Cyclic Engine Operation of Cast Vitallium Turbine Blades at an Exhaust-cone Gas Temperature of 1440 plus or Minus 20 F
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Yaker, Charles↗
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Method of reducing the green density of a slip cast article
The method disclosed in this specification is one of reducing the green density of an article cast in a slip casting operation. The article is cast from a casting slip containing silicon metal particles, yttrium containing particles, and a small amount of a fluoride salt which is effective to suppress flocculation of the silicon metal particles by y.sup.+3 ions derived from the yttrium containing particles. The method is characterized by the following step. A small amount of compound which produces a cation which will partly flocculate the particles of silicon metal is added to the casting slip. The small amount of this compound is added so that when the casting slip is slip cast into a casting mold, the partly flocculated particles of silicon will interrupt an otherwise orderly packing of the particles of silicon and particles of yttrium. In this manner, the green density of the slip cast article is reduced and the article may be more easily nitrided.
Mangels, John A.↗
Development of a CFD code for casting simulation
The task of developing a computational fluid dynamics (CFD) code to accurately model the mold filling phase of a casting operation was accomplished in a systematic manner. First the state-of-the-art was determined through a literature search, a code search, and participation with casting industry personnel involved in consortium startups. From this material and inputs from industry personnel, an evaluation of the currently available codes was made. It was determined that a few of the codes already contained sophisticated CFD algorithms and further validation of one of these codes could preclude the development of a new CFD code for this purpose. With industry concurrence, ProCAST was chosen for further evaluation. Two benchmark cases were used to evaluate the code's performance using a Silicon Graphics Personal Iris system. The results of these limited evaluations (because of machine and time constraints) are presented along with discussions of possible improvements and recommendations for further evaluation.
Murph, Jesse E.↗
Machining of low percentage beryllium copper alloys
Airborne beryllium sampling during machining of low percentage beryllium-copper alloys shows that normal dry machining creates 45.2 microgram/cu m of airborne beryllium in the casting operators breathing zone and 2.3 microgram/cu m in an adjacent machine working area. A small vacuum system placed over the tool effectively removes airborne beryllium in the breathing zone sample to 0.2 microgram/cu m.
Habermeyer, J. G.↗
Semiconductor surface protection material
A method and a product for protecting semiconductor surfaces is disclosed. The protective coating material is prepared by heating a suitable protective resin with an organic solvent which is solid at room temperature and converting the resulting solution into sheets by a conventional casting operation. Pieces of such sheets of suitable shape and thickness are placed on the semiconductor areas to be coated and heat and vacuum are then applied to melt the sheet and to drive off the solvent and cure the resin. A uniform adherent coating, free of bubbles and other defects, is thus obtained exactly where it is desired.
Packard, R. D.↗
Demonstration of a Real Time Capability to Produce Tidal Heights and Currents for Naval Operational Use: A Cast Study for the West Coast of Africa (Liberia)
This report documents an existing capability to produce operationally relevant products on sea level and currents from a tides/storm surge model for any coastal region around the world within 48 hours from the time of the request. The model is ready for transition to the Naval Oceanographic Office (NAVOCEANO) for potential contingency use anywhere around the world. A recent application to naval operations offshore Liberia illustrates this. Mississippi State University, in collaboration with the University of Colorado and NAVOCEANO, successfully deployed the Colorado University Rapidly Relocatable Nestable Tides and Storm Surge (CURReNTSS) model that predicts sea surface height, tidal currents and storm surge, and provided operational products on tidal sea level and currents in the littoral region off south-western coast of Africa. This report summarizes the results of this collaborative effort in an actual contingency use of the relocatable model, summarizes the lessons learned, and provides recommendations for further evaluation and transition of this modeling capability to operational use.
CASE STUDIES↗
Effect of Some Selected Heat Treatments on the Operating Life of Cast HS-21 Turbine Blades
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Clauss, Francis J↗
Salvaging surface-damaged aluminum castings
Repair operation for damaged aluminum parts includes anodizing the part, removing the oxide layer, filling the pit or scratch with copper, capping the fill with cadmium, and hand polishing.
Hanna, T. L.↗
Occurrence of Iron Oxides on Cast-iron Engine Surfaces After Operation
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ENGINE CYLINDERS, CAST-IRON↗
Space rescue operations in the early 1980's.
Discussion of planning requirements for space rescue missions in connection with an emergency situation involving a manned satellite with a small crew. A space rescue mission may be divided basically into three major operational phases including the response time phase, the phase concerned with the rescue operations, and the final phase which begins with the casting-off operation from the rendezvous position with the distressed vehicle. The types of possible emergency situations are discussed together with the space rescue equipment, a pressurized emergency module, an unpressurized emergency module, a portable airlock, an attachable docking fixture, a fluid jet type detumble system, a stick-on rocket type detumble system, and an antitumbling space vehicle.
