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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Optimizing the Electroforming Process to Enhance the Thickness Uniformity of Full Shell X-Ray Optics

Electroforming replication technology at Marshall Space Flight Center has a long heritage of producing highquality full-shell X-ray mirrors for various applications. Nickel alloys are electroformed onto a super-polished mandrel in the electroforming process, then separated to form the replicated full-shell optic. Various parameters in the electroplating configuration could result in the nonuniformity of the shell’s thickness. Thickness nonuniformities primarily occur due to non-uniform electric field distributions in the electroforming tank during the deposition. Using COMSOL Multiphysics simulations, we have studied the electric field distributions during the deposition process. Using these studies, we have optimized the electric fields inside the tank using customized shields and insulating gaskets on the mandrel. These efforts reduced thickness non-uniformity from over 20% to under 5% percent. Improving the thickness uniformity of the shell aids in better mounting and alignment of shells in the optics module. Optimization of the electroforming process, in some cases, improved the optical performance of the shells. COMSOL optimizing of the electroforming process and the experimental results validating these simulations are presented in this article.

X-ray optics↗
NASA NTRS2000

New Alloys for Electroformed Replicated X-Ray Optics

The process of electroforming x-ray mirror shells off a superpolished mandrel has been widely used. The recently launched XMM mission is a good example of this, containing 174 such mirror shells of diameters ranging from 0.3-0.7 m and thicknesses of 0.47-1.07 mm. To continue to utilize this technique for the next generation of x-ray observatories, where ever-larger collecting areas will be required within the constraints of tight weight budgets, demands that new alloys be developed that can withstand the large stresses imposed on very thin shells by the replication and handling processes. Towards this end, we began a development program in late 1997 to produce a high-strength alloy suitable for electroforming very thin high-resolution x-ray optics. The requirements for this task are quite severe; not only must the electroformed deposit be very strong, it must also have extremely low residual stresses to prevent serious figure distortions in large thin-walled shells. Further, the electroforming must be performed at near room temperature, as large temperature changes will modify the figure of the mandrel, in an environment that is not corrosive for the mandrel. The figure of merit for the strength of the electroformed deposit is its Precision Elastic Limit (PEL). This is a measure of permanent strain, at the few parts per million level, under applied stress. Pure nickel is very ductile and will permanently deform, at the parts-per-million level under loads of a few x 10(exp 7) Pa. These stresses are easily exceeded when thin-walled shells (150 micron thick) are replicated. Our goal was to develop an alloy an order of magnitude stronger than this. We will present the results of our development program, showing the evolution of our plating baths through to our present 'glassy' nickel alloy that satisfies the goals above. For each we will show the electroforming characteristics of the bath and the PEL measurements for the resulting alloys. We estimate the ultimate limit on shell thickness and mass for x-ray mirrors produced in these baths.

Engelhaupt, D.↗
NASA NTRS1974

Fabrication of liquid-rocket thrust chambers by electroforming

Electroforming has proven to be an excellent fabrication method for building liquid rocket regeneratively cooled thrust chambers. NASA sponsored technology programs have investigated both common and advanced methods. Using common procedures, several cooled spool pieces and thrust chambers have been made and successfully tested. The designs were made possible through the versatility of the electroforming procedure, which is not limited to simple geometric shapes. An advanced method of electroforming was used to produce a wire-wrapped, composite, pressure-loaded electroformed structure, which greatly increased the strength of the structure while still retaining the advantages of electroforming.

Duscha, R. A.↗
NASA NTRS1974

Method of electroforming a rocket chamber

A transpiration cooled rocket chamber is made by forming a porous metal wall on a suitably shaped mandrel. The porous wall may be made of sintered powdered metal, metal fibers sintered on the mandrel or wires woven onto the mandrel and then sintered to bond the interfaces of the wires. Intersecting annular and longitudinal ribs are then electroformed on the porous wall. An interchamber wall having orifices therein is then electroformed over the annular and longitudinal ribs. Parallel longitudinal ribs are then formed on the outside surface of the interchamber wall after which an annular jacket is electroformed over the parallel ribs to form distribution passages therewith. A feed manifold communicating with the distribution passages may be fabricated and welded to the rocket chamber or the feed manifold may be electroformed in place.

Fortini, A.↗
NASA NTRS1973

Development of improved electroforming technique

Techniques were studied to reinforce or strengthen electroformed nickel to allow a fuller utilization of electroforming as a reliable and low cost fabrication technique for regenerately cooled thrust chambers. Techniques for wire wrapping while electrodepositing were developed that can result in a structurally strong wall with less weight than a conventional electroformed wall. Also a technique of codepositing submicron sized THO2 particles with the nickel to form a dispersion strengthened structure was evaluated. The standard nickel cylinders exhibited an average hoop strength of 80,000 psi with a yield strength of 65,000 psi and a modulus of 25.6 x 10 to the 6th power psi. The as produced dispersion strengthened nickel showed a hoop strength of 97,000 psi with a yield strength of 67,000 psi. This is an increase of 17,000 psi or 21% over the standard nickel hoop strength. The wire wrapping cylinders showed an increased strength over the standard nickel test samples of 26,000 to 66,800 psi which is in the range of 26 to 104% increase in strength over the base standard nickel. These latter test results are indicative of a volume percent wire reinforcement from 15 to 31. The measured hoop strengths agree with calculated composite strengths based upon rule of mixtures.

