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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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At least 19 records

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NASA NTRS1983

Hermetic edge sealing of photovoltaic modules

The edge sealing technique is accomplished by a combination of a chemical bond between glass and aluminum, formed by electrostatic bonding, and a metallurgical bond between aluminum and aluminum, formed by ultrasonic welding. Such a glass to metal seal promises to provide a low cost, long lifetime, highly effective hermetic seal which can protect module components from severe environments. Development of the sealing techniques and demonstration of their effectiveness by fabricating a small number of dummy modules, up to eight inches square in size, and testing them for hermeticity using helium leak testing methods are reviewed. Non-destructive test methods are investigated.

Source record↗

NASA NTRS1992

Integral edge seals for phosphoric acid fuel cells

A phosphoric acid fuel cell having integral edge seals formed by an elastomer permeating an outer peripheral band contiguous with the outer peripheral edges of the cathode and anode assemblies and the matrix to form an integral edge seal which is reliable, easy to manufacture and has creep characteristics similar to the anode, cathode and matrix assemblies inboard of the seals to assure good electrical contact throughout the life of the fuel cell.

Granata, Jr., Samuel J.↗

NASA NTRS1988

Process for forming integral edge seals in porous gas distribution plates utilizing a vibratory means

A process for forming an integral edge seal in a gas distribution plate for use in a fuel cell. A seal layer is formed along an edge of a porous gas distribution plate by impregnating the pores in the layer with a material adapted to provide a seal which is operative dry or when wetted by an electrolyte of a fuel cell. Vibratory energy is supplied to the sealing material during the step of impregnating the pores to provide a more uniform seal throughout the cross section of the plate.

Feigenbaum, Haim↗

NASA NTRS1994

Hot compression process for making edge seals for fuel cells

A hot compression process for forming integral edge seals in anode and cade assemblies wherein the assemblies are made to a nominal size larger than a finished size, beads of AFLAS are applied to a band adjacent the peripheral margins on both sides of the assemblies, the assemblies are placed in a hot press and compressed for about five minutes with a force sufficient to permeate the peripheral margins with the AFLAS, cooled and cut to finished size.

Dunyak, Thomas J.↗

NASA NTRS1980

Knife-edge seal for vacuum bagging

Cam actuated clamps pinch bagging material between long knife edge (mounted to clamps) and high temperature rubber cushion bonded to baseplate. No adhesive, tape, or sealing groove is needed to seal edge of bagging sheet against base plate.

Rauschl, J. A.↗

NASA NTRS1986

Hermetic Edge Seals for Photovoltaic Modules

Corrosive atmospheric agents excluded to prolong cell life. Combination of two sealing techniques makes possible to protect solar cells from water vapor, oxygen, and other corrosive atmospheric constituents. Using three-step process, glass-to-metal hermetic seal formed around edge of solar-cell module. Elastomer seals used previously not as effective because they are permeable to water vapor and atmospheric gases.

Nowlan, M. J.↗

NASA NTRS1983

Hermetic edge sealing of photovoltaic modules

The feasibility of using an electrostatic bonding (ESB) and ultrasonic welding process to produce hermetic edge seals on terrestrial solar cell modules was investigated. The fabrication sequence is to attach an aluminum foil "gasket' to the perimeter of a glass sheet. A cell circuit is next encapsulated inside the gasket, and its aluminum foil back cover is seam welded ultrasonically to the gasket. An ESB process for sealing aluminum to glass was developed in an ambient air atmosphere, which eliminates the requirement for a vacuum or pressure vessel. An ultrasonic seam welding process was also developed which did not degrade the quality of the ESB seal. Good quality welds with minimal deformation were produced. The effectiveness of the above described sealing techniques was tested by constructing 400 sq cm (8 x 8 s64 sq in) sample modules, and then subjecting them to nondestructive fine and gross leak tests. The gross leak tests identified several different causes of leaks which were then eliminated by modifying the assembly process.

Nowlan, M. J.↗

NASA NTRS2013

Model Verification and Validation Concepts for a Probabilistic Fracture Assessment Model to Predict Cracking of Knife Edge Seals in the Space Shuttle Main Engine High Pressure Oxidizer

Physics-based models are routinely used to predict the performance of engineered systems to make decisions such as when to retire system components, how to extend the life of an aging system, or if a new design will be safe or available. Model verification and validation (V&V) is a process to establish credibility in model predictions. Ideally, carefully controlled validation experiments will be designed and performed to validate models or submodels. In reality, time and cost constraints limit experiments and even model development. This paper describes elements of model V&V during the development and application of a probabilistic fracture assessment model to predict cracking in space shuttle main engine high-pressure oxidizer turbopump knife-edge seals. The objective of this effort was to assess the probability of initiating and growing a crack to a specified failure length in specific flight units for different usage and inspection scenarios. The probabilistic fracture assessment model developed in this investigation combined a series of submodels describing the usage, temperature history, flutter tendencies, tooth stresses and numbers of cycles, fatigue cracking, nondestructive inspection, and finally the probability of failure. The analysis accounted for unit-to-unit variations in temperature, flutter limit state, flutter stress magnitude, and fatigue life properties. The investigation focused on the calculation of relative risk rather than absolute risk between the usage scenarios. Verification predictions were first performed for three units with known usage and cracking histories to establish credibility in the model predictions. Then, numerous predictions were performed for an assortment of operating units that had flown recently or that were projected for future flights. Calculations were performed using two NASA-developed software tools: NESSUS(Registered Trademark) for the probabilistic analysis, and NASGRO(Registered Trademark) for the fracture mechanics analysis. The goal of these predictions was to provide additional information to guide decisions on the potential of reusing existing and installed units prior to the new design certification.