Wild, J. W.↗
Experimental Study of the Coating Found on Scuffed Cast-iron Piston Rings During Operation in Nitrided-steel Cylinders
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PISTON RINGS, CAST-IRON↗
ISEP: A Joint SRAG/CCMC Collaboration to Improve Mitigation of Space Weather Effects on Crew Health in the Exo-LEO Era
The Space Radiation Analysis Group (SRAG) at Johnson Space Center (JSC) is tasked with monitoring changes to space weather and mitigating any resultant impacts to crew health and safety. As human spaceflight goals extend from Low-Earth Orbit (LEO) missions like the International Space Station (ISS) to the moon, Mars and beyond, SRAG will need to update their current approach for crew monitoring of and protection from radiation exposure due to energetic Solar Particle Events (ESPEs). Challenges faced in planning exo-LEO missions include the lack of protection from the Earth’s geomagnetic field employed by the ISS in addition to limited communication capability between the crew and the ground. In the event of an ESPE, the current ISS trajectory ensures that the vehicle is only traveling through fields of higher radiation exposure for a brief period of time; the Earth’s geomagnetic field prevents the penetration of the high-energy particles of concern throughout the majority of the orbit. Exo-LEO missions, on the other hand, require that the vehicle travel through free space, exposing vehicle and crew to the full impact of the ESPE. NASA has combined multiple approaches to resolve this radiation exposure issue. New vehicles are designed to take advantage of advances in particle transport modeling capabilities and shielding technology, allowing redistribution of mass throughout the vehicle to areas of thinner shielding when the energetic particle flux has increased to levels of concern. Although vehicle shielding is an important aspect of radiation exposure protection, there is a continued requirement to monitor and predict the space weather environment. To this end, SRAG maintains a console position in Mission Control with 24/7 mission support capability. In the event of increased solar activity, SRAG collaborates with the Flight Control Team (FCT) to determine if crew action (i.e., shelter) is required. During any increase in solar activity, the FCT needs three pieces of information to effectively decide the crew response in light of other required mission tasks: if an event (ESPE) will occur, how ‘intense’ an observed event will be, and how long will an observed event will last. An ideal alert system limits false alarms, therefore causing the crew to take action unnecessarily, without ignoring events that pose a hazard to the crew. SRAG’s current operational concept for ISS missions focuses on short-term forecasts, best described as ‘now-casting’. Console operators are in daily communication with the Space Weather Prediction Center (SWPC) for situational awareness purposes. When conditions exist that may lead to increased solar activity, operators receive notifications from SWPC. In the case of a well-connected ESPE, the console operator may only have on the order of minutes to several hours to notify the FCT of the event and provide a recommendation for crew action. As NASA shifts to exo-LEO missions, the increased time in free space as well as the reduced ability to communicate with the crew will force a transition in crew protection strategy that emphasizes improvments to both the accuracy and the lead time in forecasting capabilities.
Barzilla, Janet E.↗
Mississippi State University Center for Air Sea Technology FY95 Research Program
The Mississippi State University (MSU) Center for Air Sea Technology (CAST) evolved from the Institute for Naval Oceanography's (INO) Experimental Center for Mesoscale Ocean Prediction (ECMOP) which was started in 1989. MSU CAST subsequently began operation on 1 October 1992 under an Office of Naval Research (ONR) two-year grant which ended on 30 September 1994. In FY95 MSU CAST was successful in obtaining five additional research grants from ONR, as well as several other research contracts from the Naval Oceanographic Office via NASA, the Naval Research Laboratory, the Army Corps of Engineers, and private industry. In the past, MSU CAST technical research and development has produced tools, systems, techniques, and procedures that improve efficiency and overcome deficiency for both the operational and research communities residing with the Department of Defense, private industry, and university ocean modeling community. We continued this effort with the following thrust areas: to develop advanced methodologies and tools for model evaluation, validation and visualization, both oceanographic and atmospheric; to develop a system-level capability for conducting temporally and ; spatially scaled ocean simulations driven by or are responsive to ocean models, and take into consideration coupling to atmospheric models; to continue the existing oceanographic/atmospheric data management task with emphasis on distributed databases in a network environment, with database optimization and standardization, including use of Mosaic and World Wide Web (WWW) access; and to implement a high performance parallel computing technology for CAST ocean models
Yeske, Lanny↗
Analysis and calculation of macrosegregation in a casting ingot. MPS solidification model. Volume 3: Operating manual
The operation of solidification model 1 is described. Model 1 calculates the macrosegregation in a rectangular ingot of a binary alloy as a result of horizontal axisymmetric bidirectional solidification. The calculation is restricted to steady-state solidification; there is no variation in final local average composition in the direction of isotherm movement. The physics of the model are given.
Maples, A. L.↗
In-flight simulation of high agility through active control: Taming complexity by design
The motivation for research into helicopter agility stems from the realization that marked improvements relative to current operational types are possible, yet there is a dearth of useful criteria for flying qualities at high performance levels. Several research laboratories are currently investing resources in developing second generation airborne rotorcraft simulators. The UK's focus has been the exploitation of agility through active control technology (ACT); this paper reviews the results of studies conducted to date. The conflict between safety and performance in flight research is highlighted and the various forms of safety net to protect against system failures are described. The role of the safety pilot, and the use of actuator and flight envelope limiting are discussed. It is argued that the deep complexity of a research ACT system can only be tamed through a requirement specification assembled using design principles and cast in an operational simulation form. Work along these lines conducted at DRA is described, including the use of the Jackson System Development method and associated Ada simulation.
Padfield, Gareth D.↗
Development of failure criterion for Kevlar-epoxy fabric laminates
The development of the tensor polynomial failure criterion for composite laminate analysis is discussed. In particular, emphasis is given to the fabrication and testing of Kevlar-49 fabric (Style 285)/Narmco 5208 Epoxy. The quadratic-failure criterion with F(12)=0 provides accurate estimates of failure stresses for the Kevlar/Epoxy investigated. The cubic failure criterion was re-cast into an operationally easier form, providing the engineer with design curves that can be applied to laminates fabricated from unidirectional prepregs. In the form presented no interaction strength tests are required, although recourse to the quadratic model and the principal strength parameters is necessary. However, insufficient test data exists at present to generalize this approach for all undirectional prepregs and its use must be restricted to the generic materials investigated to-date.
Tennyson, R. C.↗
Nitrited-Steel Piston Rings for Engines of High Specific Power
Stability and control characteristics determined from tests in the Langley 19-foot pressure tunnel of a 0.2375-scale model of the Douglas XA-26 airplane are compared with those measured in flight tests of a Douglas A-26b airplane. Several designs of nitrided-steel piston rings were performance-tested under variable conditions of output. The necessity of good surface finish and conformity of the ring to the bore was indicated in the preliminary tests. Nitrided-steel rings of the same dimensions as cast-iron rings operating on the original piston were unsatisfactory, and the final design was a lighter, rectangular, thin-face-width ring used on a piston having a maximum cross-head area and a revised skirt shape. Results were obtained from single-cylinder and multicylinder engine runs.
Collins, John H↗
Mars Aqueous Processing System
The goal of the Mars Aqueous Processing System (MAPS) is to establish a flexible process that generates multiple products that are useful for human habitation. Selectively extracting useful components into an aqueous solution, and then sequentially recovering individual constituents, can obtain a suite of refined or semi-refined products. Similarities in the bulk composition (although not necessarily of the mineralogy) of Martian and Lunar soils potentially make MAPS widely applicable. Similar process steps can be conducted on both Mars and Lunar soils while tailoring the reaction extents and recoveries to the specifics of each location. The MAPS closed-loop process selectively extracts, and then recovers, constituents from soils using acids and bases. The emphasis on Mars involves the production of useful materials such as iron, silica, alumina, magnesia, and concrete with recovery of oxygen as a byproduct. On the Moon, similar chemistry is applied with emphasis on oxygen production. This innovation has been demonstrated to produce high-grade materials, such as metallic iron, aluminum oxide, magnesium oxide, and calcium oxide, from lunar and Martian soil simulants. Most of the target products exhibited purities of 80 to 90 percent or more, allowing direct use for many potential applications. Up to one-fourth of the feed soil mass was converted to metal, metal oxide, and oxygen products. The soil residue contained elevated silica content, allowing for potential additional refining and extraction for recovery of materials needed for photovoltaic, semiconductor, and glass applications. A high-grade iron oxide concentrate derived from lunar soil simulant was used to produce a metallic iron component using a novel, combined hydrogen reduction/metal sintering technique. The part was subsequently machined and found to be structurally sound. The behavior of the lunar-simulant-derived iron product was very similar to that produced using the same methods on a Michigan iron ore concentrate, which demonstrates that lunar-derived material can be used in a manner similar to conventional terrestrial iron. Metallic iron was also produced from the Mars soil simulant. The aluminum and magnesium oxide products produced by MAPS from lunar and Mars soil simulants exhibited excellent thermal stability, and were shown to be capable of use for refractory oxide structural materials, or insulation at temperatures far in excess of what could be achieved using unrefined soils. These materials exhibited the refractory characteristics needed to support iron casting and forming operations, as well as other thermal processing needs. Extraction residue samples contained up to 79 percent silica. Such samples were successfully fused into a glass that exhibited high light transmittance.
Berggren, Mark↗