life of Disk Superalloys

The effects on fatigue life of high temperature exposures simulating service conditions were considered for two disk superalloys. Powder metallurgy processed, supersolvus heat treated Udimet (trademark) 720 and ME3 fatigue specimens were exposed in air at temperatures of 650 to 704 C, for times of 100 h to over 1000 h. They were then tested using conventional fatigue tests at 650 and 704 C, to determine the effects of exposure on fatigue resistance. Cyclic dwell verification tests were also performed to contrast the effects of intermixed exposures and fatigue cycles. The prior exposures reduced life by up to 70% and increased the scatter in life, compared to unexposed levels. Cyclic dwell tests reduced lives even more. Fractographic evaluations indicated the failure mode was shifted by the exposures and cyclic dwells from predominantly internal to often surface crack initiations. The increased scatter in life was related to the competition between internal crack initiations at inclusions or large grains producing longer lives, and surface crack initiations at an environmentally affected surface layer producing shorter lives.

Gabb, Tim P.↗

Effectiveness of Shot Peening in Suppressing Fatigue Cracking at Non-Metallic Inclusions in Udimet(trademark) 720

The fatigue lives of modern powder metallurgy disk alloys can be reduced by over an order of magnitude by surface cracking at inherent non-metallic inclusions. The objective of this work was to study the effectiveness of shot peening in suppressing LCF crack initiation and growth at surface nonmetallic inclusions. Inclusions were carefully introduced at elevated levels during powder metallurgy processing of the nickel-base disk superalloy Udimet 720. Multiple strain-controlled fatigue tests were then performed on machined specimens at 427 and 650 C in peened and unpeened conditions. Analyses were performed to compare the low cycle fatigue lives and failure initiation sites as a function of inclusion content, shot peening, and fatigue conditions. A large majority of the failures in as-machined specimens with introduced inclusions occurred at cracks initiating from inclusions intersecting the specimen surface. The inclusions could reduce fatigue life by up to 100X. Large inclusions had the greatest effect on life in tests at low strain ranges and high strain ratios. Shot peening can be used to improve life in these conditions by reducing the most severe effects of inclusions.

Barrie, Robert L.↗

Elevated Temperature Fatigue Endurance of Three Ceramic Matrix Composites

High-cycle fatigue endurance of three candidate materials for the acoustic liners of the Enabling Propulsion Materials Nozzle Program was investigated. The ceramic matrix composite materials investigated were N720/AS (Nextel 720, 3M Corporation), Sylramic S200 (Dow Corning), and UT 22. High-cycle fatigue tests were conducted in air at 910 C on as-machined specimens and on specimens subjected to tensile cyclic load excursions every 160 hr followed by thermal exposure at 910 C in a furnace up to total exposure times of 2066 and 4000 hr. All the fatigue tests were conducted in air at 100 Hz with a servohydraulic test machine. In the as-machined condition, among the three materials investigated only the Sylramic S200 exhibited a deterministic type of high-cycle fatigue behavior. Both the N720/AS and UT-22 exhibited significant scatter in the experimentally observed high-cycle fatigue lives. Among the thermally exposed specimens, N720/AS and Sylramic S200 materials exhibited a reduction in the high-cycle fatigue lives, particularly at the exposure time of 4000 hr.

Kalluri, Sreeramesh↗

Epoxy hydantoins as matrix resins

Tensile strength and fracture toughness of castings of the hydantoin resins cured with methylenedianiline are significantly higher than MY 720 control castings. Water absorption of an ethyl, amyl hydantoin formulation is 2.1 percent at equilibrium and Tg's are about 160 C, approximately 15 deg below the final cure temperature. Two series of urethane and ester-extended hydantoin epoxy resins were synthesized to determine the effect of crosslink density and functional groups on properties. Castings cured with methylenedianiline or with hexahydrophthalic anhydride were made from these compounds and evaluated. The glass transition temperatures, tensile strengths and moduli, and fracture toughness values were all much lower than that of the simple hydantoin epoxy resins. Using a methylene bishydantoin epoxy with a more rigid structure gave brittle, low-energy fractures, while a more flexible, ethoxy-extended hydantoin epoxy resin gave a very low Tg.

Weiss, J.↗

Effectiveness of Shot Peening In Suppressing Fatigue Cracking At Non-Metallic Inclusions In Udimet(Registered Trademark)720

The fatigue lives of modern powder metallurgy disk alloys can be reduced over an order of magnitude by cracking at inherent non-metallic inclusions. The objective of this work was to study the effectiveness of shot peening in suppressing LCF crack initiation and growth at surface nonmetallic inclusions. Inclusions were carefully introduced at elevated levels during powder metallurgy processing of the nickel-base disk superalloy Udimet 720. Multiple strain-controlled fatigue tests were then performed on machined specimens with and without shot peened test sections at 427 C and 650 C. The low cycle fatigue lives and failure initiation sites varied as functions of inclusion content, shot peening, and fatigue conditions. A large majority of the failures in as-machined specimens with the introduced inclusions occurred at cracks initiating from inclusions intersecting the specimen surface. These inclusions reduced fatigue life by up to 100X, when compared to lives of material without inclusions residing at specimen surface. Large inclusions produced the greatest reductions in life for tests at low strain ranges and high strain ratios. Shot peening improved life in many cases by reducing the most severe effects of inclusions.

Barrie, Robert L.↗

Initial Assessment of the Effects of Nonmetallic Inclusions on Fatigue Life of Powder-Metallurgy-Processed Udimet(TM) 720

The fatigue lives of modern powder metallurgy (PM) disk alloys are influenced by variabilities in alloy microstructure and mechanical properties. These properties can vary due to the different steps of materials/component processing and machining. One of these variables, the presence of nonmetallic inclusions, has been shown to significantly degrade low-cycle fatigue (LCF) life. Nonmetallic inclusions are inherent defects in powder alloys that are a by-product of powder-processing techniques. Contamination of the powder can occur in the melt, during powder atomization, or during any of the various handling processes through consolidation. In modern nickel disk powder processing facilities, the levels of inclusion contamination have been reduced to less than 1 part per million by weight. Despite the efforts of manufacturers to ensure the cleanliness of their powder production processes, the presence of inclusions remains a source of great concern for the designer. the objective of this study was to investigate the effects on fatigue life of these inclusions. Since natural inclusions occur so infrequently, elevated levels of inclusions were carefully introduced in a nickel-based disk superalloy, Udimet 720 (registered trademark of Special Metals Corporation), produced using PM processing. Multiple strain-controlled fatigue tests were then performed on this material at 650 C. Analyses were performed to compare the LCF lives and failure initiation sites as functions of inclusion content and fatigue conditions. A large majority of the failures in specimens with introduced inclusions occurred at cracks initiating from inclusions at the specimen surface. The inclusions could reduce fatigue life by up to 100 times. These effects were found to be dependent on strain range and strain ratio. Tests at lower strain ranges and higher strain ratios produced larger effects of inclusions on life.

Gabb, T. P.↗