Pai, Shantaram S.↗

NASA NTRS2000

NEA Multi-Chamber Sample Return Container with Hermetic Sealing

A sample return container is being developed by Honeybee Robotics to receive samples from a derivative of the Champollion/ST4 Sample Acquisition and Transfer Mechanism or other samplers such as the 'Touch and Go' Surface Sampler (TGSS), and then hermetically seal the samples for a sample return mission. The container is enclosed in a phase change material (PCM) chamber to prevent phase change during return and re-entry to earth. This container is designed to operate passively with no motors and actuators. Using the rotation axis of the TGSS sampler for interfacing, transferring and sealing samples, the container consumes no electrical power and therefore minimizes sample temperature change. The circular container houses multiple isolated canisters, which will be sealed individually for samples acquired from different sites or depths. The TGSS based sampler indexes each canister to the sample transfer position, below the index interface for sample transfer. After sample transfer is completed, the sampler indexes a seal carrier, which lines up seals with the openings of the canisters. The sampler moves to the sealing interface and seals the sample canisters one by one. The sealing interface can be designed to work with C-seals, knife edge seals and cup seals. This sample return container is being developed by Honeybee Robotics in collaboration with the JPL Exploration Technology program. A breadboard system of the sample return container has been recently completed and tested. Additional information is contained in the original extended abstract.

Rafeek, Shaheed↗

NASA NTRS2000

A Sample Return Container with Hermetic Seal

A sample return container is being developed by Honeybee Robotics to receive samples from a derivative of the Champollion/ST4 Sample Acquisition and Transfer Mechanism or other samplers and then hermetically seal samples for a sample return mission. The container is enclosed in a phase change material (PCM) chamber to prevent phase change during return and re-entry to earth. This container is designed to operate passively with no motors and actuators. Using the sampler's featured drill tip for interfacing, transfer-ring and sealing samples, the container consumes no electrical power and therefore minimizes sample temperature change. The circular container houses a few isolated canisters, which will be sealed individually for samples acquired from different sites or depths. The drill based sampler indexes each canister to the sample transfer position, below the index interface for sample transfer. After sample transfer is completed, the sampler indexes a seal carrier, which lines up seals with the openings of the canisters. The sampler moves to the sealing interface and seals the sample canisters one by one. The sealing interface can be designed to work with C-seals, knife edge seals and cup seals. Again, the sampler provides all sealing actuation. This sample return container and co-engineered sample acquisition system are being developed by Honeybee Robotics in collaboration with the JPL Exploration Technology program.

Kin Yuen Kong↗

NASA NTRS1979

Ceramic-to-metal vacuum seal

Knife-edge sealing technique forms reliable, vacuum-tight bonds between materials having very different thermal-expansion characteristics. Seal is thin and flexible and absorb shear, hoop, and bonding stresses at joint so that seal remains vacuum tight.

Sackerlotzky, O. H.↗

NASA NTRS1995

Task 4 supporting technology. Part 2: Detailed test plan for thermal seals. Thermal seals evaluation, improvement and test. CAN8-1, Reusable Launch Vehicle (RLV), advanced technology demonstrator: X-33. Leading edge and seals thermal protection system technology demonstration

The objective is to develop the advanced thermal seals to a technology readiness level (TRL) of 6 to support the rapid turnaround time and low maintenance requirements of the X-33 and the future reusable launch vehicle (RLV). This program is divided into three subtasks: (1) orbiter thermal seals operation history review; (2) material, process, and design improvement; and (3) fabrication and evaluation of the advanced thermal seals.

Hogenson, P. A.↗

NASA NTRS1989

Twist seal for high-pressure vessels such as space shuttle rocket motors

Seals for sealing clevis and flange joints (14) of a solid rocket booster motor, and more particularly to a seal (30) which is twisted upon application of expansion forces to an edge seal (36). This twisting motion initially causes a leading edge seal (44) to be urged into sealing engagement with a surface (48) of an adjacent member (20) and thereafter, increasing fluid pressure on a pressurized side (64) of a seal (30) drives a broad sealing region (46) into sealing engagement with a surface (48).

von Pragenau, George L.↗

NASA NTRS2010

Labyrinth Seal Flutter Analysis and Test Validation in Support of Robust Rocket Engine Design