Mccandles, L. C.↗
NASA NTRS1975

Investigation of electroforming techniques, literature analysis report

A literature analysis is presented of reports, specifications, and documented experiences with the use of electroforming to produce copper and nickel structures for aerospace and other engineering applications. The literature period covered is from 1948 to 1974. Specific effort was made to correlate mechanical property data for the electrodeposited material with known electroforming solution compositions and operating conditions. From this survey, electrolytes are suggested for selection to electroform copper and nickel outer shells on regeneratively cooled thrust chamber liners, and other devices subject to thermal and pressure exposure, based on mechanical properties obtainable, performance under various thermal environments, and ease of process control for product reproducibility. Processes of potential value in obtaining sound bonds between electrodeposited copper and nickel and copper alloy substrates are also discussed.

Malone, G. A.↗
NASA NTRS1984

Study of high performance alloy electroforming

Using the two nickel-manganese alloy electroforming baths of near identical compositions, panels were electroformed under the same deposition parameters of current density, bath temperature, pH, and pulse plating conditions of duty cycle and frequency. By changing the electrolyte agitation conditions, significant effects on mechanical properties were noted. Since electrolyte agitation conditions on the typical flat panels studied to date will not be identical to those existing on a complex curved shape such as the SSME combustion chamber simulation, it is most important that these effects be evaluated prior to Phase B studies. The subscale chamber has been fabricated and shield support tooling is being made. Electroforming of optimized alloy test bars is being deferred until the electrolyte agitation effects are more fully appraised.

Malone, G. A.↗
NASA NTRS1989

High performance alloy electroforming

Electroformed copper and nickel are used in structural applications for advanced propellant combustion chambers. An improved process has been developed by Bell Aerospace Textron, Inc. wherein electroformed nickel-manganese alloy has demonstrated superior mechanical and thermal stability when compared to previously reported deposits from known nickel plating processes. Solution chemistry and parametric operating procedures are now established and material property data is established for deposition of thick, large complex shapes such as the Space Shuttle Main Engine. The critical operating variables are those governing the ratio of codeposited nickel and manganese. The deposition uniformity which in turn affects the manganese concentration distribution is affected by solution resistance and geometric effects as well as solution agitation. The manganese concentration in the deposit must be between 2000 and 3000 ppm for optimum physical properties to be realized. The study also includes data regarding deposition procedures for achieving excellent bond strength at an interface with copper, nickel-manganese or INCONEL 718. Applications for this electroformed material include fabrication of complex or re-entry shapes which would be difficult or impossible to form from high strength alloys such as INCONEL 718.

Malone, G. A.↗
NASA NTRS1990

Simplified Models Speed Electroforming Tests

Method of evaluating configurations of electroforming shields reduces cost of evaluation. Applicable to electroformed parts that have axes of symmetry. Involves electroforming material onto two-dimensional approximation of part in question, using side shields to be evaluated. Eliminates expense of constructing full three-dimensional model but makes possible to perform evaluation almost immediately.

Bodemeijer, Ronnald↗
DOE OSTI2020

Exchange of Ions across the TiN/TaO x Interface during Electroformation of TaO x -Based Resistive Switching Devices

The valence change model describes the resistive switching in metal oxide-based devices as due to electroreduction of the oxide and subsequent electromigration of oxygen vacancies. Here, we present cross-sectional X-ray energy-dispersive spectroscopy elemental maps of Ta, O, N, and Ti in electroformed TiN/TaO 2.0 /TiN structures. O, N, and Ti were exchanged between the anode and the functional oxide in devices formed at high power (~1 mW), but the exchange was below the detection limit at low power (<0.5 mW). All structures exhibit a similar Ta-enriched and O-depleted filament formed by the elemental segregation in the functional oxide by the temperature gradient. The elemental interchange is interpreted as due to Fick’s diffusion caused by high temperatures in the gap of the filament and is not an essential part of electroformation.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Nanoscale imaging of He-ion irradiation effects on amorphous TaO x toward electroforming-free neuromorphic functions

Resistive switching in thin films has been widely studied in a broad range of materials. Yet, the mechanisms behind electroresistive switching have been persistently difficult to decipher and control, in part due to their non-equilibrium nature. Here, we demonstrate new experimental approaches that can probe resistive switching phenomena, utilizing amorphous TaO x as a model material system. Specifically, we applied scanning microwave impedance microscopy and cathodoluminescence (CL) microscopy as direct probes of conductance and electronic structure, respectively. These methods provide direct evidence of the electronic state of TaO x despite its amorphous nature. For example, CL identifies characteristic impurity levels in TaO x , in agreement with first principles calculations. We applied these methods to investigate He-ion-beam irradiation as a path to activate conductivity of materials and enable electroforming-free control over resistive switching. However, we find that even though He-ions begin to modify the nature of bonds even at the lowest doses, the films' conductive properties exhibit remarkable stability with large displacement damage and they are driven to metallic states only at the limit of structural decomposition. Finally, we show that electroforming in a nanoscale junction can be carried out with a dissipated power of <20 nW, a much smaller value compared to earlier studies and one that minimizes irreversible structural modifications of the films. Importantly, the multimodal approach described here provides a new framework toward the theory/experiment guided design and optimization of electroresistive materials.

36 MATERIALS SCIENCE↗
NASA NTRS1968

Electroformed screens with uniform hole size

Efficient method electroforms fine-mesh nickel screens, or plagues, with uniform hole size and accurate spacing between holes. An electroformed nickel mandrel has nonconducting silicone rubber projections that duplicate the desired hole size and shape in the finished nickel screen.

Schaer, G. R.↗
NASA NTRS1974

Nondestructive evaluation of electroformed outer shells for regeneratively cooled thrust chambers

Electroforming is presently a prime technique for producing the outer jackets of regeneratively cooled thrust chambers for rocket engines. Good bond integrity of the electroformed joints adjacent to the coolant passages is important to the useful service life of these aerospace systems. This investigation demonstrated that nondestructive evaluation techniques such as ultrasonic 'C' scan, holography, and acoustic emission are capable of detecting low integrity bonds which could lead to premature failures in the subject hardware.

Malone, G. A.↗
NASA NTRS1975

Investigation of electroforming techniques

Copper and nickel electroforming was examined for the purpose of establishing the necessary processes and procedures for repeatable, successful fabrication of the outer structures of regeneratively cooled thrust chambers. The selection of electrolytes for copper and nickel deposition is described. The development studies performed to refine and complete the processes necessary for successful chamber shell fabrication and the testing employed to verify the applicability of the processes and procedures to small scale hardware are described. Specifications were developed to afford a guideline for the electroforming of high quality outer shells on regeneratively cooled thrust chamber liners. Test results indicated repeatable mechanical properties could be produced in copper deposits from the copper sulfate electrolyte with periodic current reversal and in nickel deposits from the sulfamate solution. Use of inert, removable channel fillers and the conductivizing of such is described. Techniques (verified by test) which produce high integrity bonds to copper and copper alloy liners are discussed.

Malone, G. A.↗
NASA NTRS1983

Electroforming for High-Performance Products

Report describes development of processes and procedures for preparation of specifications for electroforming nickel and copper outer shells on cooled rocket thrust-chamber liners. Specifications represent merging of technical contributions from many sources into guide for producers of electroformed, high-performance products. Raw materials, conducting solutions and deposition rates are evaluated.

Malone, G. A.↗
NASA NTRS1984

Study of high performance alloy electroforming

Nickel-manganese alloy electrodeposits from an electrolyte containing more manganese ion than previously used is being evaluated at two bath operating temperatures with a great variety of pulse plating conditions. Saccharine was added as a stress reducing agent for the electroforming of several of the samples with highest manganese content. All specimens for mechanical property testing have been produced but are not through the various heat treatments as yet. One of the heat treatment will be at 343 C (650 F), the temperature at which the MCC outer electroformed nickel shell is stress relieved. A number of retainer specimens from prior work have been tested for hardness before and after heat treatment. There appears to be a fairly good correlation between hardness and mechanical properties. Comparison of representative mechanical properties with hardnesses are made for nickel-manganese electrodeposits and nickel-cobalt-manganese deposits.

Malone, G. A.↗
NASA NTRS1985

Study of high performance alloy electroforming

More panels electroformed with intentional variations of pulse plating parameters are being made. Pulse plating frequency was noted to have a significant effect regarding mechanical properties. The use of a high pulse frequency (assuming fixed duty cycles) results in an increase in ductility and a decrease in ultimate and yield strengths. Electroforming to intermediate frequencies is being done to obtain the best possible combination of ductility and strength. Results of some tests from high frequency specimens are tabulated.

Malone, G. A.↗
NASA NTRS1985

Electroform replication of grazing incidence X-ray optics

Work to produce mirrors via electroform replication is reported. Work on small (6 cm by 9 cm) cylindrical pieces and on 40 cm long by 12 cm wide Wolter shaped mirrors is summarized. It is shown that electroforming is a viable technique for producing relatively inexpensive grazing incidence X-ray optics, as long as modest resolution (1 min of arc) and size (12 cm diameter by 40 cm long) are specified.

Ulmer, M. P.↗