High energy-density turbomachines, like the SSME turbopumps, utilize labyrinth seals, also referred to as knife-edge seals, to control leakage flow. The pressure drop for such seals is order of magnitude higher than comparable jet engine seals. This is aggravated by the requirement of tight clearances resulting in possible unfavorable fluid-structure interaction of the seal system (seal flutter). To demonstrate these characteristics, a benchmark case of a High Pressure Oxygen Turbopump (HPOTP) outlet Labyrinth seal was studied in detail. First, an analytical assessment of the seal stability was conducted using a Pratt & Whitney legacy seal flutter code. Sensitivity parameters including pressure drop, rotor-to-stator running clearances and cavity volumes were examined and modeling strategies established. Second, a concurrent experimental investigation was undertaken to validate the stability of the seal at the equivalent operating conditions of the pump. Actual pump hardware was used to construct the test rig, also referred to as the (Flutter Rig). The flutter rig did not include rotational effects or temperature. However, the use of Hydrogen gas at high inlet pressure provided good representation of the critical parameters affecting flutter especially the speed of sound. The flutter code predictions showed consistent trends in good agreement with the experimental data. The rig test program produced a stability threshold empirical parameter that separated operation with and without flutter. This empirical parameter was used to establish the seal build clearances to avoid flutter while providing the required cooling flow metering. The calibrated flutter code along with the empirical flutter parameter was used to redesign the baseline seal resulting in a flutter-free robust configuration. Provisions for incorporation of mechanical damping devices were introduced in the redesigned seal to ensure added robustness

El-Aini, Yehia↗

NASA NTRS1986

Preventing Delamination of Silverized FEP Films

Edge treatment inhibits attack by moisture. New technique prevents delamination by sealing edges where delamination starts. Samples of aluminum/FEP/silver laminate survive humidity tests and other environmental tests when edges of layers are covered by epoxy bead. Untreated laminates, in contrast, deteriorated seriously during such tests.

Domnikov, L.↗

NASA NTRS1975

Continued development of abradable gas path seals

Major program objectives were the continued development of NiCrAlY feltmetal and honeycomb systems for knife edge seal applications in the 1144 to 1366 K temperature range, and to initiate abradable seal material evaluation for blade tip seal applications in the 1366 to 1589 K temperature range. Larger fiber size, higher density feltmetal showed greatly improved erosion resistance with a slight reduction in abradability compared to the baseline feltmetal. Pack aluminide coating of the honeycomb extended the oxidation resistance and slightly improved the abradability of this material. Evaluation through selected abradability, erosion and oxidation testing, and pertinent metallography led to selection of a plasma sprayed yttria stabilized zirconia (ZrO2)/CoCrAlY layered system as the system with the most potential to meet the 1589 K requirement for blade tip seals. This system demonstrated structural integrity, erosion resistance, and some degree of abradability.

Shiembob, L. T.↗

NASA NTRS1992

Evaluation of an innovative high temperature ceramic wafer seal for hypersonic engine applications

A critical mechanical system in advanced hypersonic engines is the panel-edge seal system that seals gaps between the articulating engine panels and the adjacent engine splitter walls. Significant advancements in seal technology are required to meet the extreme demands placed on the seals, including the simultaneous requirements of low leakage, conformable, high temperature, high pressure, sliding operation. In this investigation, the design, development, analytical and experimental evaluation of a new ceramic wafer seal that shows promise of meeting these demands will be addressed. A high temperature seal test fixture was designed and fabricated to measure static seal leakage performance under engine simulated conditions. Ceramic wafer seal leakage rates are presented for engine-simulated air pressure differentials (up to 100 psi), and temperature (up to 1350 F), sealing both flat and distorted wall conditions, where distortions can be as large as 0.15 inches in only an 18 inch span. Seal leakage rates are low, meeting an industry-established tentative leakage limit for all combinations of temperature, pressure and wall conditions considered. A seal leakage model developed from externally-pressurized gas film bearing theory is also presented. Predicted leakage rates agree favorably with the measured data for nearly all conditions of temperature and pressure. Discrepancies noted at high engine pressure and temperature are attributed to thermally-induced, non-uniform changes in the size and shape of the leakage gap condition. The challenging thermal environment the seal must operate in places considerable demands on the seal concept and material selection. Of the many high temperature materials considered in the design, ceramics were the only materials that met the many challenging seal material design requirements. Of the aluminum oxide, silicon carbide, and silicon nitride ceramics considered in the material ranking scheme developed herein, the silicon nitride class of ceramics ranked the highest because of their high temperature strength; resistance to the intense heating rates; resistance to hydrogen damage; and good structural properties. Baseline seal feasibility has been established through the research conducted in this investigation. Recommendations for future work are also discussed.

Steinetz, Bruce M.↗

NASA NTRS1979

Window with integral seal

Installation concept needed for airtight, watertight, laminated window does away with O-rings and sealants needed for effective edge seal. Pliable inner layer of laminating adhesive extends to form build-in gasket. Technique is usable for plastic or glass windows where space for gaskets and sealing rings is limited, canopies, and shields for military, marine, and land transportation vehicles.

Behar, J. M.